Chevrolet - Silverado 3500 4wd - Workshop Manual - 2010 - 2010

Factory Workshop Manual Make Chevrolet Model Silverado 3500 4wd Engine and year V8-6.6L DSL Turbo (2010) Please navigate through the PDF using the options provided by OnlyManuals.com on the sidebar. This manual was submitted by Anonymous Date 1st January 2018 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams Alarm Module: Diagrams Component Connector End Views Theft Deterrent Module (TDM) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Page 7 Alarm Module: Service and Repair Theft Deterrent Module Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > OnStar(R) - Availability for Hearing Impaired Communications Control Module: Technical Service Bulletins OnStar(R) - Availability for Hearing Impaired INFORMATION Bulletin No.: 06-08-46-005B Date: February 11, 2010 Subject: Availability of OnStar(R) for Hearing Impaired Models: 2007-2010 GM Passenger Cars and Light Duty Trucks (Including Saturn and Saab) Except 2007 Cadillac CTS Except 2007-2008 HUMMER H2, H2 SUT Except 2007 Pontiac Montana SV6 Except 2007-2010 Pontiac Vibe Except 2007 Saturn ION, VUE Except 2008 Saturn Astra Supercede: This bulletin is being revised to add a Note regarding 2009 Bluetooth(R)-equipped vehicles, additional models and model years. Please discard Corporate Bulletin Number 06-08-46-005A (Section 08 - Body and Accessories). Important This service bulletin is not applicable to 'GM of Canada' dealers and retailers. Note On 2009 and newer model year vehicles equipped with the Bluetooth(R) feature (option code UPF), when up-fitted with TTY capabilities, the Bluetooth(R) feature will be disabled. OnStar with Text Telephone Capability (TTY) General Motors is pleased to announce that the safety and security of OnStar is now available to our deaf, hard of hearing and speech impaired customers. The current vehicles listed above, as well as forthcoming vehicles equipped with OnStar hardware version 7.0 or higher, have the ability to utilize texting telephones. Vehicle specific TTY capability can be determined by utilizing the VIN lookup Tool. Additional information may be found by referring to www.onstar.com/tty. TTY equipment allows people who are deaf, hard of hearing or speech impaired, in-vehicle access to 911 and basic OnStar(R) services by pressing the OnStar(R) blue button or red emergency button. The keypad provides a means to communicate by allowing customers to type messages back and forth, with an OnStar(R) advisor or other party when using the OnStar(R) Hands-Free Calling feature. A TTY is required at both ends of the conversation in order to communicate. OnStar(R) Turn by Turn Navigation and Virtual Advisor are not available with the addition of TTY. The Reimbursement Program This equipment will be made available to eligible customers through GM Mobility and OnStar(R). Under this program, the customer must complete a GM Mobility application form. To take advantage of the program, vehicles must be adapted at the time of delivery for purchase / lease and a dealer claim ($1,000 Maximum per GM Mobility guidelines) with the application form submitted to GM Mobility. Saab dealers must fax documents. GM Dealers will receive electronic reimbursement directly from GM Mobility. Saab dealers will receive a check directly from OnStar(R). Additional questions or concerns should be directed to the OnStar Dealer Center. How to Order To order the dealer installed kit, contact AutoCraft Electronics or via the web at www.autocraft.com. The kit consists of an OnStar Interface Module, a Dial Pad (for making calls), OTIM wiring harness, the TTY device, installation/Tech 2(R) programming instructions and owner's guide. Warranty Information The Ultra-Tec Compact C TTY device is manufactured by an independent manufacturer and is covered by the manufacturer's warranty. It is not covered under the GM New Vehicle Limited Warranty. All other parts (OTIM, dial pad and OTIM wiring harness) are covered by the standard GM new vehicle parts and labor warranty. Replacement parts are available through AutoCraft Electronics. Contact AutoCraft Electronics or via the web. Warranty claims for the OTIM, dial pad and OTIM wiring harness should be submitted through normal warranty procedures using a sublet warranty claim with GM Labor Operation R5140. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > OnStar(R) - Availability for Hearing Impaired > Page 12 Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > OnStar(R) - Availability for Hearing Impaired > Page 13 Communications Control Module: Technical Service Bulletins Audio - Radio Does Not Mute Enough When Using OnStar(R) TECHNICAL Bulletin No.: 10-08-46-001 Date: January 27, 2010 Subject: Radio Does Not Mute Enough When OnStar(R) Turn-by Turn Navigation Directions Are Announced (Increase Volume Setting or Request Soft Mute Feature Change Through OnStar(R) Customer Service) Models: 2009-2010 GM Passenger Cars and Trucks (Including Saturn) 2009-2010 HUMMER H2, H3 2009 Saab 9-7X All Equipped with OnStar(R) (RPO UE1) Condition Some customers may comment that when the radio is on, it does not mute enough when the OnStar(R) Turn-by-Turn Navigation directions are announced. Cause This condition may be caused by the customer improperly setting the radio volume high enough when the Turn-by-Turn Navigation messages are played. The 2009 and 2010 models with OnStar(R) initiates a "soft mute" feature when the radio is on during Turn-by-Turn Navigation direction announcements. During the announcement, the radio can still be heard at a very low volume. Previous model years initiated a "hard mute" during this function which completely muted the radio audio. Correction Instruct the customer to increase the radio volume while getting the Turn-by-Turn Navigation direction announcements. You can control the message volume using the radio volume control, only when the Turn-by-Turn navigation messages are playing. Some customers that were accustomed to previous model vehicles with the "hard mute" feature may be dissatisfied with the function of the "soft mute" feature. For those customers, contact the OnStar(R) Customer Service Center by pushing the Blue OnStar(R) Button to speak to a trained Advisor and request a change be made to the vehicle from the "soft mute" setting to that of the hard or complete muting of audio playback during Turn by Turn directions. OnStar(R) will then create a case number. Advise the customer that the vehicle update should be completed Over the Air within 5 business days, after which an OnStar(R) Customer Care advisor will follow-up with the customer to verify the fix. If the customer does not hear back from OnStar(R) within a week, advise them to press the Blue OnStar(R) Button and ask for Customer Care to check status. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > OnStar(R) - Availability for Hearing Impaired > Page 14 Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Page 15 Communications Control Module: Locations Harness Routing Views I/P Extension Harness Routing (SLT except Y91/MEX) 1 - JX223 (U2K/UK6/UE1) 2 - X203 (UE1/U3U/UVB) 3 - X204 (U42) 4 - X212 5 - X206 (U42) 6 X213 (COAX) 7 - Vehicle Communication Interface Module (VCIM) (UE1) 8 - X301 (UQA/D07) 9 Floor Panel Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Page 16 Communications Control Module: Diagrams Component Connector End Views Vehicle Communication Interface Module (VCIM) X1 (UE1) Vehicle Communication Interface Module (VCIM) X2 (UE1) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Page 17 Vehicle Communication Interface Module (VCIM) X3 (UE1 with UUL or UUK) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Page 18 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Service and Repair > Communication Interface Module Replacement (with RPO SLT) Communications Control Module: Service and Repair Communication Interface Module Replacement (with RPO SLT) Communication Interface Module Replacement (with RPO SLT) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Service and Repair > Communication Interface Module Replacement (with RPO SLT) > Page 21 Communications Control Module: Service and Repair Communication Interface Module Replacement (without RPO SLT) Communication Interface Module Replacement (without RPO SLT) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: Customer Interest OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 30 Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 36 Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Service and Repair Keyless Entry Module: Service and Repair Remote Control Door Lock Receiver Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Diagrams Parking Assist Control Module: Diagrams Component Connector End Views Rear Object Sensor Control Module X1 (UD7) Rear Object Sensor Control Module X2 (UD7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Diagrams > Page 43 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Diagrams > Page 44 Parking Assist Control Module: Service and Repair Rear Object Alarm Module Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 53 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 54 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 55 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 61 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 62 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 63 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Service and Repair Keyless Entry Module: Service and Repair Remote Control Door Lock Receiver Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations Memory Positioning Module: Locations Harness Routing Views Driver Seat Harness Routing 1 - Seat Recline Motor - Driver (AN3) 2 - Seat Lumbar Vertical Motor Position Sensor - Driver (AN3) 3 - Seat Lumbar Vertical Motor - Driver (AN3) 4 - X324 (AN3) 5 - Seat Lumbar Horizontal Motor - Driver (AN3) 6 - Seat Lumbar Horizontal Motor Position Sensor - Driver (AN3) 7 - Seat Recline Position Sensor - Driver (AN3) 8 - Seat Lumbar Switch - Driver (AN3) 9 - Seat Adjuster Switch - Driver (AG1) 10 - Memory Seat Module (MSM) (AN3) 11 - Inflatable Restraint Seat Position Sensor (SPS) - Driver (10 Series) 12 - Seat Adjuster Motor Assembly - Driver (AG1) 13 Seat Belt Buckle - Driver Passenger Seat Harness Routing Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations > Page 71 1 - Seat Frame 2 - X325 (AN3) 3 - Seat Lumbar Vertical Motor - Passenger (AN3) 4 - Seat Adjuster Switch - Passenger (AG2) 5 - Seat Lumbar Switch - Passenger (AN3) 6 - Seat Belt Buckle Passenger 7 - Inflatable Restraint Passenger Presence System (PPS) Module (AL0) 8 - Seat Adjuster Motor Assembly - Passenger (AG2) 9 - Inflatable Restraint Passenger Presence System (PPS) Sensor (AL0) 10 - Seat Recline Motor - Passenger (AN3) 11 - Seat Lumbar Horizontal Motor - Passenger (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations > Page 72 Memory Positioning Module: Diagrams Component Connector End Views Memory Seat Module (MSM) X1 (AN3) Memory Seat Module (MSM) X2 (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations > Page 73 Memory Seat Module (MSM) X3 (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations > Page 74 Memory Seat Module (MSM) X4 (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations > Page 75 Memory Seat Module (MSM) X5 (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations > Page 76 Memory Seat Module (MSM) X6 (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations > Page 77 Memory Seat Module (MSM) X7 (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations > Page 78 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations > Page 79 Memory Positioning Module: Service and Repair Memory Seat Control Module Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Fuse Block - I/P Power Door Lock Relay: Locations Fuse Block - I/P Electrical Center Identification Views Fuse Block - I/P Label Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Fuse Block - I/P > Page 84 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Fuse Block - I/P > Page 85 Power Door Lock Relay: Locations Fuse Block - Underhood Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Fuse Block - I/P > Page 86 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Fuse Block - I/P > Page 87 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Fuse Block - I/P > Page 88 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Fuse Block - I/P > Page 89 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Fuse Block - I/P > Page 90 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Fuse Block - I/P > Page 91 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Fuse Block - I/P > Page 92 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm Seat Heater Control Module: Customer Interest Seats - Driver/Passenger Heated Seats Inop./Slow to Warm TECHNICAL Bulletin No.: 10-08-50-008B Date: January 13, 2011 Subject: Driver or Passenger Heated Seat Inoperative, Slow to Warm, DTC(s) Set (Repair Connector, Re-Route Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Silverado, Suburban, Tahoe 2011 Chevrolet Silverado Heavy Duty 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2011 GMC Sierra Heavy Duty All Equipped with Heated Front Seat (RPO AN3, KA1) or Heated and Cooled Seat (RPO KB6) and/or Luxury Package (RPO PCK) Supercede: This bulletin is being revised to update the RPOs. Please discard Corporate Bulletin Number 10-08-50-008A (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger heated seat system exhibits the following symptoms: - Heated seat turns on and then turns off within 1 to 10 minutes (at any 60 second interval). - The system doesn't get warm enough, or gets warm very slowly. - The heated seat system is completely inoperative. Upon further review, DTCs B2430 0D and/or B2180 0D may be set as a current or history code if the vehicle is equipped with heated seats only (RPO KA1). Also, the LED indicator for the heated seats may come On and then flash after approximately 1 minute, then go out. If the vehicle is equipped with heated and cooled seats (KB6), the switch LED indicator may stay On, but the heated and cooled seat is inoperative. The fan will continue to blow air. Cause Heated Seats (RPO AN3, KA1) The heated seat control circuit terminal and/or ground terminal in harness connector X1 to the memory seat module (MSM) may have lost tension and is loose. The reduced terminal tension increases resistance in the connector, which may result in the symptoms described above. Heated and Cooled Seats (RPO KB6) The thermo-electric device (TED) in the seat cushion/seat back ventilation heating and cooling module may have become inoperative. Correction Heated Seats (RPO AN3, KA1) Follow the steps below to correct the concern with the heated seats. Note This repair requires a unique anti-abrasion electrical tape and harness clip from Kent Automotive. Refer to the Parts Information below. 1. Access and remove the seat bolts/nuts. 2. Adjust the seat rearward about halfway. Adjust the seat recline full forward. 3. Tilt the seat backward to access the bottom of the seat. Prop the seat up with a suitable tool if required. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 101 4. Disconnect seat harness connectors (1) X1, X2, X3 and X4 from the MSM. 5. Identify connector X1. Refer to Component Connector End Views in SI. 6. Perform a terminal drag test on connector X1, paying special attention to terminals 1, 4, 6, 11 and 14. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Refer to Testing for Intermittent Conditions and Poor Connections in SI. 7. Replace any terminal in question including connector X1 terminals 1, 4, 6, 11 and 14 if necessary. Refer to Repairing Connector Terminals in SI. 8. Identify connector X4. Refer to Component Connector End Views in SI. 9. Perform the terminal drag test described in step 6, paying special attention to terminal 14. 10. Replace any terminal in question including connector X4 terminal 14 if necessary. Refer to Repairing Connector Terminals in SI. 11. Remove the harness clip (1) from the plastic carrier. 12. Cut the electrical tape holding the harness in the plastic carrier using a sharp utility knife in the area shown (1). 13. Free the harness from the carrier back to the area shown (1). 14. Obtain "*Woven Polyester (PET) Electrical Tape" (Special Order P/N RZ97156A00) from Kent Automotive. Refer to Parts Information below. Important Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 102 DO NOT substitute with vinyl electrical tape or friction tape. Use only the tape specified above. 15. Tape the harness starting at the MSM connectors (1) extending back to the new break-out location (2) in the plastic carrier. 16. Install a plastic tie strap around the harness and the plastic carrier at the break-out point (1). 17. Install the new harness edge clip (1) 10 mm (0.4 in) further from the connectors and the existing harness clip. Ensure the clip is installed in the orientation shown. 18. Install the harness with the new harness clip in the location shown (1). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 103 19. Reinstall the harness connectors (1) to the MSM. 20. Reinstall the seat to the vehicle. Heated and Cooled Seats (RPO KB6) Follow the steps below to correct the concern with the heated and cooled seats. 1. Inspect the ventilation heating and cooling module for a concern with the TED. Refer to Seat Heating and Cooling, Diagnostic Information and Procedures in SI. Note If the heated and cooled seat function is inoperative, but the heat switch indicators are On, the MSM is functioning properly and the concern is with the TED. 2. If the TED is found to be the concern, replace the seat cushion or seat back ventilation heating and cooling module. Refer to Driver or Passenger Seat Back Ventilation Heating and Cooling Blower Replacement or Driver or Passenger Seat Cushion Ventilation Heating and Cooling Blower Replacement in SI. If the TED is not the concern, follow normal diagnostics and repair in SI. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Use the appropriate Labor Operation based on the repair completed. Heated Seats (RPO AN3, KA1) For vehicles repaired under warranty, use: Heated and Cooled Seats (RPO KB6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 104 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Control Module: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm Seat Heater Control Module: All Technical Service Bulletins Seats - Driver/Passenger Heated Seats Inop./Slow to Warm TECHNICAL Bulletin No.: 10-08-50-008B Date: January 13, 2011 Subject: Driver or Passenger Heated Seat Inoperative, Slow to Warm, DTC(s) Set (Repair Connector, Re-Route Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Silverado, Suburban, Tahoe 2011 Chevrolet Silverado Heavy Duty 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2011 GMC Sierra Heavy Duty All Equipped with Heated Front Seat (RPO AN3, KA1) or Heated and Cooled Seat (RPO KB6) and/or Luxury Package (RPO PCK) Supercede: This bulletin is being revised to update the RPOs. Please discard Corporate Bulletin Number 10-08-50-008A (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger heated seat system exhibits the following symptoms: - Heated seat turns on and then turns off within 1 to 10 minutes (at any 60 second interval). - The system doesn't get warm enough, or gets warm very slowly. - The heated seat system is completely inoperative. Upon further review, DTCs B2430 0D and/or B2180 0D may be set as a current or history code if the vehicle is equipped with heated seats only (RPO KA1). Also, the LED indicator for the heated seats may come On and then flash after approximately 1 minute, then go out. If the vehicle is equipped with heated and cooled seats (KB6), the switch LED indicator may stay On, but the heated and cooled seat is inoperative. The fan will continue to blow air. Cause Heated Seats (RPO AN3, KA1) The heated seat control circuit terminal and/or ground terminal in harness connector X1 to the memory seat module (MSM) may have lost tension and is loose. The reduced terminal tension increases resistance in the connector, which may result in the symptoms described above. Heated and Cooled Seats (RPO KB6) The thermo-electric device (TED) in the seat cushion/seat back ventilation heating and cooling module may have become inoperative. Correction Heated Seats (RPO AN3, KA1) Follow the steps below to correct the concern with the heated seats. Note This repair requires a unique anti-abrasion electrical tape and harness clip from Kent Automotive. Refer to the Parts Information below. 1. Access and remove the seat bolts/nuts. 2. Adjust the seat rearward about halfway. Adjust the seat recline full forward. 3. Tilt the seat backward to access the bottom of the seat. Prop the seat up with a suitable tool if required. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Control Module: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 110 4. Disconnect seat harness connectors (1) X1, X2, X3 and X4 from the MSM. 5. Identify connector X1. Refer to Component Connector End Views in SI. 6. Perform a terminal drag test on connector X1, paying special attention to terminals 1, 4, 6, 11 and 14. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Refer to Testing for Intermittent Conditions and Poor Connections in SI. 7. Replace any terminal in question including connector X1 terminals 1, 4, 6, 11 and 14 if necessary. Refer to Repairing Connector Terminals in SI. 8. Identify connector X4. Refer to Component Connector End Views in SI. 9. Perform the terminal drag test described in step 6, paying special attention to terminal 14. 10. Replace any terminal in question including connector X4 terminal 14 if necessary. Refer to Repairing Connector Terminals in SI. 11. Remove the harness clip (1) from the plastic carrier. 12. Cut the electrical tape holding the harness in the plastic carrier using a sharp utility knife in the area shown (1). 13. Free the harness from the carrier back to the area shown (1). 14. Obtain "*Woven Polyester (PET) Electrical Tape" (Special Order P/N RZ97156A00) from Kent Automotive. Refer to Parts Information below. Important Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Control Module: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 111 DO NOT substitute with vinyl electrical tape or friction tape. Use only the tape specified above. 15. Tape the harness starting at the MSM connectors (1) extending back to the new break-out location (2) in the plastic carrier. 16. Install a plastic tie strap around the harness and the plastic carrier at the break-out point (1). 17. Install the new harness edge clip (1) 10 mm (0.4 in) further from the connectors and the existing harness clip. Ensure the clip is installed in the orientation shown. 18. Install the harness with the new harness clip in the location shown (1). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Control Module: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 112 19. Reinstall the harness connectors (1) to the MSM. 20. Reinstall the seat to the vehicle. Heated and Cooled Seats (RPO KB6) Follow the steps below to correct the concern with the heated and cooled seats. 1. Inspect the ventilation heating and cooling module for a concern with the TED. Refer to Seat Heating and Cooling, Diagnostic Information and Procedures in SI. Note If the heated and cooled seat function is inoperative, but the heat switch indicators are On, the MSM is functioning properly and the concern is with the TED. 2. If the TED is found to be the concern, replace the seat cushion or seat back ventilation heating and cooling module. Refer to Driver or Passenger Seat Back Ventilation Heating and Cooling Blower Replacement or Driver or Passenger Seat Cushion Ventilation Heating and Cooling Blower Replacement in SI. If the TED is not the concern, follow normal diagnostics and repair in SI. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Use the appropriate Labor Operation based on the repair completed. Heated Seats (RPO AN3, KA1) For vehicles repaired under warranty, use: Heated and Cooled Seats (RPO KB6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Control Module: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 113 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 114 Seat Heater Control Module: Diagrams Component Connector End Views Seat Back Ventilation Heating and Cooling Module - Driver (KB6) Seat Back Ventilation Heating and Cooling Module - Passenger (KB6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 115 Seat Climate Control Module X1 (KB6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 116 Seat Climate Control Module X2 (KB6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 117 Seat Climate Control Module X3 (KB6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 118 Seat Cushion Ventilation Heating and Cooling Module - Driver (KB6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 119 Seat Cushion Ventilation Heating and Cooling Module - Passenger (KB6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 120 Heated Seat Control Module X1 (SPO Heated Seats) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 121 Heated Seat Control Module X2 (SPO Heated Seats) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 122 Heated Seat Control Module X3 (SPO Heated Seats) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 123 Heated Seat Control Module X4 (SPO Heated Seats) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 124 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Service and Repair > Front Seat Heater Control Module Seat Heater Control Module: Service and Repair Front Seat Heater Control Module Front Seat Heater Control Module Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Service and Repair > Front Seat Heater Control Module > Page 127 Seat Heater Control Module: Service and Repair Module Replacement - Seat Climate Control Front Seat (Denali with KB6) Module Replacement - Seat Climate Control - Front Seat (Denali with KB6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Diagrams Sunroof / Moonroof Module: Diagrams Component Connector End Views Sunroof Control Module (CF5) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Diagrams Trailer Towing Relay: Diagrams Component Connector End Views Trailer Brake Control Relay (JL1) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Diagrams > Page 134 Trailer Towing Relay: Service and Repair Trailer Brake Control Relay Replacement (2500, 3500) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams Electronic Brake Control Module: Diagrams Component Connector End Views Electronic Brake Control Module (EBCM) (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Page 139 Electronic Brake Control Module (EBCM) (JF3 or JF7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Page 140 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Page 141 Electronic Brake Control Module (EBCM) (JH6 or JH7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Page 142 Electronic Brake Control Module (EBCM) (JL4 except 10 Series) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Page 143 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Page 144 Electronic Brake Control Module (EBCM) (JL4 with 10 Series) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Page 145 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Page 146 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Non-Hybrid Less than 3900 kg (8600 lb) GVW Electronic Brake Control Module: Service and Repair Non-Hybrid Less than 3900 kg (8600 lb) GVW Electronic Brake Control Module Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Non-Hybrid Less than 3900 kg (8600 lb) GVW > Page 149 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Non-Hybrid Less than 3900 kg (8600 lb) GVW > Page 150 Electronic Brake Control Module: Service and Repair Non-Hybrid Greater than/Equal to 3900 kg (8600 lb) GVW Electronic Brake Control Module Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Accessories - Aftermarket Trailer Brake Controller Trailer Brake Control Module: Technical Service Bulletins Accessories - Aftermarket Trailer Brake Controller INFORMATION Bulletin No.: 07-08-45-001F Date: November 09, 2010 Subject: Procedure for Installation of an Aftermarket Trailer Brake Controller Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2010 HUMMER H2 with Integrated Trailer Brake Controller Supercede: This bulletin is being revised to combine information from bulletins 06-08-45-008D and 07-08-45-001E. Please discard Corporate Bulletin Numbers 07-08-45-001E and 06-08-45-008D (Section 08 - Body and Accessories). Important Installation of an electric brake controller and the wiring connections outlined in this bulletin are the responsibility of the dealership or customer. These repairs should never be charged to warranty. If you have any questions, please consult with your District Service Manager. Some customers may request to have an aftermarket trailer brake controller added to their vehicle, OR in lieu of the factory integrated trailer brake controller (ITBC) (RPO JL1). Installation Instructions Starting with the new 2007 full-size utilities and pickups and 2008 HUMMER H2, there is no longer an electric trailer brake controller pigtail harness. To install an aftermarket trailer brake controller, use the four blunt cut wires located near the data link connector. The following steps should be used to complete the installation. Important Ensure that the ringlets are not interfering with the UBEC cover. 1. Place the terminal on the larger of the two studs at the front of the electrical center and secure with an M8 nut. This is circuit #242 to stud #2, to power the aftermarket trailer brake controller. Important The fuse is already present in the vehicle to power the electrical trailer brake controller system. 2. ONLY For Vehicles Equipped with JL1 - Locate connector X126 or X115 (varies with vehicle build; refer to SI) near the underhood fuse block. Refer to SI Document ID# 1849049 - I/P Harness-Engine Compartment. Circuit 47 from the blunt cut wires near the data link connector will end Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Accessories - Aftermarket Trailer Brake Controller > Page 155 at connector X126 terminal "G" or X115 terminal "B5." Obtain enough Dark Blue 12 gauge wire to run from X126/X115 to the 7-way trailer connector at the bumper. On one end of the Dark Blue wire attach terminal part number 15304732, located in Delphi Tray 8 and insert into X126 "G" or terminal part number 15304720 located in Delphi Tray 19 and insert into X115 "B5." Run the Dark Blue wire in its own conduit along the frame to the 7-way trailer connector at the bumper. Remove circuit 47 from the 7-way trailer connector terminal "C" and tape the bare terminal and attach to the harness. Attach terminal part number 12110853, located in Delphi Tray 4, to the other end of the Dark Blue wire and insert it into the 7-way trailer connector terminal "C." 3. ONLY For Vehicles Equipped with JL1 - The Red/Black wire, circuit 242, must be connected to stud #2 of the 30 Amp fuse of the underhood fuse block. This wire is located between the left fender and the underhood fuse block. Important This procedure will not result in any trailer brake related display messages to be set. However, ITBC diagnostics will continue to function. If an ITBC fault is detected, a "Service Trailer Brake System" message will be displayed on the driver information center (DIC) and an appropriate DTC will be stored in the ITBC module. The operator will still be able to adjust gain and access the "Trailer Gain / Output" display page in the DIC. However, the factory installed ITBC system will not sense a trailer connection and will not provide output to the trailer. 4. Locate the trailer brake control circuits that are looped and taped to the main harness under the instrument panel. 5. Pull the trailering wire harness down. 6. Match the vehicle harness label circuit functions to the trailer brake controller jumper harness functions. Important The color or wires to be joined together may not match. - Dark Blue Wire: switched power from controller to trailer brakes - Red with Black Stripe: fused vehicle power to electrical brake controller Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Accessories - Aftermarket Trailer Brake Controller > Page 156 - Light Blue with White Stripe: Brake switch input to power electric brake controller - White: ground - Orange: CHMSL (Center High Mounted Stop Lamp) - not required with most systems 7. After completing the under dash connections to the electric brake controller, open the hood and locate the red wire that is taped to the harness between the underhood electrical center and the driver side front fender. 8. Break the tape on the red/black wire and pull it toward the front of vehicle. 9. Remove the lid from the electrical center. Auxiliary Power (Applies to All LD and 2007-2009 HD's Only) Without JL1 Circuit #742 for Auxiliary Power at the 7-way trailer connector is no longer connected by the GM Assembly Plant. If the customer desires auxiliary power at the trailer connector location (i.e. refrigeration, battery charger or interior light in the trailer), complete the following steps to connect circuit #742: 1. Locate the red/black wire, looped and taped to the chassis harness, below the brake master cylinder. 2. Break the tape and route the wire to the front of the underhood electrical center. Important Ensure that the ringlets are not interfering with the UBEC cover. 3. Place the terminal on the smaller of the two studs on the electrical center and secure with an M6 fastener. This is circuit #742 to stud #1 for auxiliary power to the 7-way trailer connector. 4. ONLY for vehicles without RPO TP2 - Auxiliary Battery, install a 40 amp fuse to power the circuit. Important For vehicles equipped with RPO TP2 - Devices powered by this fuse will drain the vehicle battery if left connected with the vehicle not running. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Accessories - Aftermarket Trailer Brake Controller > Page 157 Warranty Information This installation procedure is to be performed at the customer's request and at their expense. It is not a warranty repair and a claim should not be submitted for reimbursement. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Accessories - Aftermarket Trailer Brake Controller > Page 158 Trailer Brake Control Module: Technical Service Bulletins Brakes - Aftermarket Trailer Brake Controllers INFORMATION Bulletin No.: 06-08-45-008D Date: July 12, 2010 Subject: Information on Auxiliary Power Wire at Trailer and Installation of Aftermarket Trailer Brake Controller - Towing, Tow Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2011 HUMMER H2 Supercede: This bulletin is being revised to add the 2011 model year and information about the orientation of the ringlet. Please discard Corporate Bulletin Number 06-08-45-008C (Section 08 Body and Accessories). Important Installation of an electric brake controller and the wiring connections outlined in this bulletin are the responsibility of the dealership or customer. These repairs should never be charged to warranty. If you have any questions, please consult with your District Service Manager. Some customers may have questions on how to connect an electric trailer brake controller or where the brake controller pigtail harness is located. Starting with the new 2007 full-size utilities and pickups and 2008 HUMMER H2, there is no longer an electric trailer brake controller pigtail harness. An aftermarket brake controller will need to be installed/connected to the blunt wires under the left side of the IP for vehicles built without JL1 - Integrated Brake Controller (full-size utilities and pickups). The following steps should be used to complete the installation. 1. Locate the trailer brake control circuits that are looped and taped to the main harness under the instrument panel. 2. Pull the trailering wire harness down. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Accessories - Aftermarket Trailer Brake Controller > Page 159 3. Match the vehicle harness label circuit functions to the trailer brake controller jumper harness functions. Important The color or wires to be joined together may not match. - Dark Blue Wire: switched power from controller to trailer brakes - Red with Black Stripe: fused vehicle power to electrical brake controller - Light Blue with White Stripe: Brake switch input to power electric brake controller - White: ground - Orange: CHMSL (Center High Mounted Stop Lamp) - not required with most systems 4. After completing the under dash connections to the electric brake controller, open the hood and locate the red wire that is taped to the harness between the underhood electrical center and the driver side front fender. 5. Break the tape on the red/black wire and pull it toward the front of vehicle. 6. Remove the lid from the electrical center. Important Ensure that the ringlets are not interfering with the UBEC cover. 7. Place the terminal on the larger of the two studs at the front of the electrical center and secure with an M8 nut. This is circuit #242 to stud #2, to power the aftermarket trailer brake controller. Important The fuse is already present in the vehicle to power the electrical trailer brake controller system. Auxiliary Power (Applies to All LD & 07-09 HD's Only) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Accessories - Aftermarket Trailer Brake Controller > Page 160 Circuit #742 for Auxiliary Power at the 7-way trailer connector is no longer connected by the GM Assembly Plant. If the customer desires auxiliary power at the trailer connector location (i.e. refrigeration, battery charger or interior light in the trailer), complete the following steps to connect circuit #742: 1. Locate the red/black wire, looped and taped to the chassis harness, below the brake master cylinder. 2. Break the tape and route the wire to the front of the underhood electrical center. Important Ensure that the ringlets are not interfering with the UBEC cover. 3. Place the terminal on the smaller of the two studs on the electrical center and secure with an M6 fastener. This is circuit #742 to stud #1 for auxiliary power to the 7-way trailer connector. 4. ONLY for vehicles without RPO TP2 - Auxiliary Battery, install a 40 amp fuse to power the circuit. Important For vehicles equipped with RPO TP2 - Devices powered by this fuse will drain the vehicle battery if left connected with the vehicle not running. Warranty Information This installation procedure is to be performed at the customer's request and at their expense. It is not a warranty repair and a claim should not be submitted for reimbursement. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Page 161 Trailer Brake Control Module: Diagrams Component Connector End Views Trailer Brake Control Module (JL1 except 31 Series) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Page 162 Trailer Brake Control Module (JL1 with 31 Series) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Page 163 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Page 164 Fuel Pump/Trailer Brake Control Module (Gas with JL1 and except LU3, LY6 or LY6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Page 165 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Page 166 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Service and Repair > Trailer Brake Control Switch Replacement Trailer Brake Control Module: Service and Repair Trailer Brake Control Switch Replacement Trailer Brake Control Switch Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Service and Repair > Trailer Brake Control Switch Replacement > Page 169 Trailer Brake Control Module: Service and Repair Trailer Brake Control Module Replacement Trailer Brake Control Module Replacement (2500, 3500) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations Radiator Cooling Fan Motor Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 174 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 175 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 176 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 177 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 178 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 179 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 180 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 184 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 185 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 186 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 187 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 188 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 189 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 190 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Compressor Clutch Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 195 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 196 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 197 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 198 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 199 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 200 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 201 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Customer Interest for Control Module HVAC: > 11-01-38-001 > Feb > 11 > A/C Excessive Cabin Moisture/Reduced Window Clearing Control Module HVAC: Customer Interest A/C - Excessive Cabin Moisture/Reduced Window Clearing TECHNICAL Bulletin No.: 11-01-38-001 Date: February 28, 2011 Subject: Excessive Cabin Moisture / Reduced Window Clearing (Reprogram HVAC System Control Module) Models: 2010-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2010-2011 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL All with RPO CJ3 or C67 (Manual Air Conditioning) Condition In rare cases, some customers may comment on excessive cabin moisture or difficulty keeping the windows clear in low ambient temperatures. Cause This concern may be caused by the recirculation door being in the recirculation position while the mode is set to a floor through defrost position. Correction Important DO NOT replace the HVAC control module for this concern. Revised software has been developed to address this condition. Technicians are to reprogram the HVAC Control Module using the Service Programming System (SPS) with the latest software currently available in TIS2WEB. When using a Tech 2(R) or a Multiple Diagnostic Interface (MDI) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Customer Interest for Control Module HVAC: > 10-01-38-001 > Mar > 10 > A/C Reduced Windshield Clearing/Defrost Control Module HVAC: Customer Interest A/C - Reduced Windshield Clearing/Defrost TECHNICAL Bulletin No.: 10-01-38-001 Date: March 02, 2010 Subject: Reduced Windshield Clearing\Defrost at Low Ambient Temperatures (Reprogram HVAC Control Module) Models: 2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2010 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon XL Denali All Equipped with HVAC System RPOs C42, C67 or CJ3 All Built Prior to February 17, 2010 Condition In rare cases, some customers may comment that the HVAC system has reduced defrost or added difficulty keeping the windshield clear in low ambient temperatures. Cause This condition may be caused by the airflow calibrations which can contribute to the above condition. Calibration changes at the start of the 2010 model year may not meet some customers' expectations. Testing has confirmed that defrost levels will meet requirements. Correction Important DO NOT replace the HVAC Control Module for this concern. Reprogram the HVAC Control Module with the latest software calibration. Important Select the correct calibration files for the appropriate vehicle configuration (body style) and RPO codes. A revised calibration has been developed to address this condition. Technicians are to reprogram the HVAC Control Module using the Service Programming System (SPS) with the latest calibrations available on TIS2WEB. Refer to HVAC System Control Module Programming and Setup in SI. When using a Tech 2(R) or a Multiple Diagnostic Interface (MDI) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 11-01-38-001 > Feb > 11 > A/C - Excessive Cabin Moisture/Reduced Window Clearing Control Module HVAC: All Technical Service Bulletins A/C - Excessive Cabin Moisture/Reduced Window Clearing TECHNICAL Bulletin No.: 11-01-38-001 Date: February 28, 2011 Subject: Excessive Cabin Moisture / Reduced Window Clearing (Reprogram HVAC System Control Module) Models: 2010-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2010-2011 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL All with RPO CJ3 or C67 (Manual Air Conditioning) Condition In rare cases, some customers may comment on excessive cabin moisture or difficulty keeping the windows clear in low ambient temperatures. Cause This concern may be caused by the recirculation door being in the recirculation position while the mode is set to a floor through defrost position. Correction Important DO NOT replace the HVAC control module for this concern. Revised software has been developed to address this condition. Technicians are to reprogram the HVAC Control Module using the Service Programming System (SPS) with the latest software currently available in TIS2WEB. When using a Tech 2(R) or a Multiple Diagnostic Interface (MDI) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 10-01-38-001 > Mar > 10 > A/C - Reduced Windshield Clearing/Defrost Control Module HVAC: All Technical Service Bulletins A/C - Reduced Windshield Clearing/Defrost TECHNICAL Bulletin No.: 10-01-38-001 Date: March 02, 2010 Subject: Reduced Windshield Clearing\Defrost at Low Ambient Temperatures (Reprogram HVAC Control Module) Models: 2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2010 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon XL Denali All Equipped with HVAC System RPOs C42, C67 or CJ3 All Built Prior to February 17, 2010 Condition In rare cases, some customers may comment that the HVAC system has reduced defrost or added difficulty keeping the windshield clear in low ambient temperatures. Cause This condition may be caused by the airflow calibrations which can contribute to the above condition. Calibration changes at the start of the 2010 model year may not meet some customers' expectations. Testing has confirmed that defrost levels will meet requirements. Correction Important DO NOT replace the HVAC Control Module for this concern. Reprogram the HVAC Control Module with the latest software calibration. Important Select the correct calibration files for the appropriate vehicle configuration (body style) and RPO codes. A revised calibration has been developed to address this condition. Technicians are to reprogram the HVAC Control Module using the Service Programming System (SPS) with the latest calibrations available on TIS2WEB. Refer to HVAC System Control Module Programming and Setup in SI. When using a Tech 2(R) or a Multiple Diagnostic Interface (MDI) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Page 223 Control Module HVAC: Diagrams Component Connector End Views HVAC Control Module X1 (CJ2) HVAC Control Module X2 (C67, C42 or MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Page 224 HVAC Control Module X2 (CJ2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Page 225 HVAC Control Module X3 (C67, C42, CJ2 or MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Page 226 Blower Motor Control Module X1 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Page 227 Blower Motor Control Module X2 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Page 228 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Service and Repair > HVAC - Automatic Control Module HVAC: Service and Repair HVAC - Automatic HVAC Control Module Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Service and Repair > HVAC - Automatic > Page 231 Control Module HVAC: Service and Repair HVAC - Manual HVAC Control Module Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Service and Repair > HVAC - Automatic > Page 232 Control Module HVAC: Service and Repair Blower Motor Control Module Replacement Blower Motor Control Module Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Locations Backup Lamp Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Locations > Page 237 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Locations > Page 238 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Locations > Page 239 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Locations > Page 240 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Locations > Page 241 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Locations > Page 242 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Locations > Page 243 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Center Mounted Brake Lamp Relay > Component Information > Locations Center Mounted Brake Lamp Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Center Mounted Brake Lamp Relay > Component Information > Locations > Page 247 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Center Mounted Brake Lamp Relay > Component Information > Locations > Page 248 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Center Mounted Brake Lamp Relay > Component Information > Locations > Page 249 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Center Mounted Brake Lamp Relay > Component Information > Locations > Page 250 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Center Mounted Brake Lamp Relay > Component Information > Locations > Page 251 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Center Mounted Brake Lamp Relay > Component Information > Locations > Page 252 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Center Mounted Brake Lamp Relay > Component Information > Locations > Page 253 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations Fog/Driving Lamp Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 257 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 258 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 259 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 260 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 261 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 262 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 263 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Hazard Flasher Relay > Component Information > Diagrams Hazard Flasher Relay: Diagrams Component Connector End Views Roof Beacon Relay (TRW) Emergency Vehicle Roof Lamp Relay (5Y0) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Hazard Flasher Relay > Component Information > Diagrams > Page 267 Wrecker Relay X1 (5X7) Wrecker Relay X2 (5X7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Hazard Flasher Relay > Component Information > Diagrams > Page 268 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations Headlamp Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 272 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 273 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 274 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 275 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 276 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 277 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 278 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Horn Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 282 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 283 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 284 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 285 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 286 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 287 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 288 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations Parking Lamp Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 292 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 293 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 294 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 295 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 296 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 297 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 298 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations Trailer Lighting Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Page 302 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Page 303 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Page 304 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Page 305 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Page 306 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Page 307 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Page 308 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Page 309 Trailer Lighting Relay: Diagrams Component Connector End Views Trailer Stop/Turn Relay (TZ0) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Service and Repair > Relay Replacement (Attached to Wire Harness) Power Distribution Relay: Service and Repair Relay Replacement (Attached to Wire Harness) Relay Replacement (Attached to Wire Harness) Removal Procedure 1. Locate the relay. Refer to the Master Electrical Component List (See: Locations/Component Locations/A - Z Index) to locate the relay in the vehicle. 2. Remove any fasteners which hold the relay in place. 3. Remove any connector position assurance (CPA) devices or secondary locks. Note: Use care when removing a relay in a wiring harness when the relay is secured by fasteners or tape. 4. Separate the relay (1) from the wire harness connector (2). Installation Procedure 1. Connect the relay (1) to the wire harness connector (2). 2. Install any connector position assurance (CPA) devices or secondary locks. 3. Install the relay using any fasteners or tape that originally held the relay in place. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Service and Repair > Relay Replacement (Attached to Wire Harness) > Page 315 Power Distribution Relay: Service and Repair Relay Replacement (Within an Electrical Center) Relay Replacement (Within an Electrical Center) Special Tools J 43244 Relay Puller Pliers Removal Procedure 1. Remove the electrical center cover. 2. Locate the relay. Refer to Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse/Application and ID) to locate the electrical center where the relay exists. Note: * Always note the orientation of the relay. * If equipped with a notch style relay; observe the location of the notch on the old relay to verify the new relay is installed with the notch in the same location. * Ensure that the electrical center is secure, as not to put added stress on the wires or terminals. 3. Using the J 43244 (1) position the tool on opposing corners of the relay (2). Caution: Use J43244 to pull the relay straight out from the electrical center terminals. The use of pliers or a flat bladed tool could damage the electrical center. 4. Remove the relay (2) from the electrical center. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Service and Repair > Relay Replacement (Attached to Wire Harness) > Page 316 1. Install the relay (2) in the same position as removed. 2. Install the electrical center cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood Relay Box: Application and ID Fuse Block - Underhood Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 321 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 322 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 323 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 324 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 325 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 326 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 327 Fuse Block - Underhood Top View - Diesel Fuse Block - Underhood Top View - Gas Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 328 Fuse Block - Underhood Bottom View Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 329 Fuse Block - Underhood X1 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 330 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 331 Fuse Block - Underhood X2 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 332 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 333 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 334 Fuse Block - Underhood X3 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 335 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 336 Fuse Block - Underhood X4 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 337 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 338 Fuse Block - Underhood X5 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 339 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 340 Fuse Block - Underhood X6 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 341 Fuse Block - Underhood X7 (except TP2) Fuse Block - Underhood X7 (TP2) Fuse Block - Underhood X8 (except JL1) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 342 Fuse Block - Underhood X8 (JL1) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 343 Relay Box: Application and ID Fuse Block - I/P Electrical Center Identification Views Fuse Block - I/P Label Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 344 Fuse Block - I/P Top View Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 345 Fuse Block - I/P Bottom View Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 346 Fuse Block - I/P X1 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 347 Fuse Block - I/P X2 (except MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 348 Fuse Block - I/P X3 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 349 Fuse Block - I/P X4 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 350 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 351 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 352 Relay Box: Application and ID Fuse Block - Mobile Radio Electrical Center Identification Views Fuse Block - Mobile Radio, Top View (9L4) Fuse Block - Mobile Radio (9L4) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 353 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 354 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 07-08-42-006E > Nov > 10 > Instruments - Bulb Outage Detection Restoration Body Control Module: Customer Interest Instruments - Bulb Outage Detection Restoration INFORMATION Bulletin No.: 07-08-42-006E Date: November 11, 2010 Subject: Information on BCM Calibrations Available to Restore Bulb Outage Detection on Vehicles Produced by a Second Stage Manufacturer, Turn Signals Flash Fast after Factory Box Removed (Upfitter) Models: 2007-2011 Chevrolet Silverado 2007-2011 GMC Sierra Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 07-08-42-006D (Section 08 - Body and Accessories). The information contained in this bulletin applies to vehicles that are to be completed by a second stage manufacturer (upfitter) and may need to have the Body Control Module (BCM) rear turn signal bulb outage detection capability changed. All production vehicles will be manufactured with one of the following BCM rear turn signal bulb outage detection software options: 1. A standard production vehicle will have BCM software that checks for two bulbs functioning in each rear turn signal bulb circuit. If one or more bulbs are inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 2. Certain 2500 and 3500 models can be ordered with a new option (RPO 9U5) where the BCM checks for one bulb functioning in each rear turn signal bulb circuit. If the bulb goes inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 3. A vehicle built with a pickup box delete or chassis cab option (RPO ZW9) will be produced with a BCM program that has no turn signal bulb outage detection capability (LED compatible). The IPC turn signal indicator will flash at the same rate no matter how many turn signal bulbs are inoperative. In some cases, the upfitter may wish to change the turn signal bulb outage detection capability so that the turn signals work correctly with their upfit or to meet certain requirements. This will require contacting the Techline Customer Support Center (TCSC) to open a case and obtain a Vehicle Configuration Index (VCI) number. Advise the TCSC consultant which turn signal bulb outage detection capability is needed: 1. Factory standard production TWO bulb outage detection. 2. Optional (RPO 9U5) ONE bulb outage detection. NOTE: ONLY AVAILABLE ON CERTAIN 2007-2011 MODEL 2500 AND 3500 VEHICLES. 3. NO bulb outage detection (LED compatible). The BCM can then be reprogrammed with the correct software. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 07-08-42-006E > Nov > 10 > Instruments - Bulb Outage Detection Restoration Body Control Module: All Technical Service Bulletins Instruments - Bulb Outage Detection Restoration INFORMATION Bulletin No.: 07-08-42-006E Date: November 11, 2010 Subject: Information on BCM Calibrations Available to Restore Bulb Outage Detection on Vehicles Produced by a Second Stage Manufacturer, Turn Signals Flash Fast after Factory Box Removed (Upfitter) Models: 2007-2011 Chevrolet Silverado 2007-2011 GMC Sierra Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 07-08-42-006D (Section 08 - Body and Accessories). The information contained in this bulletin applies to vehicles that are to be completed by a second stage manufacturer (upfitter) and may need to have the Body Control Module (BCM) rear turn signal bulb outage detection capability changed. All production vehicles will be manufactured with one of the following BCM rear turn signal bulb outage detection software options: 1. A standard production vehicle will have BCM software that checks for two bulbs functioning in each rear turn signal bulb circuit. If one or more bulbs are inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 2. Certain 2500 and 3500 models can be ordered with a new option (RPO 9U5) where the BCM checks for one bulb functioning in each rear turn signal bulb circuit. If the bulb goes inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 3. A vehicle built with a pickup box delete or chassis cab option (RPO ZW9) will be produced with a BCM program that has no turn signal bulb outage detection capability (LED compatible). The IPC turn signal indicator will flash at the same rate no matter how many turn signal bulbs are inoperative. In some cases, the upfitter may wish to change the turn signal bulb outage detection capability so that the turn signals work correctly with their upfit or to meet certain requirements. This will require contacting the Techline Customer Support Center (TCSC) to open a case and obtain a Vehicle Configuration Index (VCI) number. Advise the TCSC consultant which turn signal bulb outage detection capability is needed: 1. Factory standard production TWO bulb outage detection. 2. Optional (RPO 9U5) ONE bulb outage detection. NOTE: ONLY AVAILABLE ON CERTAIN 2007-2011 MODEL 2500 AND 3500 VEHICLES. 3. NO bulb outage detection (LED compatible). The BCM can then be reprogrammed with the correct software. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-08-47-001A > Jun > 10 > Body Controls - Unable To Reprogram Body Control Module Body Control Module: All Technical Service Bulletins Body Controls - Unable To Reprogram Body Control Module INFORMATION Bulletin No.: 09-08-47-001A Date: June 14, 2010 Subject: Unable to Reprogram Body Control Module (BCM), BCM Reprogramming Did Not Complete - Revised Reprogramming Instructions Models: 2006-2010 Buick Lucerne 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX 2008-2010 Cadillac CTS 2010 Cadillac CTS Wagon 2010 Chevrolet Camaro 2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Impala 2007-2010 Chevrolet Avalanche, Equinox, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet Traverse 2007-2010 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2008-2010 GMC Savana 2010 GMC Terrain 2007-2009 Pontiac Torrent 2008-2009 Pontiac G8 2008-2009 HUMMER H2 2007-2009 Saturn OUTLOOK 2008-2009 Saturn VUE Refer to GMVIS Supercede: This bulletin is being revised to update the models and the model years. Please discard Corporate Bulletin Number 09-08-47-001 (Section 08 - Body and Accessories). Some technicians may experience an unsuccessful body control module (BCM) reprogramming event, when choosing the Reprogram ECU selection on the Service Programming System (SPS). The technician may also notice that when attempting to reprogram the BCM again after this incident has occurred, the BCM may not complete the programming event. This condition may be caused by the following: - A reprogramming event that was interrupted due to a lack of communication between the vehicle and the TIS2WEB terminal. - The vehicle experienced low system voltage during the reprogramming event. Important Do not replace the BCM for this condition. SPS Programming Process Selection Perform this procedure first. 1. If reprogramming has failed during the initial reprogramming event, back out of the SPS application completely. 2. Re-select SPS from the TIS2WEB terminal application. 3. When selecting the Programming Process , choose Replace and Program ECU , even though a new BCM is NOT being installed. 4. Reprogram the BCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the SPS procedures in SI. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-08-47-001A > Jun > 10 > Body Controls - Unable To Reprogram Body Control Module > Page 374 During programming, the battery voltage must be maintained within the proper range of 12-15 volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. BCM Still Fails to Reprogram If the BCM still fails to reprogram perform this procedure: 1. Turn OFF the ignition, and remove the key. 2. Remove the fuses that power up the following modules/components for a minimum of 2 minutes: - BCM - EBCM - ECM - IS LPS (located in the left IP fusebox) - TCM 3. Open and close the driver door. Allow enough time for the retained accessory power (RAP) to turn OFF. 4. Reinstall the fuses. 5. When selecting the Programming Process , choose Replace and Program ECU , even though a new BCM is NOT being installed. 6. Reprogram the BCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the SPS procedures in SI. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 11-01-38-001 > Feb > 11 > A/C - Excessive Cabin Moisture/Reduced Window Clearing Control Module HVAC: All Technical Service Bulletins A/C - Excessive Cabin Moisture/Reduced Window Clearing TECHNICAL Bulletin No.: 11-01-38-001 Date: February 28, 2011 Subject: Excessive Cabin Moisture / Reduced Window Clearing (Reprogram HVAC System Control Module) Models: 2010-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2010-2011 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL All with RPO CJ3 or C67 (Manual Air Conditioning) Condition In rare cases, some customers may comment on excessive cabin moisture or difficulty keeping the windows clear in low ambient temperatures. Cause This concern may be caused by the recirculation door being in the recirculation position while the mode is set to a floor through defrost position. Correction Important DO NOT replace the HVAC control module for this concern. Revised software has been developed to address this condition. Technicians are to reprogram the HVAC Control Module using the Service Programming System (SPS) with the latest software currently available in TIS2WEB. When using a Tech 2(R) or a Multiple Diagnostic Interface (MDI) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 10-01-38-001 > Mar > 10 > A/C - Reduced Windshield Clearing/Defrost Control Module HVAC: All Technical Service Bulletins A/C - Reduced Windshield Clearing/Defrost TECHNICAL Bulletin No.: 10-01-38-001 Date: March 02, 2010 Subject: Reduced Windshield Clearing\Defrost at Low Ambient Temperatures (Reprogram HVAC Control Module) Models: 2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2010 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon XL Denali All Equipped with HVAC System RPOs C42, C67 or CJ3 All Built Prior to February 17, 2010 Condition In rare cases, some customers may comment that the HVAC system has reduced defrost or added difficulty keeping the windshield clear in low ambient temperatures. Cause This condition may be caused by the airflow calibrations which can contribute to the above condition. Calibration changes at the start of the 2010 model year may not meet some customers' expectations. Testing has confirmed that defrost levels will meet requirements. Correction Important DO NOT replace the HVAC Control Module for this concern. Reprogram the HVAC Control Module with the latest software calibration. Important Select the correct calibration files for the appropriate vehicle configuration (body style) and RPO codes. A revised calibration has been developed to address this condition. Technicians are to reprogram the HVAC Control Module using the Service Programming System (SPS) with the latest calibrations available on TIS2WEB. Refer to HVAC System Control Module Programming and Setup in SI. When using a Tech 2(R) or a Multiple Diagnostic Interface (MDI) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 393 Body Control Module: Diagrams Component Connector End Views Body Control Module (BCM) X1 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 394 Body Control Module (BCM) X2 Body Control Module (BCM) X3 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 395 Body Control Module (BCM) X4 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 396 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 397 Body Control Module (BCM) X5 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 398 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 399 Body Control Module (BCM) X6 Body Control Module (BCM) X7 (except MEX or A52) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 400 Auxiliary Body Control Module (XBCM) X1 (EXP) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 401 Auxiliary Body Control Module (XBCM) X2 (EXP) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 402 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Auxiliary Body Control Module Replacement Body Control Module: Service and Repair Auxiliary Body Control Module Replacement Auxiliary Body Control Module Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Auxiliary Body Control Module Replacement > Page 405 Body Control Module: Service and Repair Body Control Module Replacement Body Control Module Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Auxiliary Body Control Module Replacement > Page 406 Body Control Module: Service and Repair Body Control Module Bracket Replacement Body Control Module Bracket Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Auxiliary Body Control Module Replacement > Page 407 Body Control Module: Service and Repair Serial Data Gateway Module Replacement Serial Data Gateway Module Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Power-Up/Calibration ID Engine Control Module: Technical Service Bulletins Engine Controls - Aftermarket Power-Up/Calibration ID INFORMATION Bulletin No.: 08-06-04-006H Date: February 07, 2011 Subject: Information on Identifying Non-GM ECM Calibration Usages for Duramax(TM) Diesel Engines RPOs LBZ, LLY, LMM, LML, LGH and Power-up Hardware Detection for Duramax(TM) Diesel Engine RPO LMM - Photograph Tech 2(R) Calibration IDs and Calibration Verification Numbers (CVNs) and Transmission Data Screen Before Removing Engine/Transmission/Drivetrain Components Models: 2006-2011 Chevrolet Express, Kodiak, Silverado 2006-2011 GMC Savana, Sierra, TopKick Equipped With Duramax(TM) Diesel Engine RPOs LBZ, LLY, LMM, LML, LGH Please Refer to GMVIS Attention: In order to process an engine/transmission/drivetrain hard part WARRANTY CLAIM, you MUST photograph the required Tech 2(R) screen information BEFORE disassembly or removing engine/transmission/drivetrain components from the vehicle. Supercede: This bulletin is being revised to update the model years and RPOs. Please discard Corporate Bulletin Number 08-06-04-006G (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission, diesel oxidation catalyst (DOC) and exhaust particulate filter failures that are the result of non-GM (aftermarket Power-up Kits ) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine , transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage to the powertrain and driveline components whenever the presence of a non-GM calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of first sale, or subsequently updated by GM or its dealers with approved calibrations. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different than those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM issued engine control modifications do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines procedures to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine, transmission, transfer case or rear axle components, and before disassembly, repair or replacement of an engine, transmission, transfer case or rear axle assembly under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that the diesel oxidation catalyst (DOC) needs replacement. Note BEFORE authorizing any Duramax(TM) diesel engine or transmission replacement, the PQC will require digital photographs of the following Tech 2(R) screens: - For RPOs LLY and LBZ only: Calibration ID Numbers and Verification Numbers from the Vehicle Information screen - For RPO LMM only: Calibration ID Numbers and Verification Numbers from the Vehicle Information AND the Programming History screen. - For RPO LMM only: Transmission Data screen containing the Max Transmission Calc Engine Torque parameter. Symptoms Caused by Aftermarket Power-up Kit Some customers may have reprogrammed the engine control module (ECM) with a non-GM released calibration. The Power-Up Kit engine calibration changes fueling and timing parameters and likely contributes to the following vehicle conditions: - Poor performance - Driveability concerns - Increased emissions Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Power-Up/Calibration ID > Page 412 - Black smoke (This symptom is not valid for the Duramax(TM) diesel engine RPO LMM equipped with the exhaust particulate filter. The filter will trap black smoke unless it is cracked, melted or has been removed from the exhaust system.) - Knocking noise - Engine damage (Refer to Corporate Bulletin Number 06-06-01-007C for additional information.) 2005-2007 RPO LLY and LBZ Instructions for Confirming Calibration Verification Numbers (CVNs) - Power-up Kit Detection Important In order to process an engine/transmission/drivetrain WARRANTY CLAIM , you MUST photograph the required Tech 2(R) screen information BEFORE disassembly or removing the engine/transmission/drivetrain components from the vehicle. 1. Go to TIS2WEB 2. Select: Calibration Information (SPS Info) 3. Enter the VIN 4. Select: Get Cal ID 5. Select: ECM Engine Control Module 6. Select: Next 7. Select: Complete History 8. Print 9. Take the printout to the vehicle along with the Tech 2(R) 10. Plug in the Tech 2(R) 11. Go to diagnostics and build the vehicle 12. Select: Powertrain 13. Select: Engine 14. *Select: Engine Control Module 15. *Select: Module ID Information or I/M Information System if Module ID Information selection is not available. 16. *If: I/M Information System was selected in step 15, it may be necessary to select: Vehicle Information in order to display the calibration information. *Steps may vary by engine controller. 17. Compare the Calibration ID and Calibration Verification Number (CVN) to the CVN shown on the TIS2WEB printout. Although the part numbers will be the same for each, it is the CVN that will determine if the calibration is GM issued. The CVNs should be the same. ‹› If the CVN information is displayed as "N/A" , it will be necessary to contact the TCSC to obtain the CVN information. ‹› If the part numbers match and ANY CVNs DO NOT match the printout, it is likely that a non-GM certified calibration has been installed. ‹› If ALL of the CVNs are EXACTLY the same the calibration is GM issued. Vehicle Information Screen 18. Take clear digital picture(s) of the Tech 2(R) Vehicle Information screen(s) showing the VIN, the Calibration IDs and the Verification Numbers. Retain the printout information and the Tech 2(R) screen photographs with the repair order. 1. E-mail copies of the digital pictures to [email protected]. In the subject line of the E-mail include the phrase "Duramax(TM) diesel", the complete VIN and Dealer BAC. In the body of the E-mail include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an email reply after the calibrations have been validated. The email reply will advise the dealer if the calibrations are OEM. 2. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 3. You may call the PQC two hours after submitting the required information for authorization to replace the assembly. This will provide them time to receive, review the information and set up a case on the request. Be prepared to provide all of the usual documentation that is normally Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Power-Up/Calibration ID > Page 413 required when requesting an assembly authorization from the PQC. 2007-2011 RPO LMM Instructions for Confirming Calibration Verification Numbers (CVNs) Power-up Kit Detection Important In order to process an engine/transmission/drivetrain WARRANTY CLAIM , you MUST photograph the required Tech 2(R) screen information BEFORE disassembly or removing the engine/transmission/drivetrain components from the vehicle. For 2007-2011 applications, an engine control module (ECM) algorithm was implemented that records the engine calibration part number and calibration verification number (CVN) for the last 10 flash programming events. The ECM records the engine calibration part number because it contains the parameters for increasing torque and fueling rates. If a vehicle comes in for service for a driveability/powertrain concern as a result of a Power-Up Kit installation, the dealership technician can read the last 10 engine calibration part numbers and CVN history using a Tech 2(R). The dealership technician will input each ECM calibration part number into the TIS2WEB/SPS CVN database to confirm the CVN history information. Refer to the following Tech 2(R) path table to verify the ECM calibrations. 1. Build the vehicle with the Tech 2(R). 2. Select F0: Engine Control Module. 3. Select F5: Module Identification Information. 4. Select F1: Programming History. 5. Turn On the ignition, with the engine Off. 6. Press the ENTER Key to Continue. Important An original production engine operation part number programmed in the ECM from the supplier, which is the last part number shown, would not be in the TIS2WEB/SPS database. 7. Record the Calibration ID Numbers and Calibration Verification Numbers from the Tech 2(R) Programming History Screen. If the list of Calibration Part Numbers is less than 10, the first Calibration ID Number (bottom of the list) will not be in TIS2WEB/SPS CVN database. In this case, the first Calibration ID Number is programmed at the ECM production factory and is reprogrammed at the vehicle assembly plant. 8. From TIS2WEB/SPS, record the Calibration Part Number into the CVN Database. Get the CVN. ‹› If the CVN DOES NOT MATCH the CVN database, an unauthorized engine calibration part WAS PROGRAMMED into the ECM. ‹› If the CVN MATCHES the CVN database, the calibration/s are GM issued and an unauthorized engine calibration part WAS NOT used. Programming History Screen 9. Take a clear digital picture of the Tech 2(R) Programming History screen showing the VIN, Calibration IDs and the CVNs. Retain the printout information and the Tech 2(R) screen photograph with the repair order. Vehicle Information Screen 1. Take a clear digital picture of the Tech 2(R) Vehicle Information screen. Retain the printout information and the Tech 2(R) screen photograph with the repair order. 2. Take a clear digital picture of the Transmission Data screen that contains the Max Transmission Calc Engine Torque parameter. The path table is outlined in the following Instructions for Tech 2 Transmission Data Path section. Retain the Tech 2(R) Transmission Data screen photograph with the repair order. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Power-Up/Calibration ID > Page 414 3. E-mail copies of the digital pictures to [email protected]. In the subject line of the E-mail include the phrase "Duramax(TM) diesel", the complete VIN and Dealer BAC. In the body of the E-mail include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an email reply after the calibrations have been validated. The email reply will advise the dealer if the calibrations are OEM. 4. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 5. You may call the PQC two hours after submitting the required information for authorization to replace the assembly. This will provide them time to receive, review the information and set up a case on the request. Be prepared to provide all of the usual documentation that is normally required when requesting an assembly authorization from the PQC. 2007-2011 RPO LMM Instructions for Tech 2 Transmission Data Path - Power-up Hardware Detection Transmission Data ONLY Available With GMC Sierra, TopKick, Chevrolet Kodiak, Silverado An example of this hardware is a propane injection system. A transmission control module (TCM) algorithm has been implemented that records a maximum calculated input torque. This information is available via the Tech 2(R). 1. Build the vehicle with the Tech 2(R). 2. Select F3: Transmission Control Module 3. Select F1: Data Display 4. Select F0: Transmission Data 5. Highlight: Max Transmission Calc Engine Torque Transmission Data Screen (Max. Trans Calc. Engine Torque Parameter) 6. Take a clear digital picture of the Tech 2(R) screen showing the Transmission Data and the Max Transmission Calc Engine Torque parameter. 7. Retain the Tech 2(R) Transmission Data screen photograph with the repair order. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Power-Up/Calibration ID > Page 415 Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Power-Up/Calibration ID > Page 416 Engine Control Module: Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Power-Up/Calibration ID > Page 417 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Power-Up/Calibration ID > Page 418 Engine Control Module: Technical Service Bulletins Diesel Engine - Damage Due To Power-Up Devices INFORMATION Bulletin No.: 06-06-01-007F Date: March 31, 2010 Subject: Information On Identifying Duramax(TM) Diesel LB7, LLY, LMM, LBZ Overpower Engine Breakdown or Non-Function Due to Aftermarket Power-Up Devices vs. Non Overpower Engine Non-Function of Pistons, Cylinders, Valvetrain Components and/or Turbocharger DTC P003A Set Models: 2001-2010 Chevrolet Silverado 2003-2009 Chevrolet Kodiak 2006-2010 Chevrolet Express 2001-2010 GMC Sierra 2003-2009 GMC TopKick 2006-2010 GMC Savana Equipped With Duramax(TM) Turbocharged Diesel Engine RPOs LB7, LLY, LMM, LBZ Please Refer to GMVIS Supercede: This bulletin is being revised to add text to the end of the Caution statement. Please discard Corporate Bulletin Number 06-06-01-007E (Section 06 - Engine/Propulsion System). Caution Customers should be informed if a hard part failure is observed in the engine, transmission, transfer case and/or other driveline components, it is likely that powertrain components were weakened to the point of premature failure, while subjected to the higher stresses from Aftermarket Power-Up Devices. Failures associated with the installation of Aftermarket Power-Up Devices, which have been verified, are not covered under the terms of the New Vehicle Warranty. In the majority of these cases, the Fixed Operations Manager (FOM) (in Canada, Warranty Manager) should be contacted and the remaining portion of the powertrain portion of the New Vehicle Warranty blocked. GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage. General Motors Position On Aftermarket Power-Up Devices Important General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. Refer to Service Bulletin Number 04-06-04-054A or newer - Warranty Admin. - Non-GM Parts and Accessories (Aftermarket). Important For further information on aftermarket power-up kits, refer to February 2006 Emerging Issues Course Number 10206.02D. In Canada, information on aftermarket power-up kits was covered in the April 2006 TAC TALK program. Aftermarket power-up devices are non-approved by General Motors. These devices are usually piggy-backed in the main engine harness or remain connected to the diagnostic connector to upload the calibration to the ECM. Recent warranty reviews of returned engines show engine breakdown or non-function due to power-up devices that are utilized for increased horsepower and torque. The following information will assist technicians in identifying overpower engine breakdown or non-function due to aftermarket power-up devices vs. non overpower engine breakdown or non-function. Non-GM parts can alter the design of the vehicle. GM dealers need to be aware of the quality of parts being installed on vehicles. If failure occurs as a result of installation of sub-par parts, warranty coverage may be denied. Refer to Service Bulletin Number 04-06-04-054A or newer Warranty Admin. - Non-GM Parts and Accessories (Aftermarket). Installed Power-Up Kit Aftermarket power-up kits have become a very popular add on for performance-minded customers. These devices can add horsepower and torque and can add additional stress to the engine. These aftermarket calibrations take the Duramax(TM) powertrain outside of its design torque and horsepower rating. They do this by altering air/fuel ratios and injector timing, resulting in excessive cylinder pressure and temperature. When these calibrated parameters are altered, it will upset the design balance and can lead to a reduction of engine life expectancy. Generally, in inspection of Duramax(TM) engine failure due to power-up failures, two or more cylinders will be affected. Installed Power-Up Kit - Once installed, the calibration may mask itself with the factory original calibration ID and may remain the same. Refer to Service Bulletin Number 08-06-04-006F or newer - Information on Identifying Non-GM Calibration Usage for LMM Duramax(TM) Diesel Engine. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Power-Up/Calibration ID > Page 419 - A Tech 2(R) will not positively enable you to identify the use of a power-up device. - Some companies that offer power-up devices claim increases of 150 or more horsepower and 300 or more lb/ft pounds of torque. - A vehicle that is used to the power-up device potential 100% of the time will see earlier engine wear and breakdown. - A vehicle that takes advantage of additional power, but on a less frequent basis, may not see premature engine wear and breakdown until later in the engine's life. - A vehicle not pushed to its limits of the power-up device often may not encounter premature wear and breakdown until after the engine is out of warranty. Duramax(TM) Powertrain Horsepower / Torque Ratings The following horsepower and torque increase over the past years required new internal components to accommodate the increase. - LB7 - 300 hp with 520 ft/lb of torque for model years 2000-2004 - LLY - 310 hp with 605 ft/lb of torque for model years 2004-2008 - LBZ - 360 hp with 650 ft/lb of torque for model year 2006-2008 - LMM - 365 hp with 660 ft/lb of torque for model year 2007-2009 LBZ Improvements To reliably achieve an increase in 50 horsepower with 45 ft/lb torque, the Duramax (TM) diesel had to be revised in many areas. A few of the revisions on the 2006 LBZ were: - New pistons with a revised compression ratio. - Wrist pins that are larger in diameter. - Connecting rods with added material to increase the I section strength. - Engine block and machining changes - Cylinder heads Duramax(TM) Life Expectancy The Duramax(TM) 6.6L V8 Turbo Diesel Engine is sold with a warranty of 100,000 miles/160,000 kilometers. The Duramax(TM) has been tested to survive upwards of 200,000 miles/320,000 kilometers. The Duramax(TM) powertrain is designed for reliability, peak horsepower and torque within its design limits. When a customer installs a power-up device, it drastically reduces the mileage ratings. Important Cylinder Wall Spotting (commonly referred to leopard spots) is from the induction hardening process of the top 1/3 of the cylinder wall. This is normal for the Duramax (TM) Diesel. Identifying Fuel Related Aftermarket Power-Up Devices Aftermarket companies have developed a performance pressure relief fuel valve for Duramax(TM) diesel engines. Refer to above graphic illustration. The performance pressure relief fuel valve attaches to the fuel rail in place of the OEM valve and will not allow any fuel return to the tank, giving 100% of the fuel to be available for additional engine performance. This may cause additional fuel related driveability concerns and may set the following DTCs: - DTC P1093 Fuel Rail Pressure (FRP) Low During Power Enrichment - DTC P0087 Fuel Rail Pressure (FRP) Too Low Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Power-Up/Calibration ID > Page 420 Aftermarket companies have developed a replacement performance/economy fuel injector nozzle. Refer to above illustration. The performance/economy fuel injector nozzles replace the OEM fuel injector nozzles. The aftermarket companies claim increased horsepower, improved fuel atomization, lower exhaust gas temperatures and increase fuel economy. This may cause additional fuel related driveability concerns and may cause internal engine damage to the pistons and fuel injector nozzles. Identifying Overpower Engine Premature Wear and Breakdown When premature wear and breakdown is encountered due to an aftermarket power-up device, it has some very specific characteristics to the internal engine components. The following list will assist in identifying these characteristics as you tear down the engine. - Pistons will be cracked in the lip area, or a hole in the pistons. - Pistons can also be melted on the lip of the combustion bowl, or the top of the pistons can be melted. - Crosshatch will be polished off the cylinder wall in the major thrust face of cylinder below ring belt travel. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Power-Up/Calibration ID > Page 421 - Piston pin bore will show signs of scoring, the wrist pins will be discolored, and can have oil coking on them. The connecting rod bushing surface will have accelerated wear. The above illustration shows a connecting rod bushing. - Oil coking on the underside of the piston between the wrist pin bosses. - Signs of bearing fretting will also be noticed on the connecting rod and main bearing caps. Refer to the above illustration for fretting of main bearing cap 1 and back side of connection rod bearing 2. - Excessive heat in engine compartment caused by overpower device. Refer to above illustration (1). Non Overpower Engine Premature Wear and Breakdown The following pictures show results of overheat, overspeed, low/no oil pressure or injector breakdown and how they differ from aftermarket power-up device premature wear and breakdown. Engine Overheat Overheat can be caused by a loss of coolant or a general cooling system failure. Some of the indicators of overheat are: Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Power-Up/Calibration ID > Page 422 - Melted pistons. - Head gasket breakdown or non-function. - Warped cylinder heads. - Crankshaft and connecting rod discolored. Engine Overspeed Causes If an engine has been run faster than design capability (redline), and has caused damage as a result, it may be a result of one of the following conditions: - Leaking or failed turbocharger (TC) oil seals. - Oil evident in the intake runners and compressor side of the TC. - Starting fluid use or alternative fuel added to the engine such as ether. Engine Overspeed Results The following are indicators that an overspeed event took place: - Valve train damage. - Pushrods that are bent (4). - Broken valve bridge buttons after cylinder head removal (2). - Rocker arm tip damage (1). - Dry or rusted cylinders from the use of ether, propane or nitrous oxide. - Piston to valve contact. - Cam gear pin shear. Lack of Oil Pressure Lack of lubrication causes rapid bearing wear or bearing to seize. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Power-Up/Calibration ID > Page 423 Bearing failure. Spun main bearings. Engine Premature Wear and Breakdown Due to Improper Function of Fuel Injector A fuel injector may fracture a piston or melt a piston but the damage will be limited to that cylinder only and all other pistons and cylinder walls are OK. In some cases hydraulic lock will occur on the suspected cylinder with an over-fueling fuel injector. Hydraulic lock on the suspected cylinder will cause a bent connecting rod. This can be verified with piston protrusion measurements. 2007-2010 RPO LMM Only Turbocharger DTC P003A Set General Motors has identified a turbocharger (TC) failure mode involving Power-Up Kits that causes soot leakage and DTC P003A to be set. The Power-Up Kits create an overtemperature condition from the increased exhaust gas temperatures that results in a permanent and excessive turbine housing distortion at the TC case halves. 1. A technician may observe one or more of the following conditions: - DTC P003A being set as Current or in History. - An unusual odor emanating from the TC due to an overtemperature condition. - Soot leaking and accumulating at the V-band clamp that secures the TC case halves together. - Limited or unresponsive travel when Commanding the TC Vane Pos. Ctrl. Solenoid ON and OFF with a scan tool. 2. If DTC P003A is found as Current or in History, OR there is evidence of soot leakage (1) in the area of the V-band clamp (1), then technicians MUST verify if the engine control module (ECM) has a Power-Up Kit aftermarket calibration installed or an aftermarket hardware device has been installed. Refer to Service Bulletin Number 08-06-04-006F or newer for the calibration verification information and procedures. How to Handle a Suspect Engine Failure Due to a Power-Up Device Dealers should not automatically decline warranty assistance on engine failures due to the fact that a power-up device or modification is evident or suspected. The technician must identify that the failure is due to a power-up device by teardown analysis and diagnosis of the engine components. The following steps should be taken if an engine failure occurs and it is suspected that the modification or addition of a power-up device maybe the cause of the engine failure. If unclear of this process or direction feel free to contact your Fixed Operations Manager (in Canada, Warranty Manager) for further support. 1. The technician should use proper engine diagnostics to lead him/her to the failed engine components. The Aftermarket Power-Up Kit Check List should be followed and if it is determined that at least three of the Aftermarket Power-Up Kit Check List items match the engine component failures then it can be decided that the failure is not a warrantable claim. 2. Engine failures that meet at least three criteria of the Aftermarket Power-Up Kit Check List are considered failures that are not manufacturer's defects in workmanship or materials. 3. The dealership should contact the PQC, open a case to review the findings and make the final decision on warranty coverage. The Fixed Operations Manager (in Canada, Warranty Manager) should be notified of the PQC decision. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Power-Up/Calibration ID > Page 424 4. Denied claims should be documented as follows: 1. The Aftermarket Power-Up Kit Check List completed with the technicians detailed written findings of the diagnosis on the repair order and retained in the repair order file. 2. Photographs of the failed parts should be retained in the repair order file. 5. The customer should be advised that the failure of their engine was not due to a manufacturer's defect in workmanship or materials and therefore the warranty claim is denied on this failure. Aftermarket Power-Up Kit Check List Important Print and use this aftermarket power-up kit check list when performing an engine disassembly investigation of overpower engine breakdown or non-function. Retain a copy of this checklist and photographs of the failed parts in the repair order file. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 425 Engine Control Module: Locations Harness Routing Views Engine Harness Routing - Left Front Side (4.8L/5.3L/6.0L/6.2L except LFA/HP2) 1 - Air Intake Duct 2 - X111 3 - Fuse Block - Underhood X2 4 - X109 5 - X110 (NQF/NQG/NQH) 6 Engine Control Module (ECM) X2 7 - Engine Control Module (ECM) X1 8 - G102 9 - J105 Engine Chassis Harness Routing - Top Front (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 426 1 - Battery - Right 2 - Fuse Holder 3 - X127 4 - X108 5 - X107 6 - X123 (PTO) 7 - Fuse Block Underhood 8 - X109 9 - Battery - Left 10 - Engine Control Module (ECM) 11 - Transmission Control Module (TCM) Engine Harness Routing - Top (4.3L) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 427 1 - Mega Fuse Ring Terminal 2 - X175 (M30) 3 - J128 4 - J105 5 - J106 6 - J130 (M30 with NQG/NQH) 7 - Engine Control Module (ECM) X1 8 - Engine Control Module (ECM) X2 9 - G103 10 - X112 11 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Connector Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 428 Engine Control Module: Diagrams Component Connector End Views Engine Control Module (ECM) X1 (LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 429 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 430 Engine Control Module (ECM) X1 (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 431 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 432 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 433 Engine Control Module (ECM) X1 (LY2, LMG, LC9, LY5, LH6, L76 or L9H) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 434 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 435 Engine Control Module (ECM) X1 (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 436 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 437 Engine Control Module (ECM) X1 (LY6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 438 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 439 Engine Control Module (ECM) X2 (LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 440 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 441 Engine Control Module (ECM) X2 (LY2, LY6 or L9H with Y91) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 442 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 443 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 444 Engine Control Module (ECM) X2 (LMG, LC9, LY5, LH6, L76 or L9H without Y91) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 445 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 446 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 447 Engine Control Module (ECM) X2 (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 448 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 449 Engine Control Module (ECM) X2 (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 450 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 451 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 452 Engine Control Module (ECM) X3 (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 453 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 454 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Engine Control Module Description Engine Control Module: Description and Operation Engine Control Module Description Engine Control Module Description The powertrain has electronic controls to reduce exhaust emissions while maintaining excellent driveability and fuel economy. The engine control module (ECM) is the control center of this system. The ECM monitors numerous engine and vehicle functions. The ECM constantly monitors information from various sensors and other inputs, and controls the systems that affect vehicle performance and emissions. The ECM also performs diagnostic tests on various parts of the system. The ECM can recognize operational problems and alert the driver via the malfunction indicator lamp (MIL). When the ECM detects a malfunction, the ECM stores a diagnostic trouble code (DTC). The problem area is identified by the particular DTC that is set. The control module supplies a buffered voltage to various sensors and switches. Review the components and wiring diagrams in order to determine which systems are controlled by the ECM. Malfunction Indicator Lamp (MIL) Operation The malfunction indicator lamp (MIL) is located in the instrument panel cluster. The MIL will display as either SERVICE ENGINE SOON or one of the following symbols when commanded ON: The MIL indicates that an emissions related fault has occurred and vehicle service is required. The following is a list of the modes of operation for the MIL: * The MIL illuminates when the ignition is turned ON, with the engine OFF. This is a bulb test to ensure the MIL is able to illuminate. * The MIL turns OFF after the engine is started if a diagnostic fault is not present. * The MIL remains illuminated after the engine is started if the control module detects a fault. A diagnostic trouble code (DTC) is stored any time the control module illuminates the MIL due to an emissions related fault. The MIL turns OFF after three consecutive ignition cycles in which a Test Passed has been reported for the diagnostic test that originally caused the MIL to illuminate. * The MIL flashes if the control module detects a misfire condition which could damage the catalytic converter. * When the MIL is illuminated and the engine stalls, the MIL will remain illuminated as long as the ignition is ON. * When the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition is cycled OFF and then ON. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Engine Control Module Description > Page 457 Engine Control Module: Description and Operation Engine Idle Control System Description Engine Idle Control System Description High Idle Switch The high idle switch will slowly increase engine RPM to the calibrated high idle speed when depressed. The high idle speed can be programmed by using a scan tool. Refer to High Idle Switch Programming (See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Idle Speed/Service and Repair). If the High Idle Switch is not operating as desired, refer to High Idle Switch Diagnosis (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/High Idle Switch Diagnosis). Manual High Idle The diesel engine has a high idle system to improve the warm-up time of the engine in cold weather conditions. This system allows the engine control module (ECM) to increase the idle speed above the normal calibrated value. The ECM increases the idle speed using the following adjustments: * The fuel injection timing is changed * The fuel injection quantity is changed * The turbocharger vane position is commanded closed-The vane position will be farther closed than any other normal operating condition. The instrument panel will indicate the high idle system is active one of two ways: * The driver information center (DIC) will indicate an active high idle system on light duty trucks. * An indicator lamp will flash on medium duty trucks. * The manual high idle feature comes enabled from the factory. The Elevated Idle function in the scan tool will disable or enable this feature. If the engine does not increase to the calibrated high idle speed after the procedure is performed, use the scan tool to verify the Elevated Idle speed feature is enabled. Manual High Idle Speed Enable and Disable To enable or disable the manual high idle system perform the following procedure: 1. Turn the ignition ON, with the engine OFF. 2. Depress the accelerator pedal to the floor and hold down. 3. While the accelerator pedal is depressed, depress the brake pedal 3 times in less than 8 seconds. 4. Release the accelerator pedal. 5. Start the engine. When the procedure is followed the engine idle speed will slowly increased to the calibrated high idle speed. This is 1,200 RPM for light duty, and 1,500 RPM for medium duty trucks. The idle speed will return to normal if any of the following conditions occur: * There is brake, clutch, or throttle input from the driver. * The automatic transmission is shifted out of Park or Neutral. * The air temperature is more than 7°C (45°F). * The engine coolant temperature (ECT) is more than 68°C (154°F). * The vehicle speed exceeds 0 km/h (0 mph). The high idle system will reactivate automatically when the following conditions occur: * The engine has been idling for more than 30 seconds. * The transmission is placed in Park or Neutral. * The vehicle speed is 0 km/h (0 mph). * The ambient air temperature is less than 3°C (37°F). * The ECT is less than 68°C (154°F). * The brake, clutch and throttle pedals are not depressed. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 458 Engine Control Module: Service and Repair Engine Control Module Replacement Caution: * Turn the ignition OFF when installing or removing the control module connectors and disconnecting or reconnecting the power to the control module (battery cable, powertrain control module (PCM)/engine control module (ECM)/transaxle control module (TCM) pigtail, control module fuse, jumper cables, etc.) in order to prevent internal control module damage. * Control module damage may result when the metal case contacts battery voltage. DO NOT contact the control module metal case with battery voltage when servicing a control module, using battery booster cables, or when charging the vehicle battery. * In order to prevent any possible electrostatic discharge damage to the control module, do no touch the connector pins or the soldered components on the circuit board. * Remove any debris from around the control module connector surfaces before servicing the control module. Inspect the control module connector gaskets when diagnosing or replacing the control module. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant intrusion into the control module. * The replacement control module must be programmed. Note: Before removing the engine control module (ECM), use the scan tool to capture the ECM data. This captured data will then need to be restored into the NEW ECM. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning). Removal Procedure 1. Using a scan tool, capture the ECM data. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 3. Disconnect the ECM electrical connectors (2). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 459 4. Release the ECM upper retaining tabs. 5. Remove the ECM from the bracket. Installation Procedure 1. Place the bottom edge of the ECM into the bracket lower retainers. 2. Push the ECM towards the bracket until the upper edge of the ECM snaps into place. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 460 3. Connect the ECM electrical connectors (2). 4. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 5. If a NEW ECM was installed, program the ECM. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 464 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 465 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 466 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 467 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 468 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 469 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 470 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pressure Control Module > Component Information > Diagrams Fuel Pressure Control Module: Diagrams Component Connector End Views Fuel Pump Flow Control Module (Gas except JL1 and except LU3, LY6 or LY6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pressure Control Module > Component Information > Diagrams > Page 475 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Fuse Block Underhood Fuel Pump Relay: Locations Fuse Block - Underhood Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Fuse Block Underhood > Page 480 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Fuse Block Underhood > Page 481 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Fuse Block Underhood > Page 482 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Fuse Block Underhood > Page 483 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Fuse Block Underhood > Page 484 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Fuse Block Underhood > Page 485 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Fuse Block Underhood > Page 486 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Fuse Block Underhood > Page 487 Fuel Pump Relay: Locations Harness Routing Views Harness Routing Views Chassis Harness - Front Engine Compartment (31 Series) 1 - X102 (JL1) 2 - Fuel Pump Relay - Secondary (LY6 without NQZ) 3 - Fuse Block - Underhood 4 X126 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 488 Fuel Pump Relay: Diagrams Component Connector End Views Fuel Pump Relay - Secondary (LY6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 492 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 493 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 494 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 495 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 496 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 497 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 498 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Glow Plug System > Glow Plug Control Module > Component Information > Diagrams Glow Plug Control Module: Diagrams Component Connector End Views Glow Plug Control Module (GPCM) X1 (Diesel) Glow Plug Control Module (GPCM) X2 (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Glow Plug System > Glow Plug Control Module > Component Information > Diagrams > Page 503 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Glow Plug System > Glow Plug Control Module > Component Information > Diagrams > Page 504 Glow Plug Control Module: Service and Repair Glow Plug Control Module Replacement Removal Procedure 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 2. Disconnect the positive battery cable (1) from the glow plug control module. 3. Disconnect the engine wiring harness electrical connector (2) from the glow plug control module. 4. Remove the glow plug control module bolts and module. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Glow Plug System > Glow Plug Control Module > Component Information > Diagrams > Page 505 5. Remove the fuel return pipe clamp bolt (1). 6. Remove the glow plug control module protector bolts and protector (1), if required. 7. Remove the glow plug control module bracket and bolts (2), if required. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Glow Plug System > Glow Plug Control Module > Component Information > Diagrams > Page 506 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Position the glow plug control module bracket (2) to the lower valve rocker arm cover and install the bolts, if required. Tighten the bolts to 10 Nm (89 lb in). 2. Position the glow plug control module protector (1) and install the bolts, if required. Tighten the bolts to 10 Nm (89 lb in). 3. Install the fuel return pipe clamp bolt (1). Tighten the bolt to 24 Nm (18 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Glow Plug System > Glow Plug Control Module > Component Information > Diagrams > Page 507 4. Position the glow plug control module onto the bracket and install the bolts. Tighten the bolts to 10 Nm (89 lb in). 5. Connect the engine wiring harness electrical connector (2) to the glow plug control module. 6. Connect the positive battery cable (1) to the glow plug control module. 7. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 8. If a NEW glow plug control module was installed, program the module. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Diagrams Seat Occupant Classification Module - Air Bag: Diagrams Component Connector End Views Inflatable Restraint Passenger Presence System (PPS) Module (AL0) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Auxiliary Battery Relay > Component Information > Locations Auxiliary Battery Relay: Locations Harness Routing Views Auxiliary Battery Harness Routing (TP2) 1 - Fuse Holder 2 - Auxiliary Battery Run Relay 3 - Auxiliary Battery Harness 4 - Auxiliary Battery Relay 5 - X122 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Auxiliary Battery Relay > Component Information > Locations > Page 516 Auxiliary Battery Relay: Diagrams Component Connector End Views Auxiliary Battery Relay X1 (TP2) Auxiliary Battery Relay X2 (TP2) Auxiliary Battery Relay X3 (TP2) Auxiliary Battery Run Relay (TP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Auxiliary Battery Relay > Component Information > Locations > Page 517 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Auxiliary Battery Relay > Component Information > Locations > Page 518 Auxiliary Battery Relay: Service and Repair Auxiliary Battery Relay Replacement Removal Procedure Warning: Refer to Battery Disconnect Warning (See: Starting and Charging/Battery/Service Precautions). 1. Disconnect the auxiliary battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 2. Reposition the auxiliary battery positive cable boot (5) from the auxiliary battery relay stud. 3. Remove the auxiliary battery positive cable nut (6) from the battery relay stud. 4. Remove the auxiliary battery positive cable from the auxiliary battery relay. 5. Disconnect the auxiliary battery positive cable electrical connector (1) from the battery relay. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Auxiliary Battery Relay > Component Information > Locations > Page 519 6. Reposition the auxiliary battery positive cable boot (5) from the auxiliary battery relay stud. 7. Remove the auxiliary battery positive cable nut (4) from the battery relay stud. 8. Remove the auxiliary battery positive cable from the auxiliary battery relay. 9. Remove the auxiliary battery relay nuts and relay. Installation Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the auxiliary battery relay and nuts and tighten to 9 Nm (80 lb in). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Auxiliary Battery Relay > Component Information > Locations > Page 520 2. Install the auxiliary battery positive cable to the auxiliary battery relay. 3. Install the auxiliary battery positive cable nut (4) to the battery relay stud and tighten to 9 Nm (80 lb in). 4. Position the auxiliary battery positive cable boot (5) to the auxiliary battery relay stud. 5. Connect the auxiliary battery positive cable electrical connector (1) to the battery relay. 6. Install the auxiliary battery positive cable to the auxiliary battery relay. 7. Install the auxiliary battery positive cable nut (6) to the battery relay stud and tighten to 9 Nm (80 lb in). 8. Position the auxiliary battery positive cable boot (5) to the auxiliary battery relay stud. 9. Connect the auxiliary battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Starter Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 524 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 525 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 526 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 527 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 528 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 529 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 530 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Wheel Heater Control Module > Component Information > Service and Repair Steering Wheel Heater Control Module: Service and Repair Steering Wheel Heat Control Module Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Module > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON Control Module: Customer Interest A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 551 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 552 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 553 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON Control Module: All Technical Service Bulletins A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 559 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 560 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 561 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 562 Control Module: Locations Harness Routing Views Engine Chassis Harness Routing - Top Front (Diesel) 1 - Battery - Right 2 - Fuse Holder 3 - X127 4 - X108 5 - X107 6 - X123 (PTO) 7 - Fuse Block Underhood 8 - X109 9 - Battery - Left 10 - Engine Control Module (ECM) 11 - Transmission Control Module (TCM) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 563 Control Module: Diagrams Component Connector End Views Transmission Control Module (TCM) (M30) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 564 Transmission Control Module (TCM) (MW7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 565 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 566 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 567 Control Module: Service and Repair Transmission Control Module Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Power Take-Off > Power Take-Off Relay > Component Information > Diagrams Power Take-Off Relay: Diagrams Component Connector End Views Power Take Off (PTO) Relay (PTO) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams Control Module: Diagrams Component Connector End Views Transfer Case Shift Control Module X1 (NQF or NQH) Transfer Case Shift Control Module X2 (NQF or NQH) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Page 576 Transfer Case Shift Control Module X3 (NQF or NQH) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Page 577 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case Control Module: Service and Repair MP 1625/1626-NQF - Transfer Case Transfer Case Shift Control Module Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case > Page 580 Control Module: Service and Repair MP 3023/3024-NQH - Transfer Case Transfer Case Shift Control Module Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations Heated Glass Element Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 585 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 586 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 587 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 588 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 589 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 590 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 591 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Diagrams Power Window Relay: Diagrams Component Connector End Views Sliding Rear Window Close Relay (A48) Sliding Rear Window Open Relay (A48) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Diagrams > Page 595 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations Windshield Washer Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Page 600 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Page 601 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Page 602 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Page 603 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Page 604 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Page 605 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Page 606 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations Wiper Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 610 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 611 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 612 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 613 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 614 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 615 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 616 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Diagrams Hood Sensor/Switch (For Alarm): Diagrams Component Connector End Views Hood Ajar Switch (AP3, AP8 or PTO) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams Parking Assist Distance Sensor: Diagrams Component Connector End Views Object Alarm Sensor - Left Rear Corner (UD7) Object Alarm Sensor - Left Rear Middle (UD7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Page 625 Object Alarm Sensor - Right Rear Corner (UD7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Page 626 Object Alarm Sensor - Right Rear Middle (UD7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Page 627 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Service and Repair > Rear Object Sensor Replacement Parking Assist Distance Sensor: Service and Repair Rear Object Sensor Replacement Rear Object Sensor Replacement Removal Procedure 1. Disconnect electrical from the rear object sensor. 2. Lift the locking tabs on the housing and remove the rear object sensor. Installation Procedure Note: Do not refinish previously painted sensors. Excess paint build up will cause the sensor to be inoperative. 1. Paint the rear object sensor. Refer to Basecoat/Clearcoat Paint Systems (See: Body and Frame/Paint, Striping and Decals/Paint/Application and ID/Basecoat/Clearcoat Paint Systems). 2. Ensure the paint does not exceed 6 mils. Use a paint thickness gauge suitable for non-ferrous metals. Refer to Paint Gauges (). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Service and Repair > Rear Object Sensor Replacement > Page 630 Note: Ensure the silicone decoupling ring is installed on the sensor to avoid sensor failure. 3. Insert the sensor into the housing. 4. Connect the electrical connector to the rear object sensor. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Service and Repair > Rear Object Sensor Replacement > Page 631 Parking Assist Distance Sensor: Service and Repair Rear Object Sensor Housing Replacement (Sierra/Silverado) Rear Object Sensor Housing Replacement (Sierra/Silverado) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Service and Repair > Rear Object Sensor Replacement > Page 632 Parking Assist Distance Sensor: Service and Repair Rear Object Sensor Housing Replacement (All Other Vehicles) Rear Object Sensor Housing Replacement (All Other Vehicles) 1. Remove the center rear bumper step pad or the rear bumper impact bar end cap. Refer to Rear Bumper Step Center Pad Replacement () or Rear Bumper Impact Bar End Cap Replacement (). 2. Disconnect the sensor harness. 3. Remove the sensor from the sensor housing. The sensor housing must be painted if replaced. If reinstalled, painting will not be necessary. Important: Do Not grind off alignment tabs. 4. Sand/grind sonic weld plastic residue from the fascia. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Service and Repair > Rear Object Sensor Replacement > Page 633 5. Apply structural adhesive epoxy, Lord Fusor(TM) 127EZ or equivalent, to fascia at mating surface. 6. Using the alignment tabs, install the sensor housing to the fascia. 7. Allow adhesive to cure according to manufacturer's directions. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Service and Repair > Rear Object Sensor Replacement > Page 634 8. Install the sensor to the sensor housing. 9. Connect the electrical harness. 10. Install the center rear bumper step pad or the rear bumper impact bar end cap. Refer to Rear Bumper Step Center Pad Replacement () or Rear Bumper Impact Bar End Cap Replacement (). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Sensor > Component Information > Service and Repair Pedal Positioning Sensor: Service and Repair Brake and Accelerator Pedal Adjuster Position Sensor Replacement (With Memory Seats) Removal Procedure 1. Turn the ignition switch to the OFF position. 2. Remove the driver knee bolster. Refer to Knee Bolster Replacement (With SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (With SLT))Knee Bolster Replacement (Without SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (Without SLT)). 3. Disconnect the adjustable pedal position sensor jumper harness electrical connector (1). 4. Remove the adjustable pedal position sensor bolts (1). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Sensor > Component Information > Service and Repair > Page 638 5. Remove the brake and accelerator pedal adjuster position sensor (1). Installation Procedure 1. Install the brake and accelerator pedal adjuster position sensor (1). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Sensor > Component Information > Service and Repair > Page 639 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the adjustable pedal position sensor bolts (1) and tighten to 2 Nm (18 lb in). 3. Connect the adjustable pedal position sensor jumper harness electrical connector (1). 4. Install the driver knee bolster. Refer to Knee Bolster Replacement (With SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (With SLT))Knee Bolster Replacement (Without SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (Without SLT)). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Diagrams Remote Switch: Diagrams Component Connector End Views Rear Seat Audio (RSA) Control X1 (UK6) Rear Seat Audio (RSA) Control X2 (UK6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Diagrams > Page 643 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Shock Sensor, Antitheft > Component Information > Diagrams Shock Sensor: Diagrams Component Connector End Views Vehicle Shock Sensor (SPO Alarm) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Steering Mounted Controls Assembly > Component Information > Service and Repair Steering Mounted Controls Assembly: Service and Repair Steering Wheel Control Switch Assembly Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Tow Sensor, Antitheft > Component Information > Diagrams Tow Sensor: Diagrams Component Connector End Views Vehicle Inclination Sensor (SPO Alarm) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Diagrams Hood Sensor/Switch (For Alarm): Diagrams Component Connector End Views Hood Ajar Switch (AP3, AP8 or PTO) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Sensor > Component Information > Service and Repair Pedal Positioning Sensor: Service and Repair Brake and Accelerator Pedal Adjuster Position Sensor Replacement (With Memory Seats) Removal Procedure 1. Turn the ignition switch to the OFF position. 2. Remove the driver knee bolster. Refer to Knee Bolster Replacement (With SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (With SLT))Knee Bolster Replacement (Without SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (Without SLT)). 3. Disconnect the adjustable pedal position sensor jumper harness electrical connector (1). 4. Remove the adjustable pedal position sensor bolts (1). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Sensor > Component Information > Service and Repair > Page 661 5. Remove the brake and accelerator pedal adjuster position sensor (1). Installation Procedure 1. Install the brake and accelerator pedal adjuster position sensor (1). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Sensor > Component Information > Service and Repair > Page 662 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the adjustable pedal position sensor bolts (1) and tighten to 2 Nm (18 lb in). 3. Connect the adjustable pedal position sensor jumper harness electrical connector (1). 4. Install the driver knee bolster. Refer to Knee Bolster Replacement (With SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (With SLT))Knee Bolster Replacement (Without SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (Without SLT)). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams Power Door Lock Switch: Diagrams Component Connector End Views Door Lock Switch - Driver (AU3 without AN3 or DL3) Door Lock Switch - Passenger (AU3 without AN3 or DL3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 666 Door Lock/Window Switch - Driver X1 (AN3 or DL3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 667 Door Lock/Window Switch - Driver X2 (AN3 or DL3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 668 Door Lock/Window Switch - Driver X3 (AN3 or DL3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 669 Door Lock/Window Switch - Driver X4 (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 670 Door Lock/Window Switch - Driver X7 (AN3 or DL3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 671 Door Lock/Window Switch - Passenger X1 (AN3 or DL3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 672 Door Lock/Window Switch - Passenger X2 (AN3 or DL3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 673 Door Lock/Window Switch - Passenger X3 (AN3 or DL3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 674 Door Lock/Window Switch - Passenger X4 (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 675 Door Lock/Window Switch - Passenger X7 (AN3 or DL3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 676 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Door Lock Switch Replacement - Front (with DL8 and without SLT) Power Door Lock Switch: Service and Repair Door Lock Switch Replacement - Front (with DL8 and without SLT) Door Lock Switch Replacement - Front (with DL8 and without SLT) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Door Lock Switch Replacement - Front (with DL8 and without SLT) > Page 679 Power Door Lock Switch: Service and Repair Door Lock and Side Window Switch Replacement Driver Side Door Lock and Side Window Switch Replacement - Driver Side Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Door Lock Switch Replacement - Front (with DL8 and without SLT) > Page 680 Power Door Lock Switch: Service and Repair Door Lock and Side Window Switch Replacement Passenger Side Door Lock and Side Window Switch Replacement - Passenger Side Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Position Switch/Sensor > Component Information > Technical Service Bulletins > Customer Interest for Power Mirror Position Switch/Sensor: > 06-08-64-027I > Apr > 11 > Body - LH/RH Outside Rearview Mirror Glass Shake/Flutter Power Mirror Position Switch/Sensor: Customer Interest Body - LH/RH Outside Rearview Mirror Glass Shake/Flutter TECHNICAL Bulletin No.: 06-08-64-027I Date: April 12, 2011 Subject: Left or Right Outside Rearview Mirror Glass Shake or Flutter (Relearn Power Mirrors and Replace Mirror, If Necessary) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon XL, Yukon Denali All Equipped with Power Folding Mirrors RPO DL3 Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 06-08-64-027H (Section 08 - Body and Accessories). Condition Some customers may comment that the left or right outside rearview mirror glass shakes or flutters at normal driving speeds. Cause - The mirror may have been accidentally pushed in manually or obstructed while folding. - The mirror actuator screws may be loose, allowing the mirror to move. - The metal spring may not have enough tension to hold the mirror from moving. Correction Follow the procedure below to correct this condition. 1. The power folding mirrors should be cycled three complete times to relearn the mirror positions. Then perform a road test and check the mirror glass for stability. If stability is not corrected, proceed to Step 2. 2. Remove the mirror glass. Refer to Mirror Face Replacement in SI. 3. Verify the torque on the four retaining screws on the actuator. Tighten Tighten the screws to 1.13-1.6 Nm (10-14 lb in). 4. Bend the metal spring up to increase the tension engagement to the mirror housing 13 mm (1/2 in). 5. Install the glass assembly by pressing firmly, taking care not to allow the spring finger to unseat from its intended track in the mirror housing. Road test the vehicle. If stability is not improved, replace the mirror assembly. Refer to Power Mirror Replacement in SI. Parts Information If replacing the mirror assembly, see Mirror in Group 16.068 of the appropriate Parts Catalog for part numbers and usage. Warranty Information Important Only one Labor Operation should be claimed depending on the actual repair. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Position Switch/Sensor > Component Information > Technical Service Bulletins > Customer Interest for Power Mirror Position Switch/Sensor: > 06-08-64-027I > Apr > 11 > Body - LH/RH Outside Rearview Mirror Glass Shake/Flutter > Page 689 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Position Switch/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Mirror Position Switch/Sensor: > 06-08-64-027I > Apr > 11 > Body - LH/RH Outside Rearview Mirror Glass Shake/Flutter Power Mirror Position Switch/Sensor: All Technical Service Bulletins Body - LH/RH Outside Rearview Mirror Glass Shake/Flutter TECHNICAL Bulletin No.: 06-08-64-027I Date: April 12, 2011 Subject: Left or Right Outside Rearview Mirror Glass Shake or Flutter (Relearn Power Mirrors and Replace Mirror, If Necessary) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon XL, Yukon Denali All Equipped with Power Folding Mirrors RPO DL3 Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 06-08-64-027H (Section 08 - Body and Accessories). Condition Some customers may comment that the left or right outside rearview mirror glass shakes or flutters at normal driving speeds. Cause - The mirror may have been accidentally pushed in manually or obstructed while folding. - The mirror actuator screws may be loose, allowing the mirror to move. - The metal spring may not have enough tension to hold the mirror from moving. Correction Follow the procedure below to correct this condition. 1. The power folding mirrors should be cycled three complete times to relearn the mirror positions. Then perform a road test and check the mirror glass for stability. If stability is not corrected, proceed to Step 2. 2. Remove the mirror glass. Refer to Mirror Face Replacement in SI. 3. Verify the torque on the four retaining screws on the actuator. Tighten Tighten the screws to 1.13-1.6 Nm (10-14 lb in). 4. Bend the metal spring up to increase the tension engagement to the mirror housing 13 mm (1/2 in). 5. Install the glass assembly by pressing firmly, taking care not to allow the spring finger to unseat from its intended track in the mirror housing. Road test the vehicle. If stability is not improved, replace the mirror assembly. Refer to Power Mirror Replacement in SI. Parts Information If replacing the mirror assembly, see Mirror in Group 16.068 of the appropriate Parts Catalog for part numbers and usage. Warranty Information Important Only one Labor Operation should be claimed depending on the actual repair. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Position Switch/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Mirror Position Switch/Sensor: > 06-08-64-027I > Apr > 11 > Body - LH/RH Outside Rearview Mirror Glass Shake/Flutter > Page 695 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Diagrams Power Mirror Switch: Diagrams Component Connector End Views Outside Rearview Mirror Switch (DL8 or DPN) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Diagrams > Page 699 Power Mirror Switch: Service and Repair Power Mirror Switch Replacement (with DL8 and without SLT) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Locations Power Seat Motor Position Sensor: Locations Harness Routing Views Driver Seat Harness Routing 1 - Seat Recline Motor - Driver (AN3) 2 - Seat Lumbar Vertical Motor Position Sensor - Driver (AN3) 3 - Seat Lumbar Vertical Motor - Driver (AN3) 4 - X324 (AN3) 5 - Seat Lumbar Horizontal Motor - Driver (AN3) 6 - Seat Lumbar Horizontal Motor Position Sensor - Driver (AN3) 7 - Seat Recline Position Sensor - Driver (AN3) 8 - Seat Lumbar Switch - Driver (AN3) 9 - Seat Adjuster Switch - Driver (AG1) 10 - Memory Seat Module (MSM) (AN3) 11 - Inflatable Restraint Seat Position Sensor (SPS) - Driver (10 Series) 12 - Seat Adjuster Motor Assembly - Driver (AG1) 13 Seat Belt Buckle - Driver Passenger Seat Harness Routing Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Locations > Page 703 1 - Seat Frame 2 - X325 (AN3) 3 - Seat Lumbar Vertical Motor - Passenger (AN3) 4 - Seat Adjuster Switch - Passenger (AG2) 5 - Seat Lumbar Switch - Passenger (AN3) 6 - Seat Belt Buckle Passenger 7 - Inflatable Restraint Passenger Presence System (PPS) Module (AL0) 8 - Seat Adjuster Motor Assembly - Passenger (AG2) 9 - Inflatable Restraint Passenger Presence System (PPS) Sensor (AL0) 10 - Seat Recline Motor - Passenger (AN3) 11 - Seat Lumbar Horizontal Motor - Passenger (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Locations > Page 704 Power Seat Motor Position Sensor: Diagrams Component Connector End Views Seat Lumbar Horizontal Motor Position Sensor - Driver (AN3) Seat Lumbar Vertical Motor Position Sensor - Driver (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Locations > Page 705 Seat Recline Position Sensor - Driver (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Locations > Page 706 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Customer Interest for Power Seat Switch: > 09-08-50-011A > Apr > 11 > Body - Sticking/Binding Door Mounted Seat Switches Power Seat Switch: Customer Interest Body - Sticking/Binding Door Mounted Seat Switches TECHNICAL Bulletin No.: 09-08-50-011A Date: April 13, 2011 Subject: Sticking/Binding Door Mounted Seat Switches (Align Switch) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon XL Denali All Equipped with RPOs AN3, KA1, KB6 Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 09-08-50-011 (Section 08 - Body and Accessories). Condition Some customers may comment that the door mounted memory/ heated/ cool seat switch buttons are sticking or binding. Cause This condition may be caused by the switch being out of alignment in the bezel, creating a hard contact between the switch button and the inside release handle bezel. Correction 1. Remove the door trim. Refer to Front Side Door Trim Panel Replacement in SI. 2. Loosen both screws (1) holding the switch to the inside release handle bezel. 3. Using a flat-bladed tool (1), carefully shift the position of the switch to create a nominal gap all around its perimeter within the bezel. Tighten the two screws holding the switch. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Customer Interest for Power Seat Switch: > 09-08-50-011A > Apr > 11 > Body - Sticking/Binding Door Mounted Seat Switches > Page 715 4. Confirm that the switch buttons are free moving, and there is a nominal gap (1) all around its perimeter within the bezel. 5. Reinstall the door trim. Refer to Front Side Door Trim Panel Replacement in SI. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Seat Switch: > 09-08-50-011A > Apr > 11 > Body - Sticking/Binding Door Mounted Seat Switches Power Seat Switch: All Technical Service Bulletins Body - Sticking/Binding Door Mounted Seat Switches TECHNICAL Bulletin No.: 09-08-50-011A Date: April 13, 2011 Subject: Sticking/Binding Door Mounted Seat Switches (Align Switch) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon XL Denali All Equipped with RPOs AN3, KA1, KB6 Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 09-08-50-011 (Section 08 - Body and Accessories). Condition Some customers may comment that the door mounted memory/ heated/ cool seat switch buttons are sticking or binding. Cause This condition may be caused by the switch being out of alignment in the bezel, creating a hard contact between the switch button and the inside release handle bezel. Correction 1. Remove the door trim. Refer to Front Side Door Trim Panel Replacement in SI. 2. Loosen both screws (1) holding the switch to the inside release handle bezel. 3. Using a flat-bladed tool (1), carefully shift the position of the switch to create a nominal gap all around its perimeter within the bezel. Tighten the two screws holding the switch. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Seat Switch: > 09-08-50-011A > Apr > 11 > Body - Sticking/Binding Door Mounted Seat Switches > Page 721 4. Confirm that the switch buttons are free moving, and there is a nominal gap (1) all around its perimeter within the bezel. 5. Reinstall the door trim. Refer to Front Side Door Trim Panel Replacement in SI. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Page 722 Power Seat Switch: Locations Harness Routing Views Driver Seat Harness Routing 1 - Seat Recline Motor - Driver (AN3) 2 - Seat Lumbar Vertical Motor Position Sensor - Driver (AN3) 3 - Seat Lumbar Vertical Motor - Driver (AN3) 4 - X324 (AN3) 5 - Seat Lumbar Horizontal Motor - Driver (AN3) 6 - Seat Lumbar Horizontal Motor Position Sensor - Driver (AN3) 7 - Seat Recline Position Sensor - Driver (AN3) 8 - Seat Lumbar Switch - Driver (AN3) 9 - Seat Adjuster Switch - Driver (AG1) 10 - Memory Seat Module (MSM) (AN3) 11 - Inflatable Restraint Seat Position Sensor (SPS) - Driver (10 Series) 12 - Seat Adjuster Motor Assembly - Driver (AG1) 13 Seat Belt Buckle - Driver Passenger Seat Harness Routing Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Page 723 1 - Seat Frame 2 - X325 (AN3) 3 - Seat Lumbar Vertical Motor - Passenger (AN3) 4 - Seat Adjuster Switch - Passenger (AG2) 5 - Seat Lumbar Switch - Passenger (AN3) 6 - Seat Belt Buckle Passenger 7 - Inflatable Restraint Passenger Presence System (PPS) Module (AL0) 8 - Seat Adjuster Motor Assembly - Passenger (AG2) 9 - Inflatable Restraint Passenger Presence System (PPS) Sensor (AL0) 10 - Seat Recline Motor - Passenger (AN3) 11 - Seat Lumbar Horizontal Motor - Passenger (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Page 724 Power Seat Switch: Diagrams Component Connector End Views Seat Adjuster Switch - Driver (AG1 without AN3) Seat Adjuster Switch - Driver (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Page 725 Seat Adjuster Switch - Passenger (AG2 without AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Page 726 Seat Adjuster Switch - Passenger (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Page 727 Seat Lumbar Switch - Driver (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Page 728 Seat Lumbar Switch - Passenger (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Driver or Passenger Seat Adjuster Switch Knob Replacement Power Seat Switch: Service and Repair Driver or Passenger Seat Adjuster Switch Knob Replacement Driver or Passenger Seat Adjuster Switch Knob Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Driver or Passenger Seat Adjuster Switch Knob Replacement > Page 731 Power Seat Switch: Service and Repair Power Seat Switch Replacement Power Seat Switch Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Driver or Passenger Seat Adjuster Switch Knob Replacement > Page 732 Power Seat Switch: Service and Repair Lumbar Switch Replacement Lumbar Switch Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Diagrams Seat Heater Switch: Diagrams Component Connector End Views Heated Seat Switch - Driver (SPO Heated Seats) Heated Seat Switch - Passenger (SPO Heated Seats) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Diagrams > Page 736 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Front Seat Heater Switch Replacement Seat Heater Switch: Service and Repair Front Seat Heater Switch Replacement Front Seat Heater Switch Replacement Removal Procedure 1. Remove door upper trim panel. Refer to Upper Extension Trim Panel Replacement (See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair). 2. Pull the door trim panel away from the door and support the bottom of the trim panel on the door panel hooks. Refer to Front Side Door Trim Panel Replacement (SLT, A95) (See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair)Front Side Door Trim Panel Replacement (Except YE9 or SLT) (See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair). 3. Disconnect the electrical connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Front Seat Heater Switch Replacement > Page 739 4. Remove the front side door heater switch fasteners (1). 5. Remove the front side door heater switch assembly (2). Installation Procedure 1. Install the front side door heater switch assembly (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the front side door heater switch fasteners and tighten to 2 Nm (18 lb in). 3. Connect the electrical connector. 4. Install the door trim panel. Refer to Front Side Door Trim Panel Replacement (SLT, A95) (See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair)Front Side Door Trim Panel Replacement (Except YE9 or SLT) (See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Locations Seat Memory Switch: Locations Harness Routing Views Driver Seat Harness Routing 1 - Seat Recline Motor - Driver (AN3) 2 - Seat Lumbar Vertical Motor Position Sensor - Driver (AN3) 3 - Seat Lumbar Vertical Motor - Driver (AN3) 4 - X324 (AN3) 5 - Seat Lumbar Horizontal Motor - Driver (AN3) 6 - Seat Lumbar Horizontal Motor Position Sensor - Driver (AN3) 7 - Seat Recline Position Sensor - Driver (AN3) 8 - Seat Lumbar Switch - Driver (AN3) 9 - Seat Adjuster Switch - Driver (AG1) 10 - Memory Seat Module (MSM) (AN3) 11 - Inflatable Restraint Seat Position Sensor (SPS) - Driver (10 Series) 12 - Seat Adjuster Motor Assembly - Driver (AG1) 13 Seat Belt Buckle - Driver Passenger Seat Harness Routing Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Locations > Page 743 1 - Seat Frame 2 - X325 (AN3) 3 - Seat Lumbar Vertical Motor - Passenger (AN3) 4 - Seat Adjuster Switch - Passenger (AG2) 5 - Seat Lumbar Switch - Passenger (AN3) 6 - Seat Belt Buckle Passenger 7 - Inflatable Restraint Passenger Presence System (PPS) Module (AL0) 8 - Seat Adjuster Motor Assembly - Passenger (AG2) 9 - Inflatable Restraint Passenger Presence System (PPS) Sensor (AL0) 10 - Seat Recline Motor - Passenger (AN3) 11 - Seat Lumbar Horizontal Motor - Passenger (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Locations > Page 744 Seat Memory Switch: Service and Repair Driver Seat Adjuster Memory Switch Replacement (Crew Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams Sunroof / Moonroof Switch: Diagrams Component Connector End Views Sunroof Switch (CF5) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Page 748 Sunroof / Moonroof Switch: Service and Repair Sunroof Switch Replacement (Crew Cab) Removal Procedure 1. Remove the overhead console in order to access the sunroof switch. Refer to Roof Console Replacement (See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Roof Console Replacement). 2. Disconnect the electrical connector from the sunroof switch. 3. With a flat-bladed tool, carefully release the tabs that retain the sunroof switch to the overhead console. 4. Remove the sunroof switch from the overhead console. Installation Procedure 1. Position the sunroof switch alignment tabs to the slots in the console. 2. Install the sunroof switch into the console, ensuring that the retaining tabs are fully seated. 3. Connect the electrical connector to the sunroof switch. 4. Install the overhead console to the roof. Refer to Roof Console Replacement (See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Roof Console Replacement). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Booster Vacuum Sensor > Component Information > Diagrams Brake Booster Vacuum Sensor: Diagrams Component Connector End Views Brake Booster Vacuum Sensor (JL4 with 10 Series) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Booster Vacuum Sensor > Component Information > Diagrams > Page 753 Brake Booster Vacuum Sensor: Service and Repair Power Brake Booster Vacuum Sensor Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Diagrams Brake Fluid Level Sensor/Switch: Diagrams Component Connector End Views Brake Fluid Level Switch Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Diagrams > Page 757 Brake Fluid Level Sensor/Switch: Service and Repair Brake Fluid Level Indicator Switch Replacement (Non-Hybrid) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Diagrams Brake Fluid Pressure Sensor/Switch: Diagrams Component Connector End Views Brake Master Cylinder Pressure Sensor (JL1) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Diagrams > Page 761 Brake Fluid Pressure Sensor/Switch: Service and Repair Brake Master Cylinder Pressure Sensor Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Service and Repair Braking Sensor/Switch: Service and Repair Brake Master Cylinder Primary Piston Position Sensor Replacement Removal Procedure Note: The ignition must be in the OFF position, without pausing at ACCESSORY, and without applying the brake pedal to ensure the brake modulator and high pressure accumulator (HPA) pressure relief occurs. This process will take approximately 1 to 3 minutes. 1. Turn the ignition to OFF, without pausing at ACCESSORY, and without applying the brake pedal. Remove the ignition key. 2. Wait approximately 1 to 3 minutes until the brake modulator and HPA pressure relief is complete. 3. Disconnect the brake master cylinder (BMC) primary piston position sensor electrical connector. 4. Remove the 2 BMC primary piston position sensor screws (1). 5. Remove the primary piston position sensor (2). Tilt the rear of the position sensor downward and remove the sensor. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Service and Repair > Page 765 1. Install the BMC primary piston position sensor (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the 2 BMC primary piston position sensor screws (1) and tighten to 10 Nm (89 lb in). 3. Connect the primary piston position sensor electrical connector. 4. Inspect the battery state of charge. Refer to Battery Inspection/Test (See: Starting and Charging/Testing and Inspection/Component Tests and General Diagnostics). 5. If necessary, connect a battery charger to the 12V battery. Refer to Battery Charging (See: Starting and Charging/Battery/Service and Repair/Procedures) 6. Install a scan tool to the vehicle. Note: The ignition switch must remain in the ON position with the engine OFF during this procedure. 7. Turn the ignition ON with the engine OFF. 8. Using the scan tool, perform the following steps: 1. Select Diagnostics 2. Select the appropriate vehicle information 3. Select Chassis 4. Select Electronic Brake Control Module (EBCM) 5. Select Module Setup 6. Select BMC Primary Piston Position Relearn and follow the instructions on the scan tool Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Diagrams Lateral Accelerometer: Diagrams Component Connector End Views Yaw and Lateral Accelerometer Sensor (HP2) Yaw and Lateral Accelerometer Sensor (JL4 except 10 Series) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Diagrams > Page 769 Yaw and Lateral Accelerometer Sensor (JL4 with 10 Series) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Diagrams > Page 770 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Diagrams Parking Brake Warning Switch: Diagrams Component Connector End Views Park Brake Switch Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Diagrams > Page 774 Parking Brake Warning Switch: Service and Repair Parking Brake Indicator Switch Replacement Removal Procedure Warning: Refer to Battery Disconnect Warning (See: Starting and Charging/Battery/Service Precautions). 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 2. Without disconnecting the electrical connectors, remove the left side instrument panel electrical center/junction block and position aside. Refer to Instrument Panel Electrical Center or Junction Block Replacement - Left Side (See: Maintenance/Fuses and Circuit Breakers/Fuse Block/Service and Repair/Removal and Replacement/Instrument Panel Electrical Center or Junction Block Replacement - Left Side). 3. Disconnect the park brake warning lamp switch electrical connector. 4. Remove the park brake warning lamp switch bolt. 5. Remove the park brake warning lamp switch. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Diagrams > Page 775 1. Install the park brake warning lamp switch. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the park brake warning lamp switch bolt and tighten to 3 Nm (27 lb in). 3. Connect the park brake warning lamp switch electrical connector. 4. Install the left side instrument panel electrical center/junction block. Refer to Instrument Panel Electrical Center or Junction Block Replacement Left Side (See: Maintenance/Fuses and Circuit Breakers/Fuse Block/Service and Repair/Removal and Replacement/Instrument Panel Electrical Center or Junction Block Replacement - Left Side). 5. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams Wheel Speed Sensor: Diagrams Component Connector End Views Wheel Speed Sensor (WSS) - Left Front (10 Series) Wheel Speed Sensor (WSS) - Left Front (except 10 Series) Wheel Speed Sensor (WSS) - Left Rear (JL4 or HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Page 779 Wheel Speed Sensor (WSS) - Right Front (10 Series) Wheel Speed Sensor (WSS) - Right Front (except 10 Series) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Page 780 Wheel Speed Sensor (WSS) - Right Rear (JL4 or HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement Wheel Speed Sensor: Service and Repair Front Wheel Speed Sensor Replacement Non-Hybrid Less than 3900 kg (8600 lb) GVW Front Wheel Speed Sensor Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 783 Non-Hybrid Greater than/Equal to 3900 kg (8600 lb) GVW Front Wheel Speed Sensor Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 784 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 785 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 786 Wheel Speed Sensor: Service and Repair Rear Wheel Speed Sensor Replacement Non-Hybrid Less than 3900 kg (8600 lb) GVW Rear Wheel Speed Sensor Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 787 Non-Hybrid Greater than/Equal to 3900 kg (8600 lb) GVW Rear Wheel Speed Sensor Replacement Removal Procedure Warning: Refer to Brake Dust Warning (See: Brakes and Traction Control/Service Precautions/Technician Safety Information/Brake Dust Warning) . 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 788 2. Disconnect the wheel speed sensor electrical connector (1). 3. Release the wheel speed sensor electrical connector and sensor harness clips (2) from the inboard frame rail. 4. Remove the wheel speed sensor bolt (1). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 789 5. Remove the wheel speed sensor (1) from the rear axle. Installation Procedure 1. Install the wheel speed sensor (1) to the rear axle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 790 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the wheel speed sensor bolt (1) and tighten to 9 Nm (80 lb in). 3. Connect the wheel speed sensor electrical connector (1). 4. Install the wheel speed sensor electrical connector and sensor harness clips (2) to the inboard frame rail. 5. Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 791 Wheel Speed Sensor: Service and Repair Rear Wheel Speed Sensor Ring Replacement Non-Hybrid Less than 3900 kg (8600 lb) GVW Rear Wheel Speed Sensor Ring Replacement Special Tools * J-8092 - Driver Handle * J-21128 - Axle Pinion Oil Seal Installer * J-23690 - Bearing Installer * J-2619-01 - Slide Hammer * J-45857 - Tone Wheel and/or Bearing Remover * J-45860 - Tone Ring Installer Removal Procedure 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair ). 3. Remove the rear wheel speed sensor. Refer to Rear Wheel Speed Sensor Replacement (See: Rear Wheel Speed Sensor Replacement/Non-Hybrid Less than 3900 kg (8600 lb) GVW). 4. Remove the rear axle housing cover. Refer to Rear Axle Housing Cover and Gasket Replacement (8.6, 9.5 Inch Axles) ()Rear Axle Housing Cover and Gasket Replacement (10.5/11.5 Inch Axle) (). 5. Remove the axle shaft. Refer to Rear Axle Shaft Replacement (See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft Assembly/Axle Shaft/Service and Repair). 6. Remove the axle shaft seal, the bearing and the wheel speed sensor ring from the axle housing using the J-2619-01 - Slide Hammer (1) and the J-45857 - Tone Wheel and/or Bearing Remover (2). Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 792 1. Install the wheel speed sensor ring using the J-45860 - Tone Ring Installer (1) and the J-8092 Driver Handle (2). 2. Drive the wheel speed sensor ring into the axle housing until the tool bottoms against the tube. 3. Install the axle shaft bearing using the J-23690 - Bearing Installer (1) and the J-8092 - Driver Handle (2). 4. Drive the axle shaft bearing into the axle housing until the tool bottoms against the tube. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 793 5. Install the axle shaft seal using the J-21128 - Axle Pinion Oil Seal Installer. 6. Drive the tool into the bore until the axle shaft seal bottoms flush with the tube. 7. Install the axle shaft. Refer to Rear Axle Shaft Replacement (See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft Assembly/Axle Shaft/Service and Repair). 8. Install the rear axle housing cover. Refer to Rear Axle Housing Cover and Gasket Replacement (8.6, 9.5 Inch Axles) ()Rear Axle Housing Cover and Gasket Replacement (10.5/11.5 Inch Axle) (). 9. Install the rear wheel speed sensor. Refer to Rear Wheel Speed Sensor Replacement (See: Rear Wheel Speed Sensor Replacement/Non-Hybrid Less than 3900 kg (8600 lb) GVW). 10. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 11. Fill the rear axle. Refer to Differential Oil Replacement (10.5 Inch Axle) (See: Maintenance/Fluids/Fluid - Differential/Service and Repair/Removal and Replacement)Differential Oil Replacement (11.5 Inch Axle) (See: Maintenance/Fluids/Fluid - Differential/Service and Repair/Removal and Replacement)Differential Oil Replacement (8.6 Inch Axle) (See: Maintenance/Fluids/Fluid - Differential/Service and Repair/Removal and Replacement)Differential Oil Replacement (9.5LD Inch Axle) (See: Maintenance/Fluids/Fluid - Differential/Service and Repair/Removal and Replacement). 12. Lower the vehicle. Non-Hybrid Greater than/Equal to 3900 kg (8600 lb) GVW Rear Wheel Speed Sensor Ring Replacement Removal Procedure Note: The wheel speed sensor ring is integral to the wheel hub and must be replaced as an assembly. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair ). 3. Remove the rear brake rotor. Refer to Rear Brake Rotor Replacement (JD9) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JD9))Rear Brake Rotor Replacement (JH6) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JH6))Rear Brake Rotor Replacement (JH7) ( See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JH7)). 4. Remove the rear axle hub. Refer to Rear Axle Hub, Bearing, Cup, and/or Seal Replacement (See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Bearing/Service and Repair/Rear Axle Hub, Bearing, Cup, and/or Seal Replacement). Installation Procedure 1. Install the rear axle hub. Refer to Rear Axle Hub, Bearing, Cup, and/or Seal Replacement (See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Bearing/Service and Repair/Rear Axle Hub, Bearing, Cup, and/or Seal Replacement). 2. Install the rear brake rotor. Refer to Rear Brake Rotor Replacement (JD9) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JD9))Rear Brake Rotor Replacement (JH6) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JH6))Rear Brake Rotor Replacement (JH7) ( Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 794 See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JH7)). 3. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Diagrams Yaw Rate Sensor: Diagrams Component Connector End Views Yaw and Lateral Accelerometer Sensor (HP2) Yaw and Lateral Accelerometer Sensor (JL4 except 10 Series) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Diagrams > Page 798 Yaw and Lateral Accelerometer Sensor (JL4 with 10 Series) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Diagrams > Page 799 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Service and Repair > Non-Hybrid Less than 3900 kg (8600 lb) GVW Yaw Rate Sensor: Service and Repair Non-Hybrid Less than 3900 kg (8600 lb) GVW Vehicle Yaw Sensor with Vehicle Lateral Accelerometer Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Service and Repair > Non-Hybrid Less than 3900 kg (8600 lb) GVW > Page 802 Yaw Rate Sensor: Service and Repair Non-Hybrid Greater than/Equal to 3900 kg (8600 lb) GVW Vehicle Yaw Sensor with Vehicle Lateral Accelerometer Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Coolant Level Sensor > Component Information > Diagrams Coolant Level Sensor: Diagrams Component Connector End Views Engine Coolant Level Switch (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps Coolant Temperature Sensor/Switch (For Computer): Customer Interest Engine - MIL ON P0116/P1400 Set In Very Cold Temps TECHNICAL Bulletin No.: 10-06-04-008A Date: January 24, 2011 Subject: Malfunction Indicator Lamp (MIL) Illuminated at Very Cold Ambient Temperatures When Using Engine Coolant Heater, DTC P0116 and/or P1400 Set (Relocate Engine Coolant Temperature (ECT) Sensor and Engine Coolant Heater Cord) Models: 2006-2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2006-2010 Cadillac Escalade 2006-2007 Chevrolet Monte Carlo 2006-2009 Chevrolet Impala SS, TrailBlazer 2006-2010 Chevrolet Avalanche, Express, Silverado Tahoe 2006-2009 GMC Envoy 2006-2010 GMC Savana, Sierra, Yukon 2006-2008 Pontiac Grand Prix 2006-2009 Saab 9-7X Equipped with V8 Engine RPO LC9, LH6, LH8, LH9, L76, LS2, LS4, LFA, LZ1, L92, L94, L9H or L20, L96, LMF, LMG, LY2, LY5, LY6 Please Refer to GMVIS Attention: To properly correct this condition, you must follow both of the procedures to relocate the ECT sensor and the engine coolant heater cord. Supercede: This bulletin is being revised to add cast iron block engine RPOs and to update the Warranty Information coverage period. Please discard Corporate Bulletin Number 10-06-04-008 (Section 06 - Engine/Propulsion System). Condition Some customers may comment that the malfunction indicator lamp (MIL) illuminates after starting the vehicle when they were using the engine coolant heater in very cold ambient temperatures. This usually occurs in a range of -23 to -40°C (-10 to -40°F) or colder. The technician may observe on a scan tool DTC P0116 and/or P1400 set as Current or in History. Cause This condition may be caused by the engine control module (ECM) determining that the ignition OFF time requirement has been met at start-up and interpreting the temperature difference between the engine coolant temperature (ECT) sensor and the intake air temperature (IAT) sensor as being outside of a calibrated range. Correction Important DO NOT replace the ECM for this condition. Relocating the ECT Sensor 1. Turn ON the ignition with the engine OFF. 2. Perform the diagnostic system check - vehicle. Refer to Diagnostic System Check - Vehicle in SI. ‹› If DTC P0116 and/or P1400 are set and the customer WAS using the engine coolant heater, proceed to Step 3. ‹› If DTC P0116 and/or P1400 are set and the customer WAS NOT using the engine coolant heater, refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. 3. Turn OFF the ignition. Warning To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 816 under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator are still hot. 4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle. Refer to Cooling System Draining and Filling in SI. 7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor. 10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J 38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle. 13. Disconnect the wiring harness connector from the ECT sensor (2). 14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT sensor in the hole of the cylinder head where the plug was removed. Tighten Tighten to 20 Nm (15 lb ft). 18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was removed Tighten Tighten to 20 Nm (15 lb ft). Important Leave enough wire attached to the ECT sensor harness connector in order to create manageable splices that are at least 40 mm (1.5 in) away from the other splice. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 817 20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit. Cut off the ECT sensor harness connector and wiring. 21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured TO or WITHIN an existing protective conduit. Note This step is to set up and verify the length of wiring that is required before cutting. 22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the appropriate length. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. 26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit using tie straps. Important You MUST run the engine at the specified RPM and until it reaches normal operating temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool down in order to top off the coolant level as needed. 28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI. 29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan tool to clear any DTCs. Relocating the Engine Coolant Heater Cord Important For reference, the procedure and graphics that are shown are from a Chevrolet Silverado, but are similar for the other vehicles listed above. 1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit from the engine compartment in order to determine the required extension cord length. 3. Obtain an extension cord with the following features: - 120 volt - 14/3 gauge - 15A capacity - Three prong - Polarized plug and receptacle - Chemical resistant - Grounded terminals - Designed for use in a cold outdoor environment - Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight - Maximum length of 2.5-3 m (8-10 ft) 4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N 12345579 (in Canada, use P/N 10953481) or an equivalent. 6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 818 7. Wrap electrical tape around the connection as shown. 8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to the engine coolant crossover pipe as shown. 9. Continue to route the extension cord to the exit location desired by the customer as shown. 10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the engine coolant heater cord to the vehicle that were released to provide length. Part Information The extension cord may be obtained at any of the following outlets: - Lowes* - Home Depot* - Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number: CWRSJTOW3C14-10 USA: Cords should bear the UL symbol. Canada: Cords should bear the ULc symbol or CSA approval. *We believe these sources and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from these firms or for any such items that may be available from other sources. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 819 Warranty Information (excluding Saab Models) For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps Coolant Temperature Sensor/Switch (For Computer): All Technical Service Bulletins Engine - MIL ON P0116/P1400 Set In Very Cold Temps TECHNICAL Bulletin No.: 10-06-04-008A Date: January 24, 2011 Subject: Malfunction Indicator Lamp (MIL) Illuminated at Very Cold Ambient Temperatures When Using Engine Coolant Heater, DTC P0116 and/or P1400 Set (Relocate Engine Coolant Temperature (ECT) Sensor and Engine Coolant Heater Cord) Models: 2006-2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2006-2010 Cadillac Escalade 2006-2007 Chevrolet Monte Carlo 2006-2009 Chevrolet Impala SS, TrailBlazer 2006-2010 Chevrolet Avalanche, Express, Silverado Tahoe 2006-2009 GMC Envoy 2006-2010 GMC Savana, Sierra, Yukon 2006-2008 Pontiac Grand Prix 2006-2009 Saab 9-7X Equipped with V8 Engine RPO LC9, LH6, LH8, LH9, L76, LS2, LS4, LFA, LZ1, L92, L94, L9H or L20, L96, LMF, LMG, LY2, LY5, LY6 Please Refer to GMVIS Attention: To properly correct this condition, you must follow both of the procedures to relocate the ECT sensor and the engine coolant heater cord. Supercede: This bulletin is being revised to add cast iron block engine RPOs and to update the Warranty Information coverage period. Please discard Corporate Bulletin Number 10-06-04-008 (Section 06 - Engine/Propulsion System). Condition Some customers may comment that the malfunction indicator lamp (MIL) illuminates after starting the vehicle when they were using the engine coolant heater in very cold ambient temperatures. This usually occurs in a range of -23 to -40°C (-10 to -40°F) or colder. The technician may observe on a scan tool DTC P0116 and/or P1400 set as Current or in History. Cause This condition may be caused by the engine control module (ECM) determining that the ignition OFF time requirement has been met at start-up and interpreting the temperature difference between the engine coolant temperature (ECT) sensor and the intake air temperature (IAT) sensor as being outside of a calibrated range. Correction Important DO NOT replace the ECM for this condition. Relocating the ECT Sensor 1. Turn ON the ignition with the engine OFF. 2. Perform the diagnostic system check - vehicle. Refer to Diagnostic System Check - Vehicle in SI. ‹› If DTC P0116 and/or P1400 are set and the customer WAS using the engine coolant heater, proceed to Step 3. ‹› If DTC P0116 and/or P1400 are set and the customer WAS NOT using the engine coolant heater, refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. 3. Turn OFF the ignition. Warning To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 825 under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator are still hot. 4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle. Refer to Cooling System Draining and Filling in SI. 7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor. 10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J 38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle. 13. Disconnect the wiring harness connector from the ECT sensor (2). 14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT sensor in the hole of the cylinder head where the plug was removed. Tighten Tighten to 20 Nm (15 lb ft). 18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was removed Tighten Tighten to 20 Nm (15 lb ft). Important Leave enough wire attached to the ECT sensor harness connector in order to create manageable splices that are at least 40 mm (1.5 in) away from the other splice. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 826 20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit. Cut off the ECT sensor harness connector and wiring. 21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured TO or WITHIN an existing protective conduit. Note This step is to set up and verify the length of wiring that is required before cutting. 22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the appropriate length. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. 26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit using tie straps. Important You MUST run the engine at the specified RPM and until it reaches normal operating temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool down in order to top off the coolant level as needed. 28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI. 29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan tool to clear any DTCs. Relocating the Engine Coolant Heater Cord Important For reference, the procedure and graphics that are shown are from a Chevrolet Silverado, but are similar for the other vehicles listed above. 1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit from the engine compartment in order to determine the required extension cord length. 3. Obtain an extension cord with the following features: - 120 volt - 14/3 gauge - 15A capacity - Three prong - Polarized plug and receptacle - Chemical resistant - Grounded terminals - Designed for use in a cold outdoor environment - Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight - Maximum length of 2.5-3 m (8-10 ft) 4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N 12345579 (in Canada, use P/N 10953481) or an equivalent. 6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 827 7. Wrap electrical tape around the connection as shown. 8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to the engine coolant crossover pipe as shown. 9. Continue to route the extension cord to the exit location desired by the customer as shown. 10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the engine coolant heater cord to the vehicle that were released to provide length. Part Information The extension cord may be obtained at any of the following outlets: - Lowes* - Home Depot* - Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number: CWRSJTOW3C14-10 USA: Cords should bear the UL symbol. Canada: Cords should bear the ULc symbol or CSA approval. *We believe these sources and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from these firms or for any such items that may be available from other sources. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 828 Warranty Information (excluding Saab Models) For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 829 Coolant Temperature Sensor/Switch (For Computer): Diagrams Component Connector End Views Engine Coolant Temperature (ECT) Sensor (Diesel) Engine Coolant Temperature (ECT) Sensor (Gas) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 830 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Engine Coolant Temperature Sensor Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions Oil Level Sensor: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Schematic Symbols Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 836 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 837 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 838 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 839 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 840 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 841 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 842 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 843 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 844 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 845 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 846 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 847 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 848 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 849 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 850 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 851 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 852 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 853 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 854 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 855 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 856 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 857 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 858 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 859 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 860 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 861 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 862 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 863 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 864 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 865 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 866 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 867 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 868 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 869 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 870 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 871 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 872 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 873 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 874 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 875 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 876 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 877 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 878 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 879 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 880 Oil Level Sensor: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed with Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 881 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 882 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Connector Test Adapters) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 883 Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Test Lamp) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Fused Jumper Wires) * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage Drop) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Frequency) * Testing Ground and Low Reference Circuits (See: Testing and Inspection/Component Tests and General Diagnostics/Testing Ground and Low Reference Circuits) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fuses) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Circuit Breakers) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fusible Links) Troubleshooting with a Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Testing for a Short to Voltage Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 884 Testing for a Short to Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure tests for a short to voltage in a circuit. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the Digital Multimeter (DMM) to the V (DC) position. 4. Connect the positive lead of the DMM to one end of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. Turn ON the ignition and operate all accessories. 7. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Special Tools J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure). Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents). Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 885 The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the frequency of a signal. Note: Connecting the Digital Multimeter (DMM) to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Set to Hz on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 886 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the Digital Multimeter (DMM). 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the difference in voltage potential between 2 points. 1. Set the Digital Multimeter (DMM) to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 887 Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Backprobe Note: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 888 (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for Continuity Testing for Continuity Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures verify good continuity in a circuit. With a Digital Multimeter (DMM) 1. Set the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Select the MIN MAX function on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 889 Testing for Electrical Intermittents Testing for Electrical Intermittents Special Tools J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. Note: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions). 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 890 visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing for Terminal Fretting Some intermittent conditions can be caused by wire terminal fretting corrosion. Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can pile up enough at the electrical contact spots that the electrical resistance across the connection increases. Movement between the contacting surfaces as small as 10 to 100 microns can cause fretting. To put this in perspective, a sheet of paper is about 100 microns thick, so fretting motion is small and hard to see. Vibration and thermal expansion/contraction are the main sources that create fretting motion. Since vehicles vibrate and can experience large temperature swings, they are a good source for fretting motion. Tin, copper, nickel, and iron surfaces are all susceptible to fretting corrosion. Fretting corrosion can be difficult to see but it looks like small, dark smudges on the terminals contact surface. To correct a fretting condition disconnect the suspect connector and add Nyogel lubricant 760G (dielectric grease) to both sides of the connector terminals. Then reconnect the connector and wipe away any excess lubricant. This will correct the additional terminal contact resistance due to the terminal fretting corrosion. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 891 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics). * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Ground Distribution Schematics). Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Checking Aftermarket Accessories). * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 892 Note: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures test for a short to ground in a circuit. With a Digital Multimeter (DMM) 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohms position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Danger: High voltage circuits should only be tested using a digital multimeter (DMM) and test leads with at least a CAT III rating, such as the J 39200-A Digital Multimeter. Failure to follow the procedures exactly as written may result in serious injury or death. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Digital Multimeter (DMM) Basic Requirements Service information is validated using digital multimeters that meet or exceed the following requirements. Using a multimeter that does not meet these basic requirements may give inaccurate readings which could lead to an incorrect diagnosis. Display and Settings 1. Four digits displayed 2. Voltage, amperage, resistance, frequency, diode test settings, and min-max function 3. Display positive and negative values Voltage 1. Have at least 10 M ohm input impedance Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 893 2. Test a DC voltage range of 0.1-1000 V. 3. Test an AC voltage range of 0.1-1000 V. Amperage 1. Test a DC amperage range of 0.1µA-10 A. 2. Test an AC amperage range of 0.1µA-10 A. Resistance Test a resistance range of 0.1 ohm-40 Mohm and displays infinite for a value greater than 40 M ohm (O.L. (Over-load)) Frequency Test for a frequency range of 0.5 HZ-199 K HZ Diode Test 1. Apply at least 1 mA when performing the diode bias test 2. Display the break over voltage drop (0-3 V) of a forward biased diode 3. Display infinite (O.L. (Over-load)) when a diode is reverse biased Min-Max Readings 1. Can update at a 1 ms sample rate 2. Saves and displays minimum and maximum values Note: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Probe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors). * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the EL-38125-580 GM Approved Terminal Release Tool Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the EL-38125-580 GM Approved Terminal Release Tool Kit , ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the EL-38125-580 GM Approved Terminal Release Tool Kit label on the inside of the EL-38125-580 GM Approved Terminal Release Tool Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 894 Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/EPC Connectors AFL/EPC Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 895 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 3. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 896 View showing depressing of the lever lock release tab. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 897 6. Release the rear lower half of the wiredress cover. 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 898 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 899 Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Bosch Connectors (ECM) Bosch Connectors (ECM) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 900 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. 2. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 901 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-bladed tool to release the locking tabs and remove the dress cover. 4. The terminal positive assurance (TPA) is located in the front of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 902 5. Use a small flat-blade tool to remove TPA from the connector. 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 903 Note: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 904 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 905 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Terminal Replacement Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 906 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 907 5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Position Assurance Locks) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Terminal Position Assurance Locks) * AFL/EPC Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/AFL/EPC Connectors) * Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (BSK))Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (0.64))Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (2.8 JPT))Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (ECM)) * Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Weather Pack))Delphi Connectors (Push To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Push to Seat))Delphi Connectors Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 908 (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Pull to Seat))Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro-Pack 100W))Delphi Connectors (Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro .64))Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (12-Way)) * FCI Connectors (Lever Lock) (See: General Electrical Diagnostic Procedures/Connector Repairs/FCI Connectors (Lever Lock)) * JST Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/JST Connectors) * Kostal Connectors (Glow Plug Control Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Glow Plug Control Module))Kostal Connectors (Transmission) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Transmission)) * Molex Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Molex Connectors) * Sumitomo Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Sumitomo Connectors) * Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (CM 42-Way))Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Sensor))Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (0.25 Cap))Tyco/AMP Connectors (43-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (43-Way))Tyco/AMP Connectors (Door Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Door Module))Tyco/AMP Connectors (102-Way Inline) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (102-Way Inline))Tyco/AMP Connectors (Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Seat))Tyco/AMP Connectors (SIR) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (SIR)) * Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (2-Way))Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (16-Way)) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 909 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 910 * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 911 * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 912 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 913 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 914 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Push to Seat) Delphi Connectors (Push To Seat) Special Tools J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 915 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs). 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Terminated Lead Repair 1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice sleeves depending on the gauge size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Delphi Connectors (Pull to Seat) Delphi Connectors (Pull To Seat) Special Tools Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 916 J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Note: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 917 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. View of a typical Micro 64 connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 918 Depress the lock and pull the lever over and past the lock. View of the connector when released from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 919 View of another type of Micro 64 connector. Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 920 View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 921 Note: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 922 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 923 Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Note: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 924 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 925 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 926 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 927 1. Cut the wire as close to the terminal as possible. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 928 Terminal Replacement Procedure After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Special Tools J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Note: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals). 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12-Way) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 929 Delphi Connectors (12-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 930 4. Release the lower wire dress cover locking tab. 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 931 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 932 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors (Lever Lock) FCI Connectors (Lever Lock) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 933 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. The release tab is located on the top of the wiredress cover. 3. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 934 6. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 935 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 936 1. While depressing the lock, remove the connector from the component. 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 937 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. 4. View of the TPA when removed from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 938 5. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Glow Plug Control Module) Kostal Connectors (Glow Plug Control Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 939 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 940 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 941 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. Note: The front TPA cannot be removed from the connector. Only move it to the preset position. 6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm). 7. Use a small flat-blade tool to completely remove the rear TPA from the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 942 8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Transmission) Kostal Connectors (Transmission) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 943 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 944 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Terminal Replacement Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 945 After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 946 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 947 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 948 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 949 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 950 3. To assemble the connector, reverse the connector disassembly procedure. Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 951 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 952 7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 953 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 954 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 955 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 956 Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 957 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 958 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 959 6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (102-Way Inline) Tyco/AMP Connectors (102-Way Inline) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 960 View of a typical connector in the assembled position. 1. Pull the locking lever to the 90 degree position from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 961 2. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal. 3. Slide the male connector body out away from the guide plates. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 962 Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 4. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. 5. Using terminal release tool J 38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 963 6. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 7. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 964 8. The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool J-38125-11A or equivalent to release the locking tab and slide the connector off the female body. 9. Move the locking lever 180 degrees from the connected position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 965 10. With the locking lever in the 180 degree position the guide plates can be removed from the connector body. Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 11. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 966 12. Using terminal release tool J 38125-216, lift the terminal plate past the terminals and out of the connector body cavity. 13. Terminal plate will bind slightly on each corner. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 967 14. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 15. Using terminal release tool J 38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 968 16. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 17. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 969 18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever. 19. Slide the male connector body back inward toward the guide plates. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 970 20. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly. 21. Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Seat) Tyco/AMP Connectors (Seat) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 971 Removal Procedure 1. Grasp the locking slide lever and pull outward from the end of the connector. 2. As the slide lever is pulled out the mating connector is lifted from the seated position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 972 Note: TPA is keyed and can only be inserted in one direction. 3. Using terminal release tool J 38125-11A or equivalent, push the TPA tabs into the connector body. 4. Pull the TPA from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 973 5. Using terminal release tool J 38125-11A or equivalent, release the connector wire dress cover locking tab. 6. With the lock tab released, lift the connector wire dress cover from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 974 7. Using terminal release tool J 38125-212, press the prongs into the holes each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 8. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 975 9. Using terminal release tool J 38125-556, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (SIR) Tyco/AMP Connectors (SIR) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 976 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 977 3. Using terminal tool J-38125-11A or equivalent, release the wire dress cover locking tabs. 4. Pivot connector wire dress cover while removing from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 978 5. Using terminal tool J-38125-11A or equivalent, remove the TPA by lifting straight off the connector body. 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals Repairing Connector Terminals Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 979 Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gauge size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 980 2. Disconnect the connector from the component. 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 981 4. Relieve the tension on the nose piece retainers by inserting J 38125-12A into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. 5. Once the nose piece retainers are relaxed, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 982 6. On the opposite side of the nose piece, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 983 8. Insert the J 38125-553 tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 984 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. If the TPA is removed, be sure to reinstall it before reconnecting the connector. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 985 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Special Tools Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 986 J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Note: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 987 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 988 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 989 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 990 1. While depressing the lock, pull the two connector halves apart. Note: The TPA is fragile and may break if not done carefully. 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. 3. View of the male half of the connector with female terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 991 4. View of the female half of the connector with male terminals. 5. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. View of the female half of the connector with male terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 992 7. View of the male half of the connector with female terminals. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 993 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are a one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine if the element in the fuse is broken (2). If not broken (1), also check for continuity using a Digital Multimeter (DMM) or a continuity tester. If the element is broken or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a Digital Multimeter (DMM) at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gauge size. Repairing a Fusible Link Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 994 Flat Wire Repairs The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Special Tools J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool * J 38125-5 Ultra Torch Special Tool The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Note: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation). GMLAN Connector Terminal Repair Note: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) for the appropriate connector repair procedure. GMLAN Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 995 Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 996 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Special Tools J-38125 Terminal Repair Kit Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 997 repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs High Temperature Wiring Repairs Special Tools J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gauge size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 998 splice. Note: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 999 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1000 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the wire insulation has been chafed, or broken, enough to show the conductive portion of the wire, and the wire is not damaged, determine the length of insulation that needs to be repaired. If the repair is less than 280 mm (11 in), cut the wire within the damaged area. Then slide the appropriate heat shrink tubing (listed below) over the wire, and repair the wire by splicing the wires together. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Once the wire is spliced together slide heat shrink tubing over the damaged area and apply heat to seal the repaired wire. If the wire is damaged, or the damaged area is larger than 280 mm (11 in), then replace the damaged wire by splicing in a new section of wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1001 SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Special Tools J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1002 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1003 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1004 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Special Tools J-38125 Terminal Repair Kit Note: Use only DuraSeal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use DuraSeal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use DuraSeal splice sleeves where there are special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1005 * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1006 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1007 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the instructions for Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Staggering the splices by 65 mm (2.5 in) is recommended. Note: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product AL-36FR to replace the damaged mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Flat Wire Repairs) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/GMLAN Wiring Repairs) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Heated Oxygen Sensor Wiring Repairs) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves) * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Twisted or Shielded Cable) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Inline Harness Diodes) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/SIR/SRS Wiring Repairs) US English/Metric Conversion US English/Metric Conversion Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1008 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1009 Testing Ground and Low Reference Circuits Testing Ground and Low Reference Circuits Because a test lamp can light with up to 200 ohm in a ground or low reference circuit they are not recommended to be used for this type of test. A low impedance test lamp can light and indicate the circuit is good when there is as much as 20-30 ohm present, while a high impedance test lamp can light with up to 200 ohm present in the circuit. This is why the Digital Multi-Meter (DMM) is used when validating a ground or low reference circuit continuity. When using the DMM there are many vehicle conditions that can affect the ground and low reference continuity testing. If these conditions are not met, a ground or low reference circuit test can fail on a good circuit. This may cause longer diagnosis time and incorrect component replacement. Any current flow through a ground or low reference circuit, while being tested, will skew the DMM continuity reading, or display a reading higher than when there is no current flowing. Performing a ground or low reference circuit continuity test, in reference to the vehicles battery negative terminal, will have the highest risk of failing a good ground or low reference circuit test than any other ground reference point. The best ground test points would be a control module housing (if the control modules housing is metal and grounded), door jamb striker (if attached to metal), under dash metal frame work, engine block, or body ground studs (other than where the negative battery cable is attached). A typical DMM ground or low reference circuit continuity reading can be as high as 100 ohm with the ignition ON, and drop to 15-25 ohm after the ignition is turned OFF. The reading will drop below 10 ohm after 30-40 seconds, then below 5 ohm after 60 seconds. Once the vehicle completely goes to sleep (generally 3-10 minutes) the reading will drop below 0.3 ohm. The following list of conditions may need to be met to ensure a valid continuity reading on a ground or low reference circuit: * Ignition OFF * Key out of the ignition switch (when not equipped with keyless entry and remote start) * Retained Accessory Power (RAP) OFF (open and close the driver door after ignition OFF) * Battery charger set at a 2 A or less charge rate * Scan tool not communicating with any vehicle control module (in some cases it may need to be disconnected from the DLC) * All entry doors closed * Headlamps OFF (auto headlamps disabled) * Any delay lighting OFF * HVAC after blow OFF * Any accessory that can work when the ignition is OFF * Wait up to 60 seconds (after all other listed conditions are met) Activating the DOOR LOCK function with a key fob can greatly reduce the time to achieve a valid ground or low reference continuity test result. Terminal Removal Terminal Removal Special Tools * EL-38125-580 - Terminal Release Tool Kit * EL-35616 - Connector Test Adapter Kit For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repair procedures. 1. Find the appropriate connector end view within the connector end view section. The connector end view has the following information: Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1010 * Diagnostic probe tool * Terminal release tool * Terminal/terminated lead part numbers Note: Not using the proper test kit probe may cause damage to the terminal(s) that are probed. 2. Determine if a terminal is damaged. * Locate the diagnostic probe tool from the connector end view. The connector end view describes the color and part number to help the technician find and use the correct tool. * Connect the probe tool to the Digital Multimeter. * Insert the probe tool into the cavity and follow the procedures from the Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter). 3. Disconnect the connector body to perform the repair. 4. Use the following procedure to remove the terminal from the connector body. Note: Several procedures for specific connector bodies are called out in the Wiring Repairs section. * The terminal position assurance (TPA) and connector position assurance (CPA) should be removed before releasing the terminal for the connector body. * Look at the connector end view to locate the cavity of the damaged terminal and find the proper terminal release tool from the terminal release tool kit. Note: Using the incorrect terminal release tool can damage the connector body. * Insert the terminal release tool into the cavity. Note: Some terminals have a lever that must be disengaged before the terminal can be released. 5. Gently pull the wire out of the back of the connector. 6. Repair the terminal by following the Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) procedure. 7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminated Lead Repair Terminated Lead Repair Special Tools * J-38125-8 - Splice Sleeve Crimp Tool Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1011 * J-38125-5 - Ultra Torch For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) procedures. Terminated leads are terminals that are crimped onto wires. The terminated lead can be used throughout the vehicle since it is designed for temperatures up to 150°C. The length of the wire is 450 mm. The DuraSeal splice sleeve has the following 2 critical features: * A special heat shrink tubing that environmentally seals the splice. The shrink tubing contains a sealing adhesive inside the shrink tubing. * A cross hatched (knurled) core crimp that provides the necessary contact integrity for sensitive low energy circuits. 1. Use the connector end view to identify the correct terminated lead. 2. The terminated lead package should include a DuraSeal splice sleeve. If not, use the chart to identify the correct part. 3. Open the harness by removing any tape: Use a sewing seam ripper, or a comparable tool, to cut open the harness, to avoid wire insulation damage. 4. Depending on how many terminals need repairs, cut the terminal and wire back at least 40 mm. Try to keep the harness wire length the same. If more than one terminated lead is required, stagger the lengths by 40 mm. This helps reduce the bundle size of the wire harness. 5. Use the EL-38125-10 - tool in order to position the DuraSeal splice sleeve in the proper color nest of the splice sleeve crimp tool. The crimp tool has four nests, one for each color. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1012 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the J-38125-5 - ultra torch , apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1013 Oil Level Sensor: Connector Views Component Connector End Views Engine Oil Level (EOL) Switch (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1014 Oil Level Sensor: Electrical Diagrams Engine Mechanical Schematics Engine Oil Level Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Page 1015 Oil Level Sensor: Testing and Inspection Engine Oil Level Sensor Diagnosis Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Diagnostic Fault Information Typical Scan Tool Data Circuit/System Description The engine oil level sensor/switch is normally-closed with proper engine oil level. The switch opens when the engine oil level drops below a calibrated level. The engine control module (ECM) monitors the engine oil level signal circuit when the ignition is ON, and the engine is OFF. With the switch in the closed position, the ECM detects a low voltage on the signal circuit. With the switch in the open position, the ECM detects a high voltage on the signal circuit. When high voltage is detected on the signal circuit, the ECM will send a serial data message to the instrument panel cluster (IPC). The IPC will then display a message on the driver information center (DIC) or illuminate a low engine oil level lamp. The following information determines the message sent from the ECM to the IPC: * The Low Engine Oil Level message lamp is displayed only after the ECM detects a high voltage on the signal circuit for three consecutive ignition cycles, followed by an ignition OFF event from 15 minutes to greater than 50 minutes, depending on engine oil temperatures. * The Low Engine Oil Level message is turned OFF when the ECM detects a low voltage on the signal circuit after an ignition OFF event for greater than 90 seconds, followed by an ignition ON event for less than 1 second. Reference Information Schematic Reference * Engine Mechanical Schematics (See: Diagrams/Electrical Diagrams) * Instrument Cluster Schematics (See: Diagrams/Electrical Diagrams/Instrument Panel, Gauges and Warning Indicators/System Diagram/Instrument Cluster Schematics) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views) Description and Operation * Instrument Cluster Description and Operation (See: Instrument Panel, Gauges and Warning Indicators/Description and Operation/Instrument Cluster) * Indicator/Warning Message Description and Operation (See: Instrument Panel, Gauges and Warning Indicators/Description and Operation/Indicator/Warning Message) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Page 1016 Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning) for scan tool information. Circuit/System Verification 1. Verify proper engine oil level. Add oil as necessary. 2. Ignition ON, observe the scan tool Engine Oil Level parameter. The reading should be OK and change to low when the oil level sensor/switch harness connector is disconnected. Circuit/System Testing Note: Verify proper engine oil level before continuing with diagnosis. 1. Ignition OFF, disconnect the harness connector at the engine oil level sensor and/or switch. 2. Ignition OFF, test for less than 2 ohm between the ground circuit terminal B and ground. ‹› If greater than the specified range, test the ground circuit for an open/high resistance. 3. Ignition ON, verify the scan tool Engine Oil Level Switch parameter reads Low. ‹› If the Engine Oil Level Switch parameter reads OK, test the signal circuit terminal A for a short to ground. If the circuit tests normal, replace the ECM. Note: If a short to voltage is found on the signal circuit, the fuse in the 3A jumper wire will open. 4. Ignition ON, install a 3A fused jumper wire between the signal circuit terminal A and the ground circuit terminal B. Verify the scan tool Engine Oil Level Switch parameter reads OK. ‹› If the Engine Oil Level Switch parameter reads Low, test the signal circuit terminal A for an open/high resistance. If the circuit tests normal, replace the ECM. 5. If all circuits test normal, test or replace the engine oil level sensor and/or switch. Repair Instructions Perform the Diagnostic Repair Verification (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. * Engine Oil Level Sensor and/or Switch Replacement (See: Service and Repair) * Control Module References (See: Testing and Inspection/Programming and Relearning) for the ECM replacement, setup, and programming Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Page 1017 Oil Level Sensor: Service and Repair Engine Oil Level Sensor and/or Switch Replacement Removal Procedure 1. Remove the lower oil pan. Refer to Lower Oil Pan Replacement (See: Engine, Cooling and Exhaust/Engine/Engine Lubrication/Oil Pan/Service and Repair/Lower Oil Pan Replacement). 2. Remove the oil level sensor clip (3). 3. Remove the oil level sensor bolt (2) and sensor (1). Installation Procedure Note: When routing the oil level sensor wire, ensure that the wire is routed along the side of the oil pan. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the oil level sensor (1) and bolt (2) and tighten to 9 Nm (80 lb in). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Page 1018 2. Install the oil level sensor clip (3). 3. Install the lower oil pan. Refer to Lower Oil Pan Replacement (See: Engine, Cooling and Exhaust/Engine/Engine Lubrication/Oil Pan/Service and Repair/Lower Oil Pan Replacement). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams Oil Pressure Sensor: Diagrams Component Connector End Views Engine Oil Pressure (EOP) Sensor (Diesel) Engine Oil Pressure (EOP) Sensor (Gas except LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Page 1022 Engine Oil Pressure (EOP) Sensor (LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Page 1023 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Page 1024 Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement Special Tools DT-48827 Skip Shift Socket Removal Procedure 1. Remove the left wheelhouse inner panel. Refer to Front Wheelhouse Liner Replacement - Left Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Left Side)Front Wheelhouse Liner Replacement - Left Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Left Side). Note: Clean the area around the sensor. Do not allow debris to enter the engine. 2. Disconnect the oil pressure sensor electrical connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Page 1025 3. Using DT-48827 , remove the oil pressure sensor (1). Installation Procedure 1. Apply sealant to the threads of the oil pressure sensor. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Engine, Cooling and Exhaust/Engine/Specifications/Adhesives, Fluids, Lubricants, and Sealers) for the correct part number. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Using DT-48827 , install the oil pressure sensor (1). Tighten the sensor to 49 Nm (36 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Page 1026 3. Connect the oil pressure sensor electrical connector. 4. Install the left wheelhouse inner panel. Refer to Front Wheelhouse Liner Replacement - Left Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Left Side)Front Wheelhouse Liner Replacement - Left Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Left Side). 5. Check and add engine oil if necessary. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Technical Service Bulletins > Recalls for Exhaust Temperature Sensor: > 11054 > Apr > 11 > Recall - Replace Exhaust Gas Temperature Sensor Technical Service Bulletin # 11054 Date: 110412 Recall - Replace Exhaust Gas Temperature Sensor PRODUCT EMISSION Bulletin No.: 11054 Date: April 12, 2011 Subject: 11054 - Reduced Engine Performance and Emission Control - Replace Exhaust Gas Temperature Sensors Models: 2010 Chevrolet Express, Silverado HD 2010 GMC Savana, Sierra HD With 6.6L V8 Duramax Diesel Engine (LMM) 2007-2009 Chevrolet Express, Kodiak, Silverado HD 2007-2009 GMC Savana, Sierra HD, TopKick With 6.6L V8 Duramax Diesel Engine (LMM) Serviced with a Suspect EGT Sensor Condition General Motors has decided to conduct a Voluntary Emission Recall involving certain 2010 model year Chevrolet Express, Silverado HD; and GMC Savana, Sierra HD vehicles equipped with a 6.6L V8 Duramax diesel engine (LMM); and 2007-2009 model year Chevrolet Express, Kodiak, Silverado HD; and GMC Savana, Sierra HD, and TopKick vehicles equipped with a 6.6L V8 Duramax diesel engine (LMM) that may have been serviced with a suspect Exhaust Gas Temperature (EGT) sensor. On these vehicles, the circuit board welds on the EGT sensors in the exhaust system may not be to GM specification. If a weld fails, the Service Engine Soon light will illuminate in the instrument panel, the exhaust gas may not be filtered properly, and the engine power may be reduced. Correction Dealers are to replace both EGT sensors. Vehicles Involved Involved are certain 2010 model year Chevrolet Express, Silverado HD; and GMC Savana, Sierra HD vehicles equipped with a 6.6L V8 Duramax diesel engine (LMM); and 2007-2009 model year Chevrolet Express, Kodiak, Silverado HD; and GMC Savana, Sierra HD, and TopKick vehicles equipped with a 6.6L V8 Duramax diesel engine (LMM) that may have been serviced with a suspect EGT sensor. Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Required Field Actions section in the Global Warranty system. Not all vehicles may be involved. For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to US and Canadian dealers through the GM GlobalConnect Recall Reports, or sent directly to export dealers. Dealers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information Parts required to complete this recall are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Service Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Technical Service Bulletins > Recalls for Exhaust Temperature Sensor: > 11054 > Apr > 11 > Recall - Replace Exhaust Gas Temperature Sensor > Page 1036 1. Remove and replace position 1 and position 2 exhaust gas temperature sensors (1). Refer to Exhaust Temperature Sensor Replacement in SI. 2. CALIFORNIA, CONNECTICUT, MASSACHUSETTS, MAINE, OREGON, VERMONT, & WASHINGTON VEHICLES ONLY: Install a Recall Identification Label. Also, for California vehicles complete a "Proof of Correction" certificate upon recall completion. Recall Identification Label California/Connecticut/Massachusetts/Maine/Oregon/Vermont/Washington Vehicles Only) Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five-digit dealer code of the dealer performing the recall service. This information may be inserted with a ballpoint pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Recall Identification Label, be sure to pull the tab to allow adhesion of the clear protective covering. Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials by ordering on the web from DWD Store, www.gmdealerworld.com, and then click on the DWD Store link. Request Item Number S-1015 when ordering. Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a transaction using the table below. Customer Notification - For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter included with this bulletin). In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper maintenance. The vehicle may fail a state or local emission inspection test if the recall work is not completed. Customer Notification - For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the attached sample letter. In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Technical Service Bulletins > Recalls for Exhaust Temperature Sensor: > 11054 > Apr > 11 > Recall - Replace Exhaust Gas Temperature Sensor > Page 1037 maintenance. The vehicle may fail a state or local emission inspection test if the recall work is not completed. Dealer Recall Responsibility All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. ***THE FOLLOWING 2 PARAGRAPHS ARE NOT FOR CANADA OR EXPORT*** When a California emissions recall is completed by a GM dealer, the dealer must provide the vehicle owner a "Proof of Correction Certificate" which the owner may need to present to the California Department Of Motor Vehicles (DMV) when renewing their vehicle registration. Without this correction certificate, the owner may be unable to renew their vehicle registration. Additional Certificates can be obtained, at no charge, from Dealer Support Materials by ordering on the web from the DWD Store, www.gmdealerworld.com, and then click on the DWD Store link; request GM Item Number 1825 when ordering. Disclaimer Owner Letter Owner Letter Dear General Motors Customer: This notice is sent to inform you that General Motors is conducting a voluntary emission recall that includes your vehicle. Reason For This Recall: General Motors has decided to conduct a Voluntary Emission Recall involving certain 2010 model year Chevrolet Express, Silverado HD; and GMC Savana, Sierra HD vehicles equipped with a 6.6L V8 Duramax diesel engine; and 2007-2009 model year Chevrolet Express, Kodiak, Silverado HD; and GMC Savana, Sierra HD, and TopKick vehicles equipped with a 6.6L V8 Duramax diesel engine that may have been serviced with a suspect Exhaust Gas Temperature (EGT) sensor. The circuit board welds on the EGT sensors in the exhaust system may not be to GM specification. If a weld fails, the Service Engine Soon light will illuminate in the instrument panel, the exhaust gas may not be filtered properly, and the engine power may be reduced. What Will Be Done: Your GM dealer will replace both EGT sensors. This service will be performed for you at no charge. What You Should Do: Please contact your GM dealer as soon as possible to arrange a service date and to assure parts availability. Instructions for making this correction have been sent to your dealer. Please ask your dealer if you wish to know how much time will be needed to schedule, process, and repair your vehicle. If you have any questions or need any assistance, just contact your dealer or the appropriate Customer Assistance Center at the number listed below. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Technical Service Bulletins > Recalls for Exhaust Temperature Sensor: > 11054 > Apr > 11 > Recall - Replace Exhaust Gas Temperature Sensor > Page 1038 Emission Law Information: In order to ensure your full protection under the emission warranty made applicable to your vehicle by State and Federal Law, and your right to participate in future recalls, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could legally be determined to be lack of proper maintenance of your vehicle. Also, your vehicle may fail a state or local emission inspection if this recall is not accomplished. IMPORTANT MESSAGE FOR CALIFORNIA RESIDENTS The California Air Resources Board (CARB) requires vehicle emission recalls be completed prior to California registration renewal. Uncorrected emission recalls will result in the inability to renew your California vehicle registration. At the time of emission recall completion, your California dealer will issue a "Proof of Correction Certificate". Keep this certificate and, if required, present it to the Department of Motor Vehicles when renewing your California registration as proof of recall completion. We are sorry to cause you this inconvenience; however, we have taken this action in the interest of your continued satisfaction with our products. Jim Moloney General Director, Customer and Relationship Services 11054 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exhaust Temperature Sensor: > 11054 > Apr > 11 > Recall - Replace Exhaust Gas Temperature Sensor Technical Service Bulletin # 11054 Date: 110412 Recall - Replace Exhaust Gas Temperature Sensor PRODUCT EMISSION Bulletin No.: 11054 Date: April 12, 2011 Subject: 11054 - Reduced Engine Performance and Emission Control - Replace Exhaust Gas Temperature Sensors Models: 2010 Chevrolet Express, Silverado HD 2010 GMC Savana, Sierra HD With 6.6L V8 Duramax Diesel Engine (LMM) 2007-2009 Chevrolet Express, Kodiak, Silverado HD 2007-2009 GMC Savana, Sierra HD, TopKick With 6.6L V8 Duramax Diesel Engine (LMM) Serviced with a Suspect EGT Sensor Condition General Motors has decided to conduct a Voluntary Emission Recall involving certain 2010 model year Chevrolet Express, Silverado HD; and GMC Savana, Sierra HD vehicles equipped with a 6.6L V8 Duramax diesel engine (LMM); and 2007-2009 model year Chevrolet Express, Kodiak, Silverado HD; and GMC Savana, Sierra HD, and TopKick vehicles equipped with a 6.6L V8 Duramax diesel engine (LMM) that may have been serviced with a suspect Exhaust Gas Temperature (EGT) sensor. On these vehicles, the circuit board welds on the EGT sensors in the exhaust system may not be to GM specification. If a weld fails, the Service Engine Soon light will illuminate in the instrument panel, the exhaust gas may not be filtered properly, and the engine power may be reduced. Correction Dealers are to replace both EGT sensors. Vehicles Involved Involved are certain 2010 model year Chevrolet Express, Silverado HD; and GMC Savana, Sierra HD vehicles equipped with a 6.6L V8 Duramax diesel engine (LMM); and 2007-2009 model year Chevrolet Express, Kodiak, Silverado HD; and GMC Savana, Sierra HD, and TopKick vehicles equipped with a 6.6L V8 Duramax diesel engine (LMM) that may have been serviced with a suspect EGT sensor. Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Required Field Actions section in the Global Warranty system. Not all vehicles may be involved. For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to US and Canadian dealers through the GM GlobalConnect Recall Reports, or sent directly to export dealers. Dealers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information Parts required to complete this recall are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Service Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exhaust Temperature Sensor: > 11054 > Apr > 11 > Recall - Replace Exhaust Gas Temperature Sensor > Page 1044 1. Remove and replace position 1 and position 2 exhaust gas temperature sensors (1). Refer to Exhaust Temperature Sensor Replacement in SI. 2. CALIFORNIA, CONNECTICUT, MASSACHUSETTS, MAINE, OREGON, VERMONT, & WASHINGTON VEHICLES ONLY: Install a Recall Identification Label. Also, for California vehicles complete a "Proof of Correction" certificate upon recall completion. Recall Identification Label California/Connecticut/Massachusetts/Maine/Oregon/Vermont/Washington Vehicles Only) Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five-digit dealer code of the dealer performing the recall service. This information may be inserted with a ballpoint pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Recall Identification Label, be sure to pull the tab to allow adhesion of the clear protective covering. Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials by ordering on the web from DWD Store, www.gmdealerworld.com, and then click on the DWD Store link. Request Item Number S-1015 when ordering. Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a transaction using the table below. Customer Notification - For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter included with this bulletin). In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper maintenance. The vehicle may fail a state or local emission inspection test if the recall work is not completed. Customer Notification - For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the attached sample letter. In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exhaust Temperature Sensor: > 11054 > Apr > 11 > Recall - Replace Exhaust Gas Temperature Sensor > Page 1045 maintenance. The vehicle may fail a state or local emission inspection test if the recall work is not completed. Dealer Recall Responsibility All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. ***THE FOLLOWING 2 PARAGRAPHS ARE NOT FOR CANADA OR EXPORT*** When a California emissions recall is completed by a GM dealer, the dealer must provide the vehicle owner a "Proof of Correction Certificate" which the owner may need to present to the California Department Of Motor Vehicles (DMV) when renewing their vehicle registration. Without this correction certificate, the owner may be unable to renew their vehicle registration. Additional Certificates can be obtained, at no charge, from Dealer Support Materials by ordering on the web from the DWD Store, www.gmdealerworld.com, and then click on the DWD Store link; request GM Item Number 1825 when ordering. Disclaimer Owner Letter Owner Letter Dear General Motors Customer: This notice is sent to inform you that General Motors is conducting a voluntary emission recall that includes your vehicle. Reason For This Recall: General Motors has decided to conduct a Voluntary Emission Recall involving certain 2010 model year Chevrolet Express, Silverado HD; and GMC Savana, Sierra HD vehicles equipped with a 6.6L V8 Duramax diesel engine; and 2007-2009 model year Chevrolet Express, Kodiak, Silverado HD; and GMC Savana, Sierra HD, and TopKick vehicles equipped with a 6.6L V8 Duramax diesel engine that may have been serviced with a suspect Exhaust Gas Temperature (EGT) sensor. The circuit board welds on the EGT sensors in the exhaust system may not be to GM specification. If a weld fails, the Service Engine Soon light will illuminate in the instrument panel, the exhaust gas may not be filtered properly, and the engine power may be reduced. What Will Be Done: Your GM dealer will replace both EGT sensors. This service will be performed for you at no charge. What You Should Do: Please contact your GM dealer as soon as possible to arrange a service date and to assure parts availability. Instructions for making this correction have been sent to your dealer. Please ask your dealer if you wish to know how much time will be needed to schedule, process, and repair your vehicle. If you have any questions or need any assistance, just contact your dealer or the appropriate Customer Assistance Center at the number listed below. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exhaust Temperature Sensor: > 11054 > Apr > 11 > Recall - Replace Exhaust Gas Temperature Sensor > Page 1046 Emission Law Information: In order to ensure your full protection under the emission warranty made applicable to your vehicle by State and Federal Law, and your right to participate in future recalls, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could legally be determined to be lack of proper maintenance of your vehicle. Also, your vehicle may fail a state or local emission inspection if this recall is not accomplished. IMPORTANT MESSAGE FOR CALIFORNIA RESIDENTS The California Air Resources Board (CARB) requires vehicle emission recalls be completed prior to California registration renewal. Uncorrected emission recalls will result in the inability to renew your California vehicle registration. At the time of emission recall completion, your California dealer will issue a "Proof of Correction Certificate". Keep this certificate and, if required, present it to the Department of Motor Vehicles when renewing your California registration as proof of recall completion. We are sorry to cause you this inconvenience; however, we have taken this action in the interest of your continued satisfaction with our products. Jim Moloney General Director, Customer and Relationship Services 11054 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Service and Repair > Exhaust Temperature Sensor Replacement - Position 1 Exhaust Temperature Sensor: Service and Repair Exhaust Temperature Sensor Replacement Position 1 Exhaust Temperature Sensor Replacement - Position 1 Removal Procedure Caution: The exhaust temperature sensor and exhaust pressure differential sensor line fittings may be difficult to remove when the engine exhaust system temperature is below 48°C (120°F). Excessive force may damage the threads in the exhaust manifold or exhaust pipe. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the exhaust temperature sensor electrical connector (1) from the chassis wiring harness electrical connector (2). 3. Remove the exhaust temperature sensor. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Service and Repair > Exhaust Temperature Sensor Replacement - Position 1 > Page 1049 Note: A special anti-seize compound is used in the sensor or line fittings threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor or line fitting easier to remove. New, or service replacement sensors or line fittings already have the compound applied to the threads. If the sensor or line fittings are removed from an exhaust component and if for any reason the sensor or line fitting are reinstalled, the threads must have anti-seize compound applied before reinstallation. 1. If reinstalling the old temperature sensor or differential pressor sensor line fittings, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the exhaust temperature sensor. Tighten the sensor to 45 Nm (33 lb ft). 3. Connect the exhaust temperature sensor electrical connector (1) to the chassis wiring harness electrical connector (2). 4. Lower the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Service and Repair > Exhaust Temperature Sensor Replacement - Position 1 > Page 1050 Exhaust Temperature Sensor: Service and Repair Exhaust Temperature Sensor Replacement Position 2 Exhaust Temperature Sensor Replacement - Position 2 Removal Procedure Caution: The exhaust temperature sensor and exhaust pressure differential sensor line fittings may be difficult to remove when the engine exhaust system temperature is below 48°C (120°F). Excessive force may damage the threads in the exhaust manifold or exhaust pipe. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the exhaust temperature sensor (3) electrical connector from the chassis wiring harness electrical connector (4). 3. Remove the exhaust temperature sensor. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Service and Repair > Exhaust Temperature Sensor Replacement - Position 1 > Page 1051 Note: A special anti-seize compound is used in the sensor or line fittings threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor or line fitting easier to remove. New, or service replacement sensors or line fittings already have the compound applied to the threads. If the sensor or line fittings are removed from an exhaust component and if for any reason the sensor or line fitting are reinstalled, the threads must have anti-seize compound applied before reinstallation. 1. If reinstalling the old temperature sensor or differential pressor sensor line fittings, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the exhaust temperature sensor. Tighten the sensor to 45 Nm (33 lb ft). 3. Connect the exhaust temperature sensor (3) electrical connector to the chassis wiring harness electrical connector (4). 4. Lower the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams Ambient Temperature Sensor / Switch HVAC: Diagrams Component Connector End Views Ambient Air Temperature Sensor (CJ2 or C67) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Page 1056 Ambient Temperature Sensor / Switch HVAC: Service and Repair Ambient Air Temperature Sensor Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Service and Repair Cabin Temperature Sensor / Switch: Service and Repair Inside Air Temperature Sensor Replacement Removal Procedure 1. Remove the left windshield garnish molding. Refer to Windshield Pillar Garnish Molding Replacement (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Windshield Pillar Garnish Molding Replacement). 2. Remove the left center pillar assist handle. Refer to Roof Rail Rear Assist Handle Replacement (See: Body and Frame/Interior Moulding / Trim/Passenger Assist Handle/Service and Repair/Roof Rail Rear Assist Handle Replacement). 3. Remove the center pillar garnish molding. Refer to Center Pillar Upper Garnish Molding Replacement (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Center Pillar Upper Garnish Molding Replacement). 4. Remove the left sunshade. Refer to Sunshade Replacement (See: Body and Frame/Interior Moulding / Trim/Sun Visor/Service and Repair). 5. Gently pull down the headliner. 6. Disconnect the electrical connector from the inside air temperature sensor. 7. Partially remove the inside air temperature sensor from the headliner. 8. Remove the sensor grille from the inside air temperature sensor. 9. Remove the inside air temperature sensor from the headliner. Installation Procedure 1. Install the new sensor grille to the headliner. 2. Install the inside air temperature sensor to the headliner and sensor grille. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Service and Repair > Page 1060 3. Connect the electrical connector to the inside air temperature sensor. 4. Install the left sunshade. Refer to Sunshade Replacement (See: Body and Frame/Interior Moulding / Trim/Sun Visor/Service and Repair). 5. Install the left center pillar garnish molding. Refer to Center Pillar Upper Garnish Molding Replacement (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Center Pillar Upper Garnish Molding Replacement). 6. Install the left center assist handle. Refer to Roof Rail Rear Assist Handle Replacement (See: Body and Frame/Interior Moulding / Trim/Passenger Assist Handle/Service and Repair/Roof Rail Rear Assist Handle Replacement). 7. Install the left windshield garnish molding. Refer to Windshield Pillar Garnish Molding Replacement (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Windshield Pillar Garnish Molding Replacement). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Service and Repair > Duct Air Temperature Sensor Replacement Lower Left Side Discharge Air Temperature Sensor / Switch: Service and Repair Duct Air Temperature Sensor Replacement - Lower Left Side Duct Air Temperature Sensor Replacement - Lower Left Side Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Service and Repair > Duct Air Temperature Sensor Replacement Lower Left Side > Page 1065 Discharge Air Temperature Sensor / Switch: Service and Repair Duct Air Temperature Sensor Replacement - Lower Right Side Duct Air Temperature Sensor Replacement - Lower Right Side Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Service and Repair > Duct Air Temperature Sensor Replacement Lower Left Side > Page 1066 Discharge Air Temperature Sensor / Switch: Service and Repair Duct Air Temperature Sensor Replacement - Upper Left Side Duct Air Temperature Sensor Replacement - Upper Left Side Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Service and Repair > Duct Air Temperature Sensor Replacement Lower Left Side > Page 1067 Discharge Air Temperature Sensor / Switch: Service and Repair Duct Air Temperature Sensor Replacement - Upper Right Side Duct Air Temperature Sensor Replacement - Upper Right Side Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Diagrams Evaporator Temperature Sensor / Switch: Diagrams Component Connector End Views Air Temperature Sensor - Inside (CJ2) Air Temperature Sensor - Lower Left (CJ2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Page 1071 Air Temperature Sensor - Lower Right (CJ2) Air Temperature Sensor - Upper Left (CJ2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Page 1072 Air Temperature Sensor - Upper Right (CJ2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Page 1073 Evaporator Temperature Sensor (except HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams Refrigerant Pressure Sensor / Switch: Diagrams Component Connector End Views A/C Refrigerant Pressure Sensor (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Air Conditioning Cycling Switch Replacement (Non-HP2) Refrigerant Pressure Sensor / Switch: Service and Repair Air Conditioning Cycling Switch Replacement (Non-HP2) Air Conditioning Cycling Switch Replacement (Non-HP2) Removal Procedure 1. Disconnect the electrical connector from the A/C low pressure switch. 2. Remove the A/C low pressure switch from the accumulator. 3. Remove the O-ring and discard. Installation Procedure 1. Install the new O-ring seal to the switch. Refer to Air Conditioning O-Ring Seal Replacement (See: Heating and Air Conditioning/Coupler HVAC/A/C Coupler O-ring/Service and Repair/Air Conditioning O-Ring Seal Replacement). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the A/C low pressure switch to the accumulator and tighten to 6 Nm (53 lb in). 3. Connect the electrical connector to the A/C low pressure switch. 4. Leak test the fittings of the components using the J 39400-A . Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Air Conditioning Cycling Switch Replacement (Non-HP2) > Page 1079 Refrigerant Pressure Sensor / Switch: Service and Repair Air Conditioning (A/C) Refrigerant Pressure Sensor Replacement (Non-HP2) Air Conditioning (A/C) Refrigerant Pressure Sensor Replacement (Non-HP2) Special Tools J 39400-A Halogen Leak Detector Removal Procedure 1. Disconnect the electrical connector from the A/C refrigerant pressure sensor. 2. Remove the A/C refrigerant pressure sensor (1) from the condenser tube. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Air Conditioning Cycling Switch Replacement (Non-HP2) > Page 1080 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the A/C refrigerant pressure sensor (1). Tighten the switch to 6 Nm (53 lb in). 2. Connect the electrical connector to the A/C refrigerant pressure sensor. 3. Leak test the fittings of the components using the J 39400-A . 4. Lower the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Temperature Sensor > Component Information > Service and Repair > HVAC - Automatic Refrigerant Temperature Sensor: Service and Repair HVAC - Automatic Air Conditioning Refrigerant Temperature Sensor Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Temperature Sensor > Component Information > Service and Repair > HVAC - Automatic > Page 1085 Refrigerant Temperature Sensor: Service and Repair HVAC - Manual Air Conditioning Refrigerant Temperature Sensor Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Diagrams Solar Sensor: Diagrams Component Connector End Views Ambient Light Sensor (C67, C42 or MEX) Ambient Light/Sunload Sensor (CJ2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Diagrams > Page 1089 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Diagrams > Page 1090 Solar Sensor: Service and Repair Sun Load Temperature Sensor Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams Dimmer Switch: Diagrams Component Connector End Views Headlamp and Panel Dimmer Switch Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Service and Repair Fuel Gauge Sender: Service and Repair Fuel Sender Assembly Replacement Special Tools J 45722 Fuel Sender Lock Ring Wrench Removal Procedure 1. Remove the fuel tank. Refer to Fuel Tank Replacement (Pickup) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (Cab/Chassis Front) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (Cab/Chassis - Rear) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement). 2. Disconnect the fuel lines from the sending unit. Refer to Metal Collar Quick Connect Fitting Service (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Metal Collar Quick Connect Fitting Service) or Plastic Collar Quick Connect Fitting Service (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). Caution: Avoid damaging the lock ring. Use only J-45722 to prevent damage to the lock ring. Caution: Do Not handle the fuel sender assembly by the fuel pipes. The amount of leverage generated by handling the fuel pipes could damage the joints. Note: Do NOT use impact tools. Significant force will be required to release the lock ring. The use of a hammer and screwdriver is not recommended. Secure the fuel tank in order to prevent fuel tank rotation. 3. Use the J 45722 and a long breaker-bar in order to unlock the fuel sender lock ring. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Service and Repair > Page 1098 4. Remove the sending unit and seal. Discard the seal. 5. Clean the sending unit sealing surfaces. Note: Some lock rings were manufactured with "DO NOT REUSE" stamped into them. These lock rings may be reused if they are not damaged or warped. Note: Inspect the lock ring for damage due to improper removal or installation procedures. If damage is found, install a NEW lock ring. Note: Check the lock ring for flatness. 6. Place the lock ring on a flat surface. Measure the clearance between the lock ring and the flat surface using a feeler gauge at 7 points. 7. If warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement. 8. If warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Service and Repair > Page 1099 1. Install the sending unit and a NEW seal. Note: Always replace the fuel sender seal when installing the fuel sender assembly. Replace the lock ring if necessary. DO NOT apply any type of lubrication in the seal groove. Ensure the lock ring is installed with the correct side facing upward. A correctly installed lock ring will only turn in a clockwise direction. 2. Use the J 45722 in order to install the fuel sender lock ring. Turn the fuel sender lock ring in a clockwise direction. 3. Connect the fuel lines to the sending unit. Refer to Metal Collar Quick Connect Fitting Service (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Metal Collar Quick Connect Fitting Service) or Plastic Collar Quick Connect Fitting Service (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). 4. Install the fuel tank. Refer to Fuel Tank Replacement (Pickup) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (Cab/Chassis - Front) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (Cab/Chassis - Rear) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Diagrams Parking Brake Warning Switch: Diagrams Component Connector End Views Park Brake Switch Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Diagrams > Page 1103 Parking Brake Warning Switch: Service and Repair Parking Brake Indicator Switch Replacement Removal Procedure Warning: Refer to Battery Disconnect Warning (See: Starting and Charging/Battery/Service Precautions). 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 2. Without disconnecting the electrical connectors, remove the left side instrument panel electrical center/junction block and position aside. Refer to Instrument Panel Electrical Center or Junction Block Replacement - Left Side (See: Maintenance/Fuses and Circuit Breakers/Fuse Block/Service and Repair/Removal and Replacement/Instrument Panel Electrical Center or Junction Block Replacement - Left Side). 3. Disconnect the park brake warning lamp switch electrical connector. 4. Remove the park brake warning lamp switch bolt. 5. Remove the park brake warning lamp switch. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Diagrams > Page 1104 1. Install the park brake warning lamp switch. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the park brake warning lamp switch bolt and tighten to 3 Nm (27 lb in). 3. Connect the park brake warning lamp switch electrical connector. 4. Install the left side instrument panel electrical center/junction block. Refer to Instrument Panel Electrical Center or Junction Block Replacement Left Side (See: Maintenance/Fuses and Circuit Breakers/Fuse Block/Service and Repair/Removal and Replacement/Instrument Panel Electrical Center or Junction Block Replacement - Left Side). 5. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Water In Fuel Sensor > Component Information > Diagrams Water In Fuel Sensor: Diagrams Component Connector End Views Water in Fuel Sensor (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Service and Repair Ambient Light Sensor: Service and Repair Ambient Light Sensor Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams Backup Lamp Switch: Diagrams Component Connector End Views Backup Lamp Switch (TZ0) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Service and Repair > Tremec 5-Speed (M96) - Manual Transmission Backup Lamp Switch: Service and Repair Tremec 5-Speed (M96) - Manual Transmission Backup Lamp Switch Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Service and Repair > Tremec 5-Speed (M96) - Manual Transmission > Page 1117 Backup Lamp Switch: Service and Repair Tremec 5-Speed (TZ0) - Manual Transmission Backup Lamp Switch Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the backup lamp switch electrical connector (3). 3. Remove the backup lamp switch. Installation Procedure Caution: Refer to Component Fastener Tightening Caution (See: Service Precautions/Vehicle Damage Warnings/Component Fastener Tightening Caution). Note: The backup lamp switch has pre-applied thread sealant on the threads. 1. Install the backup lamp switch. Tighten the switch to 37 Nm (27 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Service and Repair > Tremec 5-Speed (M96) - Manual Transmission > Page 1118 2. Connect the backup lamp switch electrical connector (3). 3. Lower the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams Brake Light Switch: Diagrams Component Connector End Views Stop Lamp Switch Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Service and Repair > Stop Lamp Switch Replacement (With Adjustable Pedals) Brake Light Switch: Service and Repair Stop Lamp Switch Replacement (With Adjustable Pedals) Stop Lamp Switch Replacement (With Adjustable Pedals) Removal Procedure 1. Apply the park brake. 2. Remove the driver knee bolster. Refer to Knee Bolster Replacement (With SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (With SLT))Knee Bolster Replacement (Without SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (Without SLT)). 3. Disconnect the stoplamp switch electrical connector. 4. Remove the power vacuum brake booster pushrod retainer bolt (1). 5. Remove the power vacuum brake booster pushrod retainer (1). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Service and Repair > Stop Lamp Switch Replacement (With Adjustable Pedals) > Page 1124 6. Slide the power vacuum brake booster pushrod off of the brake pedal pin and remove the stoplamp switch (1). Installation Procedure 1. Install the stoplamp switch (1) to the power vacuum brake booster pushrod. 2. Install the power vacuum brake booster pushrod with the stoplamp switch to the brake pedal pin. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Service and Repair > Stop Lamp Switch Replacement (With Adjustable Pedals) > Page 1125 3. Install the power vacuum brake booster pushrod retainer (1). 4. Rotate the pushrod retainer 360 degrees to verify the retainer is fully engaged in the groove on the brake pedal pin. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Install the power vacuum brake booster pushrod retainer bolt (1) and tighten to 10 Nm (89 lb in). 6. Connect the stoplamp switch electrical connector. 7. Install the driver knee bolster. Refer to Knee Bolster Replacement (With SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (With SLT))Knee Bolster Replacement (Without SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (Without SLT)). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Service and Repair > Stop Lamp Switch Replacement (With Adjustable Pedals) > Page 1126 Brake Light Switch: Service and Repair Stop Lamp Switch Replacement (Without Adjustable Pedals) Stop Lamp Switch Replacement (Without Adjustable Pedals) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Diagrams Combination Switch: Diagrams Component Connector End Views Turn Signal/Multifunction Switch X1 Turn Signal/Multifunction Switch X2 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Diagrams > Page 1130 Turn Signal/Multifunction Switch X3 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Service and Repair > Fog Lamp Switch Replacement (with RPO SLT) Fog/Driving Lamp Switch: Service and Repair Fog Lamp Switch Replacement (with RPO SLT) Fog Lamp Switch Replacement (with RPO SLT) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Service and Repair > Fog Lamp Switch Replacement (with RPO SLT) > Page 1135 Fog/Driving Lamp Switch: Service and Repair Fog Lamp Switch Replacement (without RPO SLT) Fog Lamp Switch Replacement (without RPO SLT) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams Hazard Warning Switch: Diagrams Component Connector End Views Roof Beacon Switch (5X7, 5Y0 or TRW) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Service and Repair > Headlamp Switch Replacement (with RPO SLT) Headlamp Switch: Service and Repair Headlamp Switch Replacement (with RPO SLT) Headlamp Switch Replacement (with RPO SLT) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Service and Repair > Headlamp Switch Replacement (with RPO SLT) > Page 1143 Headlamp Switch: Service and Repair Headlamp Switch Replacement (without RPO SLT) Headlamp Switch Replacement (without RPO SLT) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Service and Repair Horn Switch: Service and Repair Steering Wheel Horn Switch Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams Turn Signal Switch: Diagrams Component Connector End Views Turn Signal/Multifunction Switch X1 Turn Signal/Multifunction Switch X2 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 1150 Turn Signal/Multifunction Switch X3 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Service and Repair > Turn Signal Multifunction Switch Replacement Turn Signal Switch: Service and Repair Turn Signal Multifunction Switch Replacement Turn Signal Multifunction Switch Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Service and Repair > Turn Signal Multifunction Switch Replacement > Page 1153 Turn Signal Switch: Service and Repair Turn Signal Switch Cancel Cam Position Plate Replacement Turn Signal Switch Cancel Cam Position Plate Replacement Tools Required * J 23653-SIR Steering Column Lock Plate Compressor * J 42137 Cam Orientation Plate Adapter Removal Procedure 1. Remove the inflatable restraint steering wheel module coil and the inflatable restraint steering wheel module coil wave washer. Refer to Steering Wheel Inflatable Restraint Module Coil Replacement (See: Restraint Systems/Air Bag Systems/Clockspring Assembly / Spiral Cable/Service and Repair/Removal and Replacement). Important: DISCARD the old steering shaft lock plate ring. 2. Remove the following parts from the steering shaft: 1. Steering shaft lock plate retaining ring (1) using compressor J 23653-SIR and adapter J 42137 . 2. Turn signal switch cancel cam position plate (2) 3. Turn signal switch cancel cam (3) Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Service and Repair > Turn Signal Multifunction Switch Replacement > Page 1154 Important: Use a NEW steering shaft lock plate retaining ring. 1. Install the following parts onto the steering shaft: 1. Lubricate the turn signal switch cancel cam (3) with GM P/N 12377900 (Canadian P/N 10953529). 2. Turn signal switch cancel cam position plate (2) 3. Steering shaft lock plate retaining ring (1) using compressor J 23653-SIR and adapter J 42137 . 2. Install the inflatable restraint steering wheel module coil and the inflatable restraint steering wheel module coil wave washer. Refer to Steering Wheel Inflatable Restraint Module Coil Replacement (See: Restraint Systems/Air Bag Systems/Clockspring Assembly / Spiral Cable/Service and Repair/Removal and Replacement). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations Accelerator Pedal Position Sensor: Locations Harness Routing Views Brake Clutch Harness Routing 1 - Driver Door Frame 2 - X205 3 - X102 (JL1) 4 - Accelerator Pedal Position (APP) Sensor Connector 5 - Junction Block - Left I/P (except MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 1160 Accelerator Pedal Position Sensor: Diagrams Component Connector End Views Accelerator Pedal Position (APP) Sensor Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 1161 Accelerator Pedal Position Sensor: Description and Operation Accelerator Pedal Position System Description The accelerator pedal position (APP) sensor is mounted inside the accelerator pedal control assembly. The sensor is made up of the two individual sensors within a single housing. Each sensor has a unique functionality to determine pedal position. The accelerator pedal position (APP) system along with the engine control module (ECM) is used to calculate and control the amount of acceleration and deceleration through fuel injector control. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 1162 Accelerator Pedal Position Sensor: Service and Repair Accelerator Pedal Position Sensor Replacement Removal Procedure Caution: Handle the electronic throttle control components carefully. Use cleanliness in order to prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the electronic throttle control components. Do not immerse the electronic throttle control components in cleaning solvents of any type. 1. Remove the connector position assurance (CPA) retainer. 2. Disconnect the accelerator pedal position (APP) sensor electrical connector (1). 3. Remove the accelerator pedal bolts. 4. Remove the accelerator pedal. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 1163 Installation Procedure 1. Position the accelerator pedal to the accelerator pedal bracket. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the accelerator pedal bolts and tighten to 9 Nm (80 lb in).. 3. Connect the APP sensor electrical connector (1). 4. Install the CPA retainer. 5. Connect a scan tool to the diagnostic port in order to test for proper throttle-opening and throttle-closing range. 6. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle, and a wide open throttle (WOT). 7. Verify that the vehicle meets the following conditions: * The vehicle is not in a reduced engine power mode. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 1164 * The ignition is ON. * The engine is OFF. 8. Inspect the carpet fit under the accelerator pedal. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations Air Flow Meter/Sensor: Locations Harness Routing Views Engine Harness Routing - Top (4.3L) 1 - Mega Fuse Ring Terminal 2 - X175 (M30) 3 - J128 4 - J105 5 - J106 6 - J130 (M30 with NQG/NQH) 7 - Engine Control Module (ECM) X1 8 - Engine Control Module (ECM) X2 9 - G103 10 - X112 11 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Connector Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 1168 Air Flow Meter/Sensor: Diagrams Component Connector End Views Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (Diesel) Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (Gas) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 1169 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 1170 Air Flow Meter/Sensor: Service and Repair Mass Airflow Sensor with Intake Air Temperature Sensor Replacement Removal Procedure 1. Disconnect the engine wiring harness electrical connector (1) from the mass air flow (MAF)/intake air temperature (IAT) sensor. 2. Remove the MAF/IAT sensor TORX(R) screws. 3. Remove the MAF/IAT sensor. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 1171 1. Install the MAF/IAT sensor. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the MAF/IAT sensor TORX(R) screws. Tighten the screws to 8 Nm (70 lb in). 3. Connect the engine wiring harness electrical connector (1) to the MAF/IAT sensor. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Current Sensor > Component Information > Diagrams Battery Current Sensor: Diagrams Component Connector End Views Battery Current Sensor (10 Series without MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Current Sensor > Component Information > Diagrams > Page 1175 Battery Current Sensor: Service and Repair Battery Current Sensor Replacement Removal Procedure 1. Remove the negative battery cable. Refer to Battery Negative Cable Replacement (V6) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Replacement (V8) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Replacement (Diesel) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 2. Mark the location of the battery current sensor on the battery cable with tape for reference during installation. 3. Remove the tape securing the battery current sensor to the negative battery cable. 4. Mark the location of the negative battery cable clips (1) and remove the clips from the cable. 5. Squeeze the negative battery cable branches together. Important: Note the orientation of the battery current sensor prior to removal. 6. Slide the battery current sensor (2) off of the negative battery cable. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Current Sensor > Component Information > Diagrams > Page 1176 1. Squeeze the negative battery cable branches together. Important: Ensure the battery current sensor is installed in the correct direction and location on the negative battery cable. 2. Slide the NEW battery current sensor (2) up onto the negative battery cable to the location previously marked during removal. 3. Wrap electrical tape around the battery current sensor leg in order to secure the sensor to the negative battery cable. 4. Install the negative battery cable clips (1) to the cable to the locations previously marked during removal. 5. Install the negative battery cable. Refer to Battery Negative Cable Replacement (V6) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Replacement (V8) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Replacement (Diesel) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Harness Routing Views Camshaft Position Sensor Jumper Harness Routing (4.8L/5.3L/6.0L/6.2L) 1 - X112 2 - Camshaft Position Sensor Jumper Harness Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 1180 Camshaft Position Sensor: Diagrams Component Connector End Views Camshaft Position (CMP) Actuator Solenoid Valve (LZ1, LY6, L96 or L9H) Camshaft Position (CMP) Sensor (LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 1181 Camshaft Position (CMP) Sensor (Gas except LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 1182 Camshaft Position (CMP) Sensor (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 1183 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 1184 Camshaft Position Sensor: Service Precautions Camshaft Position Actuator Removal and Installation Warning Warning Do not push or pull on the reluctor wheel of the camshaft position (CMP) actuator during removal or installation. The reluctor wheel is retained to the front of the CMP actuator by 3 roll pins. Pushing or pulling on the wheel may dislodge the wheel from the front of the actuator. The actuator return spring is under tension and may rotate the dislodged reluctor wheel, causing personal injury. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 1185 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor Replacement Removal Procedure 1. Remove the cooling fan pulley. Refer to Fan Pulley Replacement (See: Engine, Cooling and Exhaust/Cooling System/Radiator Cooling Fan/Service and Repair). 2. Remove the camshaft position (CMP) sensor bolt. 3. Remove the CMP sensor. Installation Procedure 1. Lubricate the CMP sensor O-ring with clean engine oil. 2. Install the CMP sensor. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 1186 3. Install the CMP sensor bolt. Tighten the bolt to 10 Nm (89 lb in). 4. Install the cooling fan pulley. Refer to Fan Pulley Replacement (See: Engine, Cooling and Exhaust/Cooling System/Radiator Cooling Fan/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Clutch Switch, ECM > Component Information > Diagrams Clutch Switch: Diagrams Component Connector End Views Clutch Pedal Position (CPP) Switch (TZ0) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps Coolant Temperature Sensor/Switch (For Computer): Customer Interest Engine - MIL ON P0116/P1400 Set In Very Cold Temps TECHNICAL Bulletin No.: 10-06-04-008A Date: January 24, 2011 Subject: Malfunction Indicator Lamp (MIL) Illuminated at Very Cold Ambient Temperatures When Using Engine Coolant Heater, DTC P0116 and/or P1400 Set (Relocate Engine Coolant Temperature (ECT) Sensor and Engine Coolant Heater Cord) Models: 2006-2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2006-2010 Cadillac Escalade 2006-2007 Chevrolet Monte Carlo 2006-2009 Chevrolet Impala SS, TrailBlazer 2006-2010 Chevrolet Avalanche, Express, Silverado Tahoe 2006-2009 GMC Envoy 2006-2010 GMC Savana, Sierra, Yukon 2006-2008 Pontiac Grand Prix 2006-2009 Saab 9-7X Equipped with V8 Engine RPO LC9, LH6, LH8, LH9, L76, LS2, LS4, LFA, LZ1, L92, L94, L9H or L20, L96, LMF, LMG, LY2, LY5, LY6 Please Refer to GMVIS Attention: To properly correct this condition, you must follow both of the procedures to relocate the ECT sensor and the engine coolant heater cord. Supercede: This bulletin is being revised to add cast iron block engine RPOs and to update the Warranty Information coverage period. Please discard Corporate Bulletin Number 10-06-04-008 (Section 06 - Engine/Propulsion System). Condition Some customers may comment that the malfunction indicator lamp (MIL) illuminates after starting the vehicle when they were using the engine coolant heater in very cold ambient temperatures. This usually occurs in a range of -23 to -40°C (-10 to -40°F) or colder. The technician may observe on a scan tool DTC P0116 and/or P1400 set as Current or in History. Cause This condition may be caused by the engine control module (ECM) determining that the ignition OFF time requirement has been met at start-up and interpreting the temperature difference between the engine coolant temperature (ECT) sensor and the intake air temperature (IAT) sensor as being outside of a calibrated range. Correction Important DO NOT replace the ECM for this condition. Relocating the ECT Sensor 1. Turn ON the ignition with the engine OFF. 2. Perform the diagnostic system check - vehicle. Refer to Diagnostic System Check - Vehicle in SI. ‹› If DTC P0116 and/or P1400 are set and the customer WAS using the engine coolant heater, proceed to Step 3. ‹› If DTC P0116 and/or P1400 are set and the customer WAS NOT using the engine coolant heater, refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. 3. Turn OFF the ignition. Warning To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 1198 under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator are still hot. 4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle. Refer to Cooling System Draining and Filling in SI. 7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor. 10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J 38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle. 13. Disconnect the wiring harness connector from the ECT sensor (2). 14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT sensor in the hole of the cylinder head where the plug was removed. Tighten Tighten to 20 Nm (15 lb ft). 18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was removed Tighten Tighten to 20 Nm (15 lb ft). Important Leave enough wire attached to the ECT sensor harness connector in order to create manageable splices that are at least 40 mm (1.5 in) away from the other splice. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 1199 20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit. Cut off the ECT sensor harness connector and wiring. 21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured TO or WITHIN an existing protective conduit. Note This step is to set up and verify the length of wiring that is required before cutting. 22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the appropriate length. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. 26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit using tie straps. Important You MUST run the engine at the specified RPM and until it reaches normal operating temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool down in order to top off the coolant level as needed. 28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI. 29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan tool to clear any DTCs. Relocating the Engine Coolant Heater Cord Important For reference, the procedure and graphics that are shown are from a Chevrolet Silverado, but are similar for the other vehicles listed above. 1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit from the engine compartment in order to determine the required extension cord length. 3. Obtain an extension cord with the following features: - 120 volt - 14/3 gauge - 15A capacity - Three prong - Polarized plug and receptacle - Chemical resistant - Grounded terminals - Designed for use in a cold outdoor environment - Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight - Maximum length of 2.5-3 m (8-10 ft) 4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N 12345579 (in Canada, use P/N 10953481) or an equivalent. 6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 1200 7. Wrap electrical tape around the connection as shown. 8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to the engine coolant crossover pipe as shown. 9. Continue to route the extension cord to the exit location desired by the customer as shown. 10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the engine coolant heater cord to the vehicle that were released to provide length. Part Information The extension cord may be obtained at any of the following outlets: - Lowes* - Home Depot* - Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number: CWRSJTOW3C14-10 USA: Cords should bear the UL symbol. Canada: Cords should bear the ULc symbol or CSA approval. *We believe these sources and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from these firms or for any such items that may be available from other sources. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 1201 Warranty Information (excluding Saab Models) For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps Coolant Temperature Sensor/Switch (For Computer): All Technical Service Bulletins Engine - MIL ON P0116/P1400 Set In Very Cold Temps TECHNICAL Bulletin No.: 10-06-04-008A Date: January 24, 2011 Subject: Malfunction Indicator Lamp (MIL) Illuminated at Very Cold Ambient Temperatures When Using Engine Coolant Heater, DTC P0116 and/or P1400 Set (Relocate Engine Coolant Temperature (ECT) Sensor and Engine Coolant Heater Cord) Models: 2006-2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2006-2010 Cadillac Escalade 2006-2007 Chevrolet Monte Carlo 2006-2009 Chevrolet Impala SS, TrailBlazer 2006-2010 Chevrolet Avalanche, Express, Silverado Tahoe 2006-2009 GMC Envoy 2006-2010 GMC Savana, Sierra, Yukon 2006-2008 Pontiac Grand Prix 2006-2009 Saab 9-7X Equipped with V8 Engine RPO LC9, LH6, LH8, LH9, L76, LS2, LS4, LFA, LZ1, L92, L94, L9H or L20, L96, LMF, LMG, LY2, LY5, LY6 Please Refer to GMVIS Attention: To properly correct this condition, you must follow both of the procedures to relocate the ECT sensor and the engine coolant heater cord. Supercede: This bulletin is being revised to add cast iron block engine RPOs and to update the Warranty Information coverage period. Please discard Corporate Bulletin Number 10-06-04-008 (Section 06 - Engine/Propulsion System). Condition Some customers may comment that the malfunction indicator lamp (MIL) illuminates after starting the vehicle when they were using the engine coolant heater in very cold ambient temperatures. This usually occurs in a range of -23 to -40°C (-10 to -40°F) or colder. The technician may observe on a scan tool DTC P0116 and/or P1400 set as Current or in History. Cause This condition may be caused by the engine control module (ECM) determining that the ignition OFF time requirement has been met at start-up and interpreting the temperature difference between the engine coolant temperature (ECT) sensor and the intake air temperature (IAT) sensor as being outside of a calibrated range. Correction Important DO NOT replace the ECM for this condition. Relocating the ECT Sensor 1. Turn ON the ignition with the engine OFF. 2. Perform the diagnostic system check - vehicle. Refer to Diagnostic System Check - Vehicle in SI. ‹› If DTC P0116 and/or P1400 are set and the customer WAS using the engine coolant heater, proceed to Step 3. ‹› If DTC P0116 and/or P1400 are set and the customer WAS NOT using the engine coolant heater, refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. 3. Turn OFF the ignition. Warning To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 1207 under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator are still hot. 4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle. Refer to Cooling System Draining and Filling in SI. 7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor. 10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J 38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle. 13. Disconnect the wiring harness connector from the ECT sensor (2). 14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT sensor in the hole of the cylinder head where the plug was removed. Tighten Tighten to 20 Nm (15 lb ft). 18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was removed Tighten Tighten to 20 Nm (15 lb ft). Important Leave enough wire attached to the ECT sensor harness connector in order to create manageable splices that are at least 40 mm (1.5 in) away from the other splice. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 1208 20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit. Cut off the ECT sensor harness connector and wiring. 21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured TO or WITHIN an existing protective conduit. Note This step is to set up and verify the length of wiring that is required before cutting. 22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the appropriate length. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. 26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit using tie straps. Important You MUST run the engine at the specified RPM and until it reaches normal operating temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool down in order to top off the coolant level as needed. 28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI. 29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan tool to clear any DTCs. Relocating the Engine Coolant Heater Cord Important For reference, the procedure and graphics that are shown are from a Chevrolet Silverado, but are similar for the other vehicles listed above. 1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit from the engine compartment in order to determine the required extension cord length. 3. Obtain an extension cord with the following features: - 120 volt - 14/3 gauge - 15A capacity - Three prong - Polarized plug and receptacle - Chemical resistant - Grounded terminals - Designed for use in a cold outdoor environment - Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight - Maximum length of 2.5-3 m (8-10 ft) 4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N 12345579 (in Canada, use P/N 10953481) or an equivalent. 6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 1209 7. Wrap electrical tape around the connection as shown. 8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to the engine coolant crossover pipe as shown. 9. Continue to route the extension cord to the exit location desired by the customer as shown. 10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the engine coolant heater cord to the vehicle that were released to provide length. Part Information The extension cord may be obtained at any of the following outlets: - Lowes* - Home Depot* - Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number: CWRSJTOW3C14-10 USA: Cords should bear the UL symbol. Canada: Cords should bear the ULc symbol or CSA approval. *We believe these sources and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from these firms or for any such items that may be available from other sources. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 1210 Warranty Information (excluding Saab Models) For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 1211 Coolant Temperature Sensor/Switch (For Computer): Diagrams Component Connector End Views Engine Coolant Temperature (ECT) Sensor (Diesel) Engine Coolant Temperature (ECT) Sensor (Gas) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 1212 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Engine Coolant Temperature Sensor Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams Crankshaft Position Sensor: Diagrams Component Connector End Views Crankshaft Position (CKP) Sensor (LU3) Crankshaft Position (CKP) Sensor (Gas except LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 1216 Crankshaft Position (CKP) Sensor (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 1217 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement Crankshaft Position Sensor Replacement Removal Procedure 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 2. Remove the right wheelhouse panel. Refer to Front Wheelhouse Liner Replacement - Right Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side)Front Wheelhouse Liner Replacement - Right Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side). 3. Disconnect the crankshaft position (CKP) sensor electrical connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 1220 4. Remove the CKP sensor bolt. 5. Remove the CKP sensor. 6. If necessary, remove the CKP sensor spacer bolts. 7. If necessary, remove the CKP sensor spacer. Installation Procedure 1. If necessary, lubricate a NEW CKP spacer O-ring with clean engine oil. 2. If necessary, install the NEW O-ring to the CKP sensor spacer. Note: The crankshaft position sensor spacers are machined with different timing positions. However, if the crankshaft position sensor spacer requires replacement, replace with a grade "C" spacer. 3. If necessary, install the CKP sensor spacer. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. If necessary, install the CKP sensor spacer bolts. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 1221 Tighten the bolts to 10 Nm (89 lb in). 5. Lubricate a NEW CKP sensor O-ring with clean engine oil. 6. Install the NEW O-ring to the CKP sensor. 7. Install the CKP sensor. 8. Install the CKP sensor bolt. Tighten the bolt to 10 Nm (89 lb in). 9. Connect the CKP sensor electrical connector. 10. Install the right wheelhouse panel. Refer to Front Wheelhouse Liner Replacement - Right Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side)Front Wheelhouse Liner Replacement - Right Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side). 11. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 1222 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Exciter Ring and Oil Pump Drive Gear Replacement Crankshaft Position Sensor Exciter Ring and Oil Pump Drive Gear Replacement Removal Procedure 1. Remove the engine front cover. Refer to Engine Front Cover Replacement (See: Engine, Cooling and Exhaust/Engine/Timing Components/Timing Cover/Service and Repair). 2. Remove the upper oil pan. Refer to Upper Oil Pan Replacement (See: Engine, Cooling and Exhaust/Engine/Engine Lubrication/Oil Pan/Service and Repair/Upper Oil Pan Replacement). Caution: Do not use an impact driver to remove or install the oil pump driven gear nut. Use of an impact driver may shear the oil pump drive gear pin in the crankshaft. 3. While holding the secondary oil pump shaft with a hex driver, remove the oil pump driven gear nut. 4. Remove the oil pump driven gear. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 1223 5. Remove the oil pump drive gear and crankshaft sensor reluctor. Do not damage the crankshaft reluctor teeth. Note: Do not remove the reluctor from the oil pump drive gear unless replacing the reluctor or the oil pump drive gear. The reluctor is timed to the gear and once removed the correct timing will be lost. 6. Remove the crankshaft reluctor to oil pump drive gear bolts. 7. Inspect the crankshaft reluctor for the damage, bent teeth, being bent or warped. 8. Inspect the oil pump drive gear for damaged or worn teeth. 9. Inspect the oil pump drive gear crankshaft pin for wear. 10. Inspect the groove of the crankshaft pin in the oil pump drive gear for wear. 11. Replace any parts that are damaged or worn. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 1224 Note: The crankshaft reluctor and the oil pump drive gear are timed at the factory. In order to re-establish proper timing, install knock pins in the oil pump drive gear if the crankshaft reluctor was removed from the oil pump drive gear. The knock pins are available through the parts department. 1. Install the knock pins in the oil pump drive gear to a height of 4.5-5.5 mm (0.177-0.217 in) 2. Install the crankshaft reluctor on the oil pump drive gear. Ensure the reluctor is aligned on the knock pins. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the crankshaft reluctor bolts and tighten to 8 Nm (71 lb in). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 1225 Note: Do not damage the teeth on the crankshaft reluctor. 4. Install the oil pump drive gear and reluctor to the crankshaft. 5. Install the oil pump driven gear. Caution: Do not use an impact driver to remove or install the oil pump driven gear nut. Use of an impact driver may shear the oil pump drive gear pin in the crankshaft. 6. While holding the secondary oil pump shaft with a hex driver, install the oil pump driven gear nut and tighten to 100 Nm (74 lb ft). 7. Install the upper oil pan. Refer to Upper Oil Pan Replacement (See: Engine, Cooling and Exhaust/Engine/Engine Lubrication/Oil Pan/Service and Repair/Upper Oil Pan Replacement). 8. Install the engine front cover. Refer to Engine Front Cover Replacement (See: Engine, Cooling and Exhaust/Engine/Timing Components/Timing Cover/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Technical Service Bulletins > Recalls for Exhaust Temperature Sensor: > 11054 > Apr > 11 > Recall - Replace Exhaust Gas Temperature Sensor Technical Service Bulletin # 11054 Date: 110412 Recall - Replace Exhaust Gas Temperature Sensor PRODUCT EMISSION Bulletin No.: 11054 Date: April 12, 2011 Subject: 11054 - Reduced Engine Performance and Emission Control - Replace Exhaust Gas Temperature Sensors Models: 2010 Chevrolet Express, Silverado HD 2010 GMC Savana, Sierra HD With 6.6L V8 Duramax Diesel Engine (LMM) 2007-2009 Chevrolet Express, Kodiak, Silverado HD 2007-2009 GMC Savana, Sierra HD, TopKick With 6.6L V8 Duramax Diesel Engine (LMM) Serviced with a Suspect EGT Sensor Condition General Motors has decided to conduct a Voluntary Emission Recall involving certain 2010 model year Chevrolet Express, Silverado HD; and GMC Savana, Sierra HD vehicles equipped with a 6.6L V8 Duramax diesel engine (LMM); and 2007-2009 model year Chevrolet Express, Kodiak, Silverado HD; and GMC Savana, Sierra HD, and TopKick vehicles equipped with a 6.6L V8 Duramax diesel engine (LMM) that may have been serviced with a suspect Exhaust Gas Temperature (EGT) sensor. On these vehicles, the circuit board welds on the EGT sensors in the exhaust system may not be to GM specification. If a weld fails, the Service Engine Soon light will illuminate in the instrument panel, the exhaust gas may not be filtered properly, and the engine power may be reduced. Correction Dealers are to replace both EGT sensors. Vehicles Involved Involved are certain 2010 model year Chevrolet Express, Silverado HD; and GMC Savana, Sierra HD vehicles equipped with a 6.6L V8 Duramax diesel engine (LMM); and 2007-2009 model year Chevrolet Express, Kodiak, Silverado HD; and GMC Savana, Sierra HD, and TopKick vehicles equipped with a 6.6L V8 Duramax diesel engine (LMM) that may have been serviced with a suspect EGT sensor. Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Required Field Actions section in the Global Warranty system. Not all vehicles may be involved. For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to US and Canadian dealers through the GM GlobalConnect Recall Reports, or sent directly to export dealers. Dealers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information Parts required to complete this recall are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Service Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Technical Service Bulletins > Recalls for Exhaust Temperature Sensor: > 11054 > Apr > 11 > Recall - Replace Exhaust Gas Temperature Sensor > Page 1234 1. Remove and replace position 1 and position 2 exhaust gas temperature sensors (1). Refer to Exhaust Temperature Sensor Replacement in SI. 2. CALIFORNIA, CONNECTICUT, MASSACHUSETTS, MAINE, OREGON, VERMONT, & WASHINGTON VEHICLES ONLY: Install a Recall Identification Label. Also, for California vehicles complete a "Proof of Correction" certificate upon recall completion. Recall Identification Label California/Connecticut/Massachusetts/Maine/Oregon/Vermont/Washington Vehicles Only) Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five-digit dealer code of the dealer performing the recall service. This information may be inserted with a ballpoint pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Recall Identification Label, be sure to pull the tab to allow adhesion of the clear protective covering. Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials by ordering on the web from DWD Store, www.gmdealerworld.com, and then click on the DWD Store link. Request Item Number S-1015 when ordering. Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a transaction using the table below. Customer Notification - For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter included with this bulletin). In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper maintenance. The vehicle may fail a state or local emission inspection test if the recall work is not completed. Customer Notification - For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the attached sample letter. In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Technical Service Bulletins > Recalls for Exhaust Temperature Sensor: > 11054 > Apr > 11 > Recall - Replace Exhaust Gas Temperature Sensor > Page 1235 maintenance. The vehicle may fail a state or local emission inspection test if the recall work is not completed. Dealer Recall Responsibility All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. ***THE FOLLOWING 2 PARAGRAPHS ARE NOT FOR CANADA OR EXPORT*** When a California emissions recall is completed by a GM dealer, the dealer must provide the vehicle owner a "Proof of Correction Certificate" which the owner may need to present to the California Department Of Motor Vehicles (DMV) when renewing their vehicle registration. Without this correction certificate, the owner may be unable to renew their vehicle registration. Additional Certificates can be obtained, at no charge, from Dealer Support Materials by ordering on the web from the DWD Store, www.gmdealerworld.com, and then click on the DWD Store link; request GM Item Number 1825 when ordering. Disclaimer Owner Letter Owner Letter Dear General Motors Customer: This notice is sent to inform you that General Motors is conducting a voluntary emission recall that includes your vehicle. Reason For This Recall: General Motors has decided to conduct a Voluntary Emission Recall involving certain 2010 model year Chevrolet Express, Silverado HD; and GMC Savana, Sierra HD vehicles equipped with a 6.6L V8 Duramax diesel engine; and 2007-2009 model year Chevrolet Express, Kodiak, Silverado HD; and GMC Savana, Sierra HD, and TopKick vehicles equipped with a 6.6L V8 Duramax diesel engine that may have been serviced with a suspect Exhaust Gas Temperature (EGT) sensor. The circuit board welds on the EGT sensors in the exhaust system may not be to GM specification. If a weld fails, the Service Engine Soon light will illuminate in the instrument panel, the exhaust gas may not be filtered properly, and the engine power may be reduced. What Will Be Done: Your GM dealer will replace both EGT sensors. This service will be performed for you at no charge. What You Should Do: Please contact your GM dealer as soon as possible to arrange a service date and to assure parts availability. Instructions for making this correction have been sent to your dealer. Please ask your dealer if you wish to know how much time will be needed to schedule, process, and repair your vehicle. If you have any questions or need any assistance, just contact your dealer or the appropriate Customer Assistance Center at the number listed below. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Technical Service Bulletins > Recalls for Exhaust Temperature Sensor: > 11054 > Apr > 11 > Recall - Replace Exhaust Gas Temperature Sensor > Page 1236 Emission Law Information: In order to ensure your full protection under the emission warranty made applicable to your vehicle by State and Federal Law, and your right to participate in future recalls, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could legally be determined to be lack of proper maintenance of your vehicle. Also, your vehicle may fail a state or local emission inspection if this recall is not accomplished. IMPORTANT MESSAGE FOR CALIFORNIA RESIDENTS The California Air Resources Board (CARB) requires vehicle emission recalls be completed prior to California registration renewal. Uncorrected emission recalls will result in the inability to renew your California vehicle registration. At the time of emission recall completion, your California dealer will issue a "Proof of Correction Certificate". Keep this certificate and, if required, present it to the Department of Motor Vehicles when renewing your California registration as proof of recall completion. We are sorry to cause you this inconvenience; however, we have taken this action in the interest of your continued satisfaction with our products. Jim Moloney General Director, Customer and Relationship Services 11054 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exhaust Temperature Sensor: > 11054 > Apr > 11 > Recall - Replace Exhaust Gas Temperature Sensor Technical Service Bulletin # 11054 Date: 110412 Recall - Replace Exhaust Gas Temperature Sensor PRODUCT EMISSION Bulletin No.: 11054 Date: April 12, 2011 Subject: 11054 - Reduced Engine Performance and Emission Control - Replace Exhaust Gas Temperature Sensors Models: 2010 Chevrolet Express, Silverado HD 2010 GMC Savana, Sierra HD With 6.6L V8 Duramax Diesel Engine (LMM) 2007-2009 Chevrolet Express, Kodiak, Silverado HD 2007-2009 GMC Savana, Sierra HD, TopKick With 6.6L V8 Duramax Diesel Engine (LMM) Serviced with a Suspect EGT Sensor Condition General Motors has decided to conduct a Voluntary Emission Recall involving certain 2010 model year Chevrolet Express, Silverado HD; and GMC Savana, Sierra HD vehicles equipped with a 6.6L V8 Duramax diesel engine (LMM); and 2007-2009 model year Chevrolet Express, Kodiak, Silverado HD; and GMC Savana, Sierra HD, and TopKick vehicles equipped with a 6.6L V8 Duramax diesel engine (LMM) that may have been serviced with a suspect Exhaust Gas Temperature (EGT) sensor. On these vehicles, the circuit board welds on the EGT sensors in the exhaust system may not be to GM specification. If a weld fails, the Service Engine Soon light will illuminate in the instrument panel, the exhaust gas may not be filtered properly, and the engine power may be reduced. Correction Dealers are to replace both EGT sensors. Vehicles Involved Involved are certain 2010 model year Chevrolet Express, Silverado HD; and GMC Savana, Sierra HD vehicles equipped with a 6.6L V8 Duramax diesel engine (LMM); and 2007-2009 model year Chevrolet Express, Kodiak, Silverado HD; and GMC Savana, Sierra HD, and TopKick vehicles equipped with a 6.6L V8 Duramax diesel engine (LMM) that may have been serviced with a suspect EGT sensor. Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Required Field Actions section in the Global Warranty system. Not all vehicles may be involved. For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to US and Canadian dealers through the GM GlobalConnect Recall Reports, or sent directly to export dealers. Dealers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information Parts required to complete this recall are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Service Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exhaust Temperature Sensor: > 11054 > Apr > 11 > Recall - Replace Exhaust Gas Temperature Sensor > Page 1242 1. Remove and replace position 1 and position 2 exhaust gas temperature sensors (1). Refer to Exhaust Temperature Sensor Replacement in SI. 2. CALIFORNIA, CONNECTICUT, MASSACHUSETTS, MAINE, OREGON, VERMONT, & WASHINGTON VEHICLES ONLY: Install a Recall Identification Label. Also, for California vehicles complete a "Proof of Correction" certificate upon recall completion. Recall Identification Label California/Connecticut/Massachusetts/Maine/Oregon/Vermont/Washington Vehicles Only) Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five-digit dealer code of the dealer performing the recall service. This information may be inserted with a ballpoint pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Recall Identification Label, be sure to pull the tab to allow adhesion of the clear protective covering. Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials by ordering on the web from DWD Store, www.gmdealerworld.com, and then click on the DWD Store link. Request Item Number S-1015 when ordering. Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a transaction using the table below. Customer Notification - For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter included with this bulletin). In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper maintenance. The vehicle may fail a state or local emission inspection test if the recall work is not completed. Customer Notification - For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the attached sample letter. In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exhaust Temperature Sensor: > 11054 > Apr > 11 > Recall - Replace Exhaust Gas Temperature Sensor > Page 1243 maintenance. The vehicle may fail a state or local emission inspection test if the recall work is not completed. Dealer Recall Responsibility All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. ***THE FOLLOWING 2 PARAGRAPHS ARE NOT FOR CANADA OR EXPORT*** When a California emissions recall is completed by a GM dealer, the dealer must provide the vehicle owner a "Proof of Correction Certificate" which the owner may need to present to the California Department Of Motor Vehicles (DMV) when renewing their vehicle registration. Without this correction certificate, the owner may be unable to renew their vehicle registration. Additional Certificates can be obtained, at no charge, from Dealer Support Materials by ordering on the web from the DWD Store, www.gmdealerworld.com, and then click on the DWD Store link; request GM Item Number 1825 when ordering. Disclaimer Owner Letter Owner Letter Dear General Motors Customer: This notice is sent to inform you that General Motors is conducting a voluntary emission recall that includes your vehicle. Reason For This Recall: General Motors has decided to conduct a Voluntary Emission Recall involving certain 2010 model year Chevrolet Express, Silverado HD; and GMC Savana, Sierra HD vehicles equipped with a 6.6L V8 Duramax diesel engine; and 2007-2009 model year Chevrolet Express, Kodiak, Silverado HD; and GMC Savana, Sierra HD, and TopKick vehicles equipped with a 6.6L V8 Duramax diesel engine that may have been serviced with a suspect Exhaust Gas Temperature (EGT) sensor. The circuit board welds on the EGT sensors in the exhaust system may not be to GM specification. If a weld fails, the Service Engine Soon light will illuminate in the instrument panel, the exhaust gas may not be filtered properly, and the engine power may be reduced. What Will Be Done: Your GM dealer will replace both EGT sensors. This service will be performed for you at no charge. What You Should Do: Please contact your GM dealer as soon as possible to arrange a service date and to assure parts availability. Instructions for making this correction have been sent to your dealer. Please ask your dealer if you wish to know how much time will be needed to schedule, process, and repair your vehicle. If you have any questions or need any assistance, just contact your dealer or the appropriate Customer Assistance Center at the number listed below. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exhaust Temperature Sensor: > 11054 > Apr > 11 > Recall - Replace Exhaust Gas Temperature Sensor > Page 1244 Emission Law Information: In order to ensure your full protection under the emission warranty made applicable to your vehicle by State and Federal Law, and your right to participate in future recalls, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could legally be determined to be lack of proper maintenance of your vehicle. Also, your vehicle may fail a state or local emission inspection if this recall is not accomplished. IMPORTANT MESSAGE FOR CALIFORNIA RESIDENTS The California Air Resources Board (CARB) requires vehicle emission recalls be completed prior to California registration renewal. Uncorrected emission recalls will result in the inability to renew your California vehicle registration. At the time of emission recall completion, your California dealer will issue a "Proof of Correction Certificate". Keep this certificate and, if required, present it to the Department of Motor Vehicles when renewing your California registration as proof of recall completion. We are sorry to cause you this inconvenience; however, we have taken this action in the interest of your continued satisfaction with our products. Jim Moloney General Director, Customer and Relationship Services 11054 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Exhaust Temperature Sensor Replacement - Position 1 Exhaust Temperature Sensor: Service and Repair Exhaust Temperature Sensor Replacement Position 1 Exhaust Temperature Sensor Replacement - Position 1 Removal Procedure Caution: The exhaust temperature sensor and exhaust pressure differential sensor line fittings may be difficult to remove when the engine exhaust system temperature is below 48°C (120°F). Excessive force may damage the threads in the exhaust manifold or exhaust pipe. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the exhaust temperature sensor electrical connector (1) from the chassis wiring harness electrical connector (2). 3. Remove the exhaust temperature sensor. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Exhaust Temperature Sensor Replacement - Position 1 > Page 1247 Note: A special anti-seize compound is used in the sensor or line fittings threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor or line fitting easier to remove. New, or service replacement sensors or line fittings already have the compound applied to the threads. If the sensor or line fittings are removed from an exhaust component and if for any reason the sensor or line fitting are reinstalled, the threads must have anti-seize compound applied before reinstallation. 1. If reinstalling the old temperature sensor or differential pressor sensor line fittings, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the exhaust temperature sensor. Tighten the sensor to 45 Nm (33 lb ft). 3. Connect the exhaust temperature sensor electrical connector (1) to the chassis wiring harness electrical connector (2). 4. Lower the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Exhaust Temperature Sensor Replacement - Position 1 > Page 1248 Exhaust Temperature Sensor: Service and Repair Exhaust Temperature Sensor Replacement Position 2 Exhaust Temperature Sensor Replacement - Position 2 Removal Procedure Caution: The exhaust temperature sensor and exhaust pressure differential sensor line fittings may be difficult to remove when the engine exhaust system temperature is below 48°C (120°F). Excessive force may damage the threads in the exhaust manifold or exhaust pipe. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the exhaust temperature sensor (3) electrical connector from the chassis wiring harness electrical connector (4). 3. Remove the exhaust temperature sensor. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Exhaust Temperature Sensor Replacement - Position 1 > Page 1249 Note: A special anti-seize compound is used in the sensor or line fittings threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor or line fitting easier to remove. New, or service replacement sensors or line fittings already have the compound applied to the threads. If the sensor or line fittings are removed from an exhaust component and if for any reason the sensor or line fitting are reinstalled, the threads must have anti-seize compound applied before reinstallation. 1. If reinstalling the old temperature sensor or differential pressor sensor line fittings, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the exhaust temperature sensor. Tighten the sensor to 45 Nm (33 lb ft). 3. Connect the exhaust temperature sensor (3) electrical connector to the chassis wiring harness electrical connector (4). 4. Lower the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Diagrams Fuel Level Sensor: Diagrams Component Connector End Views Fuel Level Sensor - Primary (Diesel) Fuel Level Sensor - Secondary (Diesel with 31 Series without NQZ) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Diagrams > Page 1253 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor (Cab/Chassis - Rear Tank) Fuel Level Sensor: Service and Repair Fuel Level Sensor (Cab/Chassis - Rear Tank) Fuel Level Sensor Replacement (Cab/Chassis - Rear Tank) Removal Procedure 1. Remove the sending unit. Refer to Fuel Sender Assembly Replacement (See: Sensors and Switches - Instrument Panel/Fuel Gauge Sender/Service and Repair). 2. Disconnect the fuel level sensor electrical connector (1). 3. Remove the sensor retaining clip (3). 4. Squeeze the locking tangs (2) and remove the fuel level sensor. Installation Procedure 1. Install the fuel level sensor. 2. Install the sensor retaining clip (3). 3. Connect the sensor electrical connector (1). 4. Install the sending unit. Refer to Fuel Sender Assembly Replacement (See: Sensors and Switches - Instrument Panel/Fuel Gauge Sender/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor (Cab/Chassis - Rear Tank) > Page 1256 Fuel Level Sensor: Service and Repair Fuel Level Sensor Replacement (35 Reg/Ext/Crew Cab With 34 gal Tank) Fuel Level Sensor Replacement (35 Reg/Ext/Crew Cab With 34 gal Tank) Removal Procedure 1. Remove the fuel tank module. Refer to Fuel Tank Fuel Pump Module Replacement (25 Ext/Crew Cab With 26 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15/25 Reg/Ext/Crw Cab With 34 Gal Tnk) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Ext/Crew Cab With 26 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Reg Cab With 26 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (35 Reg/Ext/Crew Cab With 34 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair). 2. Disconnect the fuel level sensor wiring pigtail electrical connector (1) from the module cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor (Cab/Chassis - Rear Tank) > Page 1257 3. Remove the fuel level sensor wiring pigtail from under the module clip (2). 4. Gently push in the fuel level sensor retainers (1), disengaging them from the module reservoir. 5. Slide the fuel level sensor up, in order to remove the sensor from the module slot. Installation Procedure 1. Position the fuel level sensor over the slot in the reservoir and slide the sensor down into the slot. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor (Cab/Chassis - Rear Tank) > Page 1258 2. Ensure that the fuel level sensor retainers (1) engage the module reservoir. 3. Install the fuel level sensor wiring pigtail under the module clip (2) behind the fuel pump wires. 4. Connect the fuel level sensor wiring pigtail electrical connector (1) to the module cover. 5. Install the fuel tank module. Refer to Fuel Tank Fuel Pump Module Replacement (25 Ext/Crew Cab With 26 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15/25 Reg/Ext/Crw Cab With 34 Gal Tnk) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Ext/Crew Cab With 26 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Reg Cab With 26 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (35 Reg/Ext/Crew Cab With 34 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor (Cab/Chassis - Rear Tank) > Page 1259 Fuel Level Sensor: Service and Repair Fuel Sender Assembly Replacement Fuel Sender Assembly Replacement Special Tools J 45722 Fuel Sender Lock Ring Wrench Removal Procedure 1. Remove the fuel tank. Refer to Fuel Tank Replacement (Pickup) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (Cab/Chassis Front) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (Cab/Chassis - Rear) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement). 2. Disconnect the fuel lines from the sending unit. Refer to Metal Collar Quick Connect Fitting Service (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Metal Collar Quick Connect Fitting Service) or Plastic Collar Quick Connect Fitting Service (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). Caution: Avoid damaging the lock ring. Use only J-45722 to prevent damage to the lock ring. Caution: Do Not handle the fuel sender assembly by the fuel pipes. The amount of leverage generated by handling the fuel pipes could damage the joints. Note: Do NOT use impact tools. Significant force will be required to release the lock ring. The use of a hammer and screwdriver is not recommended. Secure the fuel tank in order to prevent fuel tank rotation. 3. Use the J 45722 and a long breaker-bar in order to unlock the fuel sender lock ring. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor (Cab/Chassis - Rear Tank) > Page 1260 4. Remove the sending unit and seal. Discard the seal. 5. Clean the sending unit sealing surfaces. Note: Some lock rings were manufactured with "DO NOT REUSE" stamped into them. These lock rings may be reused if they are not damaged or warped. Note: Inspect the lock ring for damage due to improper removal or installation procedures. If damage is found, install a NEW lock ring. Note: Check the lock ring for flatness. 6. Place the lock ring on a flat surface. Measure the clearance between the lock ring and the flat surface using a feeler gauge at 7 points. 7. If warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement. 8. If warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor (Cab/Chassis - Rear Tank) > Page 1261 1. Install the sending unit and a NEW seal. Note: Always replace the fuel sender seal when installing the fuel sender assembly. Replace the lock ring if necessary. DO NOT apply any type of lubrication in the seal groove. Ensure the lock ring is installed with the correct side facing upward. A correctly installed lock ring will only turn in a clockwise direction. 2. Use the J 45722 in order to install the fuel sender lock ring. Turn the fuel sender lock ring in a clockwise direction. 3. Connect the fuel lines to the sending unit. Refer to Metal Collar Quick Connect Fitting Service (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Metal Collar Quick Connect Fitting Service) or Plastic Collar Quick Connect Fitting Service (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). 4. Install the fuel tank. Refer to Fuel Tank Replacement (Pickup) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (Cab/Chassis - Front) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (Cab/Chassis - Rear) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Diagrams Fuel Tank Pressure Sensor: Diagrams Component Connector End Views Fuel Tank Pressure (FTP) Sensor (Gas) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Diagrams > Page 1265 Fuel Tank Pressure Sensor: Service and Repair Fuel Tank Pressure Sensor Replacement (35 Reg/Ext/Crew Cab With 34 Gal Tank) Removal Procedure 1. Remove the fuel tank. Refer to Fuel Tank Replacement (35 Reg/Ext/Crew Cab With 34 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15 Ext/Crew Cab With 26 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15/25 Reg/Ext/Crw Cab With 34 Gal Tnk) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15 Rec Cab With 26 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (25 Ext/Crew Cab With 26 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement). 2. Remove the fuel tank pressure sensor by pulling straight up using a slight rocking motion. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Diagrams > Page 1266 1. Install the fuel tank pressure sensor. 2. Install the fuel tank pressure sensor cover. 3. Install the fuel tank. Refer to Fuel Tank Replacement (35 Reg/Ext/Crew Cab With 34 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15 Ext/Crew Cab With 26 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15/25 Reg/Ext/Crw Cab With 34 Gal Tnk) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15 Rec Cab With 26 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (25 Ext/Crew Cab With 26 Gal Tank) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > High Idle Switch > Component Information > Testing and Inspection High Idle Switch: Testing and Inspection High Idle Switch Diagnosis Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions )provide an overview of each diagnostic category. Diagnostic Fault Information Reference Information Schematic Reference Engine Controls Schematics (See: Powertrain Management/Diagrams/Electrical Diagrams) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning)for scan tool information Circuit/System Verification Ignition ON, observe the scan tool High Idle switch parameter while exercising the switch. The reading should change between ON/OFF. Circuit/System Testing 1. Ignition OFF, disconnect the harness connector at the high idle switch. 2. Test for less than 5 ohms between the ground circuit terminal A and ground. ‹› If greater than 5 ohms, test the ground circuit for an open/high resistance. 3. Ignition ON, verify the scan tool High Idle switch parameter is OFF. ‹› If not OFF, test the signal circuit for a short to ground. If the circuit tests normal, replace the ECM. 4. Install a 3A fused jumper wire between the signal circuit terminal C and ground. Verify the scan tool High Idle switch parameter is ON. ‹› If not ON, test the signal circuit for a short to voltage or an open/high resistance. If the circuit tests normal, replace the ECM. 5. If all circuits test normal, test or replace the high idle switch. Component Testing Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > High Idle Switch > Component Information > Testing and Inspection > Page 1270 1. Ignition OFF, disconnect the harness connector at the high idle switch. 2. Test for infinite resistance between the signal terminal C and the ground circuit terminal A with the switch in the open position. ‹› If less than infinite resistance, replace the high idle switch. 3. Test for less than 1 ohm between the signal terminal C and the ground terminal A with the switch in the closed position. ‹› If greater than 1 ohm, replace the high idle switch. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams Intake Air Temperature Sensor: Diagrams Component Connector End Views Intake Air Temperature (IAT) Sensor 2 (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Intake Air Temperature (IAT) Sensor 2 Replacement Intake Air Temperature Sensor: Service and Repair Intake Air Temperature (IAT) Sensor 2 Replacement Intake Air Temperature (IAT) Sensor 2 Replacement Removal Procedure 1. Remove the air intake pipe. Refer to Air Intake Pipe Replacement (See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair/Air Intake Pipe Replacement). 2. Disconnect the engine wiring harness electrical connector (1) from the intake air temperature (IAT) sensor pigtail. 3. Remove the IAT sensor (2) from the center intake manifold. Installation Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Intake Air Temperature (IAT) Sensor 2 Replacement > Page 1276 1. Install the IAT sensor (2) to the center intake manifold. Tighten the sensor to 25 Nm (18 lb ft). 2. Connect the engine wiring harness electrical connector (1) to the IAT sensor pigtail. 3. Install the air intake pipe. Refer to Air Intake Pipe Replacement (See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair/Air Intake Pipe Replacement). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Intake Air Temperature (IAT) Sensor 2 Replacement > Page 1277 Intake Air Temperature Sensor: Service and Repair Mass Airflow Sensor with Intake Air Temperature Sensor Replacement Mass Airflow Sensor with Intake Air Temperature Sensor Replacement Removal Procedure 1. Disconnect the engine wiring harness electrical connector (1) from the mass air flow (MAF)/intake air temperature (IAT) sensor. 2. Remove the MAF/IAT sensor TORX(R) screws. 3. Remove the MAF/IAT sensor. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Intake Air Temperature (IAT) Sensor 2 Replacement > Page 1278 1. Install the MAF/IAT sensor. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the MAF/IAT sensor TORX(R) screws. Tighten the screws to 8 Nm (70 lb in). 3. Connect the engine wiring harness electrical connector (1) to the MAF/IAT sensor. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams Knock Sensor: Diagrams Component Connector End Views Knock Sensor (KS) 1 (Gas) Knock Sensor (KS) 2 (Gas) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 1282 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams Manifold Pressure/Vacuum Sensor: Diagrams Component Connector End Views Manifold Absolute Pressure (MAP) Sensor (LU3) Manifold Absolute Pressure (MAP) Sensor (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Page 1286 Manifold Absolute Pressure (MAP) Sensor (Gas except LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Page 1287 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Page 1288 Manifold Pressure/Vacuum Sensor: Service and Repair Manifold Absolute Pressure Sensor Replacement Removal Procedure 1. Disconnect the engine wiring harness electrical connector (2) from the manifold absolute pressure (MAP) sensor. 2. Remove the MAP sensor bolt. 3. Remove the MAP sensor bracket and sensor. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Page 1289 1. Install the MAP sensor and bracket. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the MAP sensor bolt. Tighten the bolt to 10 Nm (89 lb in). 3. Connect the engine wiring harness electrical connector (2) to the MAP sensor. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams Oil Pressure Sensor: Diagrams Component Connector End Views Engine Oil Pressure (EOP) Sensor (Diesel) Engine Oil Pressure (EOP) Sensor (Gas except LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Page 1293 Engine Oil Pressure (EOP) Sensor (LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Page 1294 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Page 1295 Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement Special Tools DT-48827 Skip Shift Socket Removal Procedure 1. Remove the left wheelhouse inner panel. Refer to Front Wheelhouse Liner Replacement - Left Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Left Side)Front Wheelhouse Liner Replacement - Left Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Left Side). Note: Clean the area around the sensor. Do not allow debris to enter the engine. 2. Disconnect the oil pressure sensor electrical connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Page 1296 3. Using DT-48827 , remove the oil pressure sensor (1). Installation Procedure 1. Apply sealant to the threads of the oil pressure sensor. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Engine, Cooling and Exhaust/Engine/Specifications/Adhesives, Fluids, Lubricants, and Sealers) for the correct part number. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Using DT-48827 , install the oil pressure sensor (1). Tighten the sensor to 49 Nm (36 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Page 1297 3. Connect the oil pressure sensor electrical connector. 4. Install the left wheelhouse inner panel. Refer to Front Wheelhouse Liner Replacement - Left Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Left Side)Front Wheelhouse Liner Replacement - Left Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Left Side). 5. Check and add engine oil if necessary. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations Oxygen Sensor: Locations Harness Routing Views Heated Oxygen Sensor (HO2S) Jumper Harness Routing (LY6) 1 - X125 2 - Heated Oxygen Sensor (HO2S) Bank 2 Sensor 2 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 1301 Oxygen Sensor: Diagrams Component Connector End Views Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 (LU3) Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 (Gas except LU3 and except ZW9) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 1302 Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 (LY6 or L96 with ZW9) Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 2 (LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 1303 Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 2 (Gas except LU3) Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 (LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 1304 Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 (Gas except LU3 and except ZW9) Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 (LY6 or L96 with ZW9) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 1305 Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 2 (LU3) Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 2 (Gas except LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 1306 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service Precautions > Excessive Force and Oxygen Sensor Caution Oxygen Sensor: Service Precautions Excessive Force and Oxygen Sensor Caution Excessive Force and Oxygen Sensor Caution Caution: The oxygen sensor may be difficult to remove when the engine temperature is below 48°C (120°F). Excessive force may damage threads in the exhaust manifold or the exhaust pipe. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service Precautions > Excessive Force and Oxygen Sensor Caution > Page 1309 Oxygen Sensor: Service Precautions Heated Oxygen and Oxygen Sensor Caution Heated Oxygen and Oxygen Sensor Caution Caution: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen sensor (O2S). Removing the pigtail or the connector will affect sensor operation. Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical connector and the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of any type. Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring, connector, or terminal is damaged. This external clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air reference and degraded sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. * Do not damage the sensor pigtail and harness wires in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp bends or kinks could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire, where applicable. Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will cause poor engine performance. * Ensure that the peripheral seal remains intact on the vehicle harness connector in order to prevent damage due to water intrusion. The engine harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service Precautions > Excessive Force and Oxygen Sensor Caution > Page 1310 Oxygen Sensor: Service Precautions Heated Oxygen Sensor Resistance Learn Reset Caution Heated Oxygen Sensor Resistance Learn Reset Caution Caution: When replacing the HO2S perform the following: * A code clear with a scan tool, regardless of whether or not a DTC is set * HO2S heater resistance learn reset with a scan tool, where available Perform the above in order to reset the HO2S resistance learned value and avoid possible HO2S failure. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service Precautions > Excessive Force and Oxygen Sensor Caution > Page 1311 Oxygen Sensor: Service Precautions Silicon Contamination of Heated Oxygen Sensors Caution Silicon Contamination of Heated Oxygen Sensors Caution Caution: Contamination of the oxygen sensor can result from the use of an inappropriate RTV sealant (not oxygen sensor safe) or excessive engine coolant or oil consumption. Remove the HO2S and visually inspect the portion of the sensor exposed to the exhaust stream in order to check for contamination. If contaminated, the portion of the sensor exposed to the exhaust stream will have a white powdery coating. Silicon contamination causes a high but false HO2S signal voltage (rich exhaust indication). The control module will then reduce the amount of fuel delivered to the engine, causing a severe driveability problem. Eliminate the source of contamination before replacing the oxygen sensor. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Diagrams Pressure Feedback Exhaust Sensor: Diagrams Component Connector End Views Exhaust Pressure Differential Sensor (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams Transmission Position Switch/Sensor: Diagrams Component Connector End Views Park/Neutral Position (PNP) Switch (M30) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 1318 Transmission Position Switch/Sensor: Service and Repair Manual Shift Shaft, Detent Lever, and Position Switch Assembly Replacement Removal Procedure 1. Remove the control valve assembly from the transmission. Refer to Control Valve Body Replacement (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Valve Body/Service and Repair). Note: The detent lever/IMS retaining bolt contains patch lock material on the threads. Do not reuse the retaining bolt. 2. Remove the detent lever/IMS retaining bolt (1) using a T27 TORX(R) bit and discard the retaining bolt. Caution: DO NOT mar the transmission case surface around the spherical pin when removing or installing the spherical pin. An unmarred surface is required to maintain the seal between the control valve assembly and the transmission case. Caution: DO NOT twist the spherical pin when removing the pin from the transmission case. Damage to the transmission case can occur. 3. Place a protective plate on the transmission case surface around the spherical pin (3). Remove the spherical pin (3) from the transmission case. 4. Slide the manual shift shaft (5) through the detent lever/IMS assembly (4) and through the manual shift shaft seal. 5. Rotate the detent lever/IMS assembly to disengage the park pawl apply assembly (2). Remove the detent lever/IMS assembly (4). Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 1319 1. Place the new detent lever/IMS assembly (4) in position in the transmission case. Rotate the detent lever/IMS assembly to engage the park pawl apply assembly (2). Reinstall the manual shift shaft (5) through the manual shift shaft seal and through the detent lever/IMS assembly (4). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Push the manual shift shaft (5) into the final position in the transmission case. 3. Install the spherical pin (3) into the transmission case that retains the manual shift shaft. 4. Install the detent lever/IMS retaining bolt (1) using a T27 TORX(R) bit. Tighten the bolt (1) to 10 Nm (92 lb in). 5. Install the control valve assembly. Refer to Control Valve Body Replacement (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Valve Body/Service and Repair). Note: The FastLearn, adapt, procedure must be performed. This can be done in 1 step using a scan tool. If this procedure is not done, the TCM adaptive values will be at the settings that it learned for the old components and will be in slow adaptive mode. Under these conditions, it will take an unacceptably long time for the adaptive values to converge to levels suitable for the new transmission. 6. Perform the FastLearn procedure. Refer to FastLearn Procedure (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Testing and Inspection/Programming and Relearning). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Turbocharger Vane Position Sensor > Component Information > Technical Service Bulletins > Engine - Info on Duramax Turbo Vane Position Sensor Turbocharger Vane Position Sensor: Technical Service Bulletins Engine - Info on Duramax Turbo Vane Position Sensor INFORMATION Bulletin No.: 10-06-04-014 Date: November 03, 2010 Subject: Information on Duramax Turbo Vane Position Sensor Models: 2010-2011 Chevrolet Express Vans, Silverado 2010-2011 GMC Savana Vans, Sierra Equipped with Duramax(TM) Diesel Engine (RPOs LGH, LML) An improvement has been implemented to the turbocharger vane position sensor. Some turbochargers existing in inventory have the old style vane position sensor. If turbochargers, GM P/N 12635325 or 12635167 are being replaced, the original turbo vane sensor should be removed and replaced with the new style sensor, GM P/N 12643471. Turbochargers that are supersessions to these part numbers will have the new style vane position sensor and no action is necessary. Parts Information Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Turbocharger Vane Position Sensor > Component Information > Technical Service Bulletins > Page 1324 Turbocharger Vane Position Sensor: Diagrams Component Connector End Views Turbocharger Vane Position Sensor (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > A/T - Shifting/Poor Performance Vehicle Speed Sensor: Technical Service Bulletins A/T - Shifting/Poor Performance INFORMATION Bulletin No.: 01-03-10-010G Date: July 22, 2009 Subject: Inspection of Tire and Wheel Size Prior to Diagnosis of Transmission Shifts, Poor Performance, Speedometer, Cruise Control Concerns Models: 2001-2007 Chevrolet Silverado Pickup (Classic) Models Equipped with Allison(R) Automatic Transmission Only 2001-2007 GMC Sierra Pickup (Classic) Models Equipped with Allison(R) Automatic Transmission Only 2007-2010 Chevrolet Silverado Pickup HD Models 2007-2010 GMC Sierra Pickup HD Models Supercede: This bulletin is being revised to add the 2008-2010 model years, update the tire size information and reference the vehicle tire information label locations. Please discard Corporate Bulletin Number 01-03-10-010F (Section 03 - Suspension). GM has developed and matched specific tires for your vehicle. The original equipment tires and their respective size installed on the vehicle when it was new, were designed to meet General Motors Tire Performance Criteria Specification (TPC Spec) system rating. GM's exclusive TPC Spec system considers over a dozen critical specifications that impact the overall performance of the vehicle. A truck that has different tires and wheels from the original equipment designed for that vehicle will have engine power/performance concerns, transmission shift concerns, speedometer registered speed concerns, cruise control concerns and increased steering effort, especially during parking lot maneuvers at slow speeds. The engine control module (ECM) and transmission control module (TCM) use engine speed (RPM) and vehicle speed sensor (VSS) inputs as operational parameters for engine torque, transmission shifting, cruise control operation and speedometer indicated vehicle speed. Calibrations for different tire/wheel combinations are not available. Therefore, changing of tire and/or wheel size should not be undertaken by dealerships or truck owners. Proper diagnosis of engine, transmission, speedometer and cruise control concerns MUST begin with an inspection of tire/wheel size. Important A vehicle specific Tire and Loading Information label is attached to the center pillar (B-pillar) of the vehicle. With the driver's door open, you will find the label attached below the door lock post (striker). The label shows the size of the original equipment tires and the recommended cold tire inflation pressures.A vehicle specific Certification/Tire label is found on the rear edge of the driver's door. The label shows the size of the original equipment tires and the recommended cold tire inflation pressures. 2001-2007 Pickups (Classic) Equipped with Allison(R) Automatic Transmission Only Inspect the vehicle for the proper tire size as indicated in the following information. - The 2500 series trucks have LT245/75R16E tires as standard equipment. - The 3500 series trucks with single rear wheels have LT265/75R16E tires as standard equipment. - The 3500 series trucks with dual rear wheels have LT215/85R16D tires as standard equipment. 2007 Pickups HD Models (New Design Pickups) Inspect the vehicle for the proper tire size as indicated in the following information. - The 2500 series trucks have LT245/75R16E tires as standard equipment. - The 3500 series trucks with single rear wheels have LT265/75R16E tires as standard equipment. - The 3500 series trucks with dual rear wheels have LT215/85R16E tires as standard equipment. 2008-2010 Pickups HD Models (New Design Pickups) Inspect the vehicle for the proper tire size as indicated in the following information. - The 2500 series trucks have LT245/75R16E tires as standard equipment. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > A/T - Shifting/Poor Performance > Page 1329 - The 3500 series trucks with single rear wheels have LT265/75R16E tires as standard equipment. - The 3500 series trucks with dual rear wheels have LT225/75R17E tires as standard equipment. If a truck is found to have other than the above listed tire sizes, no further diagnosis should be undertaken until the original size tires and wheels are reinstalled on the truck. Warranty Information Reinstalling the proper wheels and tires on the vehicle, prior to performing any type of diagnosis of the truck, would be considered truck owner responsibility and not a warranty repair. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Page 1330 Vehicle Speed Sensor: Locations Harness Routing Views Engine Chassis Harness Routing - Rear (Diesel) 1 - X300 2 - G300 3 - Automatic Transmission Turbine Speed Sensor (MW7) 4 - Automatic Transmission (MW7) 5 - Vehicle Speed Sensor (VSS) (MW7) 6 - X124 (PTO) 7 - Power Take Off (PTO) Module (PTO) 8 - X175 (MW7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Page 1331 Vehicle Speed Sensor: Diagrams Component Connector End Views Vehicle Speed Sensor (VSS) (M30, TZ0, MYC and MW7or M99 with NQG or NQF) Vehicle Speed Sensor (VSS) (MW7 except NQG or NQF) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Page 1332 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Tremec 5-Speed (M96) - Manual Transmission Vehicle Speed Sensor: Service and Repair Tremec 5-Speed (M96) - Manual Transmission Vehicle Speed Sensor Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Tremec 5-Speed (M96) - Manual Transmission > Page 1335 Vehicle Speed Sensor: Service and Repair Tremec 5-Speed (TZ0) - Manual Transmission Vehicle Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the vehicle speed sensor (VSS) electrical connector (1). 3. Remove the VSS and O-ring seal. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Tremec 5-Speed (M96) - Manual Transmission > Page 1336 1. Coat a NEW O-ring seal with a thin film of Synchro-mesh transmission fluid GM P/N 12345349 (Canadian P/N 10953465), or equivalent. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the VSS and O-ring seal. Tighten the VSS to 16 Nm (12 lb ft). 3. Connect the VSS electrical connector (1). 4. Lower the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Tremec 5-Speed (M96) - Manual Transmission > Page 1337 Vehicle Speed Sensor: Service and Repair MP 1222/1225/1226-NQG - Transfer Case Vehicle Speed Sensor Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Tremec 5-Speed (M96) - Manual Transmission > Page 1338 Vehicle Speed Sensor: Service and Repair MP 1625/1626-NQF - Transfer Case Vehicle Speed Sensor Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Tremec 5-Speed (M96) - Manual Transmission > Page 1339 Vehicle Speed Sensor: Service and Repair MP 3023/3024-NQH - Transfer Case Vehicle Speed Sensor Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Technical Service Bulletins > Recalls for Exhaust Temperature Sensor: > 11054 > Apr > 11 > Recall - Replace Exhaust Gas Temperature Sensor Technical Service Bulletin # 11054 Date: 110412 Recall - Replace Exhaust Gas Temperature Sensor PRODUCT EMISSION Bulletin No.: 11054 Date: April 12, 2011 Subject: 11054 - Reduced Engine Performance and Emission Control - Replace Exhaust Gas Temperature Sensors Models: 2010 Chevrolet Express, Silverado HD 2010 GMC Savana, Sierra HD With 6.6L V8 Duramax Diesel Engine (LMM) 2007-2009 Chevrolet Express, Kodiak, Silverado HD 2007-2009 GMC Savana, Sierra HD, TopKick With 6.6L V8 Duramax Diesel Engine (LMM) Serviced with a Suspect EGT Sensor Condition General Motors has decided to conduct a Voluntary Emission Recall involving certain 2010 model year Chevrolet Express, Silverado HD; and GMC Savana, Sierra HD vehicles equipped with a 6.6L V8 Duramax diesel engine (LMM); and 2007-2009 model year Chevrolet Express, Kodiak, Silverado HD; and GMC Savana, Sierra HD, and TopKick vehicles equipped with a 6.6L V8 Duramax diesel engine (LMM) that may have been serviced with a suspect Exhaust Gas Temperature (EGT) sensor. On these vehicles, the circuit board welds on the EGT sensors in the exhaust system may not be to GM specification. If a weld fails, the Service Engine Soon light will illuminate in the instrument panel, the exhaust gas may not be filtered properly, and the engine power may be reduced. Correction Dealers are to replace both EGT sensors. Vehicles Involved Involved are certain 2010 model year Chevrolet Express, Silverado HD; and GMC Savana, Sierra HD vehicles equipped with a 6.6L V8 Duramax diesel engine (LMM); and 2007-2009 model year Chevrolet Express, Kodiak, Silverado HD; and GMC Savana, Sierra HD, and TopKick vehicles equipped with a 6.6L V8 Duramax diesel engine (LMM) that may have been serviced with a suspect EGT sensor. Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Required Field Actions section in the Global Warranty system. Not all vehicles may be involved. For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to US and Canadian dealers through the GM GlobalConnect Recall Reports, or sent directly to export dealers. Dealers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information Parts required to complete this recall are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Service Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Technical Service Bulletins > Recalls for Exhaust Temperature Sensor: > 11054 > Apr > 11 > Recall - Replace Exhaust Gas Temperature Sensor > Page 1349 1. Remove and replace position 1 and position 2 exhaust gas temperature sensors (1). Refer to Exhaust Temperature Sensor Replacement in SI. 2. CALIFORNIA, CONNECTICUT, MASSACHUSETTS, MAINE, OREGON, VERMONT, & WASHINGTON VEHICLES ONLY: Install a Recall Identification Label. Also, for California vehicles complete a "Proof of Correction" certificate upon recall completion. Recall Identification Label California/Connecticut/Massachusetts/Maine/Oregon/Vermont/Washington Vehicles Only) Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five-digit dealer code of the dealer performing the recall service. This information may be inserted with a ballpoint pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Recall Identification Label, be sure to pull the tab to allow adhesion of the clear protective covering. Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials by ordering on the web from DWD Store, www.gmdealerworld.com, and then click on the DWD Store link. Request Item Number S-1015 when ordering. Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a transaction using the table below. Customer Notification - For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter included with this bulletin). In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper maintenance. The vehicle may fail a state or local emission inspection test if the recall work is not completed. Customer Notification - For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the attached sample letter. In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Technical Service Bulletins > Recalls for Exhaust Temperature Sensor: > 11054 > Apr > 11 > Recall - Replace Exhaust Gas Temperature Sensor > Page 1350 maintenance. The vehicle may fail a state or local emission inspection test if the recall work is not completed. Dealer Recall Responsibility All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. ***THE FOLLOWING 2 PARAGRAPHS ARE NOT FOR CANADA OR EXPORT*** When a California emissions recall is completed by a GM dealer, the dealer must provide the vehicle owner a "Proof of Correction Certificate" which the owner may need to present to the California Department Of Motor Vehicles (DMV) when renewing their vehicle registration. Without this correction certificate, the owner may be unable to renew their vehicle registration. Additional Certificates can be obtained, at no charge, from Dealer Support Materials by ordering on the web from the DWD Store, www.gmdealerworld.com, and then click on the DWD Store link; request GM Item Number 1825 when ordering. Disclaimer Owner Letter Owner Letter Dear General Motors Customer: This notice is sent to inform you that General Motors is conducting a voluntary emission recall that includes your vehicle. Reason For This Recall: General Motors has decided to conduct a Voluntary Emission Recall involving certain 2010 model year Chevrolet Express, Silverado HD; and GMC Savana, Sierra HD vehicles equipped with a 6.6L V8 Duramax diesel engine; and 2007-2009 model year Chevrolet Express, Kodiak, Silverado HD; and GMC Savana, Sierra HD, and TopKick vehicles equipped with a 6.6L V8 Duramax diesel engine that may have been serviced with a suspect Exhaust Gas Temperature (EGT) sensor. The circuit board welds on the EGT sensors in the exhaust system may not be to GM specification. If a weld fails, the Service Engine Soon light will illuminate in the instrument panel, the exhaust gas may not be filtered properly, and the engine power may be reduced. What Will Be Done: Your GM dealer will replace both EGT sensors. This service will be performed for you at no charge. What You Should Do: Please contact your GM dealer as soon as possible to arrange a service date and to assure parts availability. Instructions for making this correction have been sent to your dealer. Please ask your dealer if you wish to know how much time will be needed to schedule, process, and repair your vehicle. If you have any questions or need any assistance, just contact your dealer or the appropriate Customer Assistance Center at the number listed below. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Technical Service Bulletins > Recalls for Exhaust Temperature Sensor: > 11054 > Apr > 11 > Recall - Replace Exhaust Gas Temperature Sensor > Page 1351 Emission Law Information: In order to ensure your full protection under the emission warranty made applicable to your vehicle by State and Federal Law, and your right to participate in future recalls, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could legally be determined to be lack of proper maintenance of your vehicle. Also, your vehicle may fail a state or local emission inspection if this recall is not accomplished. IMPORTANT MESSAGE FOR CALIFORNIA RESIDENTS The California Air Resources Board (CARB) requires vehicle emission recalls be completed prior to California registration renewal. Uncorrected emission recalls will result in the inability to renew your California vehicle registration. At the time of emission recall completion, your California dealer will issue a "Proof of Correction Certificate". Keep this certificate and, if required, present it to the Department of Motor Vehicles when renewing your California registration as proof of recall completion. We are sorry to cause you this inconvenience; however, we have taken this action in the interest of your continued satisfaction with our products. Jim Moloney General Director, Customer and Relationship Services 11054 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exhaust Temperature Sensor: > 11054 > Apr > 11 > Recall - Replace Exhaust Gas Temperature Sensor Technical Service Bulletin # 11054 Date: 110412 Recall - Replace Exhaust Gas Temperature Sensor PRODUCT EMISSION Bulletin No.: 11054 Date: April 12, 2011 Subject: 11054 - Reduced Engine Performance and Emission Control - Replace Exhaust Gas Temperature Sensors Models: 2010 Chevrolet Express, Silverado HD 2010 GMC Savana, Sierra HD With 6.6L V8 Duramax Diesel Engine (LMM) 2007-2009 Chevrolet Express, Kodiak, Silverado HD 2007-2009 GMC Savana, Sierra HD, TopKick With 6.6L V8 Duramax Diesel Engine (LMM) Serviced with a Suspect EGT Sensor Condition General Motors has decided to conduct a Voluntary Emission Recall involving certain 2010 model year Chevrolet Express, Silverado HD; and GMC Savana, Sierra HD vehicles equipped with a 6.6L V8 Duramax diesel engine (LMM); and 2007-2009 model year Chevrolet Express, Kodiak, Silverado HD; and GMC Savana, Sierra HD, and TopKick vehicles equipped with a 6.6L V8 Duramax diesel engine (LMM) that may have been serviced with a suspect Exhaust Gas Temperature (EGT) sensor. On these vehicles, the circuit board welds on the EGT sensors in the exhaust system may not be to GM specification. If a weld fails, the Service Engine Soon light will illuminate in the instrument panel, the exhaust gas may not be filtered properly, and the engine power may be reduced. Correction Dealers are to replace both EGT sensors. Vehicles Involved Involved are certain 2010 model year Chevrolet Express, Silverado HD; and GMC Savana, Sierra HD vehicles equipped with a 6.6L V8 Duramax diesel engine (LMM); and 2007-2009 model year Chevrolet Express, Kodiak, Silverado HD; and GMC Savana, Sierra HD, and TopKick vehicles equipped with a 6.6L V8 Duramax diesel engine (LMM) that may have been serviced with a suspect EGT sensor. Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Required Field Actions section in the Global Warranty system. Not all vehicles may be involved. For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to US and Canadian dealers through the GM GlobalConnect Recall Reports, or sent directly to export dealers. Dealers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information Parts required to complete this recall are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Service Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exhaust Temperature Sensor: > 11054 > Apr > 11 > Recall - Replace Exhaust Gas Temperature Sensor > Page 1357 1. Remove and replace position 1 and position 2 exhaust gas temperature sensors (1). Refer to Exhaust Temperature Sensor Replacement in SI. 2. CALIFORNIA, CONNECTICUT, MASSACHUSETTS, MAINE, OREGON, VERMONT, & WASHINGTON VEHICLES ONLY: Install a Recall Identification Label. Also, for California vehicles complete a "Proof of Correction" certificate upon recall completion. Recall Identification Label California/Connecticut/Massachusetts/Maine/Oregon/Vermont/Washington Vehicles Only) Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five-digit dealer code of the dealer performing the recall service. This information may be inserted with a ballpoint pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Recall Identification Label, be sure to pull the tab to allow adhesion of the clear protective covering. Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials by ordering on the web from DWD Store, www.gmdealerworld.com, and then click on the DWD Store link. Request Item Number S-1015 when ordering. Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a transaction using the table below. Customer Notification - For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter included with this bulletin). In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper maintenance. The vehicle may fail a state or local emission inspection test if the recall work is not completed. Customer Notification - For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the attached sample letter. In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exhaust Temperature Sensor: > 11054 > Apr > 11 > Recall - Replace Exhaust Gas Temperature Sensor > Page 1358 maintenance. The vehicle may fail a state or local emission inspection test if the recall work is not completed. Dealer Recall Responsibility All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. ***THE FOLLOWING 2 PARAGRAPHS ARE NOT FOR CANADA OR EXPORT*** When a California emissions recall is completed by a GM dealer, the dealer must provide the vehicle owner a "Proof of Correction Certificate" which the owner may need to present to the California Department Of Motor Vehicles (DMV) when renewing their vehicle registration. Without this correction certificate, the owner may be unable to renew their vehicle registration. Additional Certificates can be obtained, at no charge, from Dealer Support Materials by ordering on the web from the DWD Store, www.gmdealerworld.com, and then click on the DWD Store link; request GM Item Number 1825 when ordering. Disclaimer Owner Letter Owner Letter Dear General Motors Customer: This notice is sent to inform you that General Motors is conducting a voluntary emission recall that includes your vehicle. Reason For This Recall: General Motors has decided to conduct a Voluntary Emission Recall involving certain 2010 model year Chevrolet Express, Silverado HD; and GMC Savana, Sierra HD vehicles equipped with a 6.6L V8 Duramax diesel engine; and 2007-2009 model year Chevrolet Express, Kodiak, Silverado HD; and GMC Savana, Sierra HD, and TopKick vehicles equipped with a 6.6L V8 Duramax diesel engine that may have been serviced with a suspect Exhaust Gas Temperature (EGT) sensor. The circuit board welds on the EGT sensors in the exhaust system may not be to GM specification. If a weld fails, the Service Engine Soon light will illuminate in the instrument panel, the exhaust gas may not be filtered properly, and the engine power may be reduced. What Will Be Done: Your GM dealer will replace both EGT sensors. This service will be performed for you at no charge. What You Should Do: Please contact your GM dealer as soon as possible to arrange a service date and to assure parts availability. Instructions for making this correction have been sent to your dealer. Please ask your dealer if you wish to know how much time will be needed to schedule, process, and repair your vehicle. If you have any questions or need any assistance, just contact your dealer or the appropriate Customer Assistance Center at the number listed below. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exhaust Temperature Sensor: > 11054 > Apr > 11 > Recall - Replace Exhaust Gas Temperature Sensor > Page 1359 Emission Law Information: In order to ensure your full protection under the emission warranty made applicable to your vehicle by State and Federal Law, and your right to participate in future recalls, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could legally be determined to be lack of proper maintenance of your vehicle. Also, your vehicle may fail a state or local emission inspection if this recall is not accomplished. IMPORTANT MESSAGE FOR CALIFORNIA RESIDENTS The California Air Resources Board (CARB) requires vehicle emission recalls be completed prior to California registration renewal. Uncorrected emission recalls will result in the inability to renew your California vehicle registration. At the time of emission recall completion, your California dealer will issue a "Proof of Correction Certificate". Keep this certificate and, if required, present it to the Department of Motor Vehicles when renewing your California registration as proof of recall completion. We are sorry to cause you this inconvenience; however, we have taken this action in the interest of your continued satisfaction with our products. Jim Moloney General Director, Customer and Relationship Services 11054 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Exhaust Temperature Sensor Replacement - Position 1 Exhaust Temperature Sensor: Service and Repair Exhaust Temperature Sensor Replacement Position 1 Exhaust Temperature Sensor Replacement - Position 1 Removal Procedure Caution: The exhaust temperature sensor and exhaust pressure differential sensor line fittings may be difficult to remove when the engine exhaust system temperature is below 48°C (120°F). Excessive force may damage the threads in the exhaust manifold or exhaust pipe. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the exhaust temperature sensor electrical connector (1) from the chassis wiring harness electrical connector (2). 3. Remove the exhaust temperature sensor. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Exhaust Temperature Sensor Replacement - Position 1 > Page 1362 Note: A special anti-seize compound is used in the sensor or line fittings threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor or line fitting easier to remove. New, or service replacement sensors or line fittings already have the compound applied to the threads. If the sensor or line fittings are removed from an exhaust component and if for any reason the sensor or line fitting are reinstalled, the threads must have anti-seize compound applied before reinstallation. 1. If reinstalling the old temperature sensor or differential pressor sensor line fittings, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the exhaust temperature sensor. Tighten the sensor to 45 Nm (33 lb ft). 3. Connect the exhaust temperature sensor electrical connector (1) to the chassis wiring harness electrical connector (2). 4. Lower the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Exhaust Temperature Sensor Replacement - Position 1 > Page 1363 Exhaust Temperature Sensor: Service and Repair Exhaust Temperature Sensor Replacement Position 2 Exhaust Temperature Sensor Replacement - Position 2 Removal Procedure Caution: The exhaust temperature sensor and exhaust pressure differential sensor line fittings may be difficult to remove when the engine exhaust system temperature is below 48°C (120°F). Excessive force may damage the threads in the exhaust manifold or exhaust pipe. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the exhaust temperature sensor (3) electrical connector from the chassis wiring harness electrical connector (4). 3. Remove the exhaust temperature sensor. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Exhaust Temperature Sensor Replacement - Position 1 > Page 1364 Note: A special anti-seize compound is used in the sensor or line fittings threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor or line fitting easier to remove. New, or service replacement sensors or line fittings already have the compound applied to the threads. If the sensor or line fittings are removed from an exhaust component and if for any reason the sensor or line fitting are reinstalled, the threads must have anti-seize compound applied before reinstallation. 1. If reinstalling the old temperature sensor or differential pressor sensor line fittings, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the exhaust temperature sensor. Tighten the sensor to 45 Nm (33 lb ft). 3. Connect the exhaust temperature sensor (3) electrical connector to the chassis wiring harness electrical connector (4). 4. Lower the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Temperature Sensor > Component Information > Diagrams EGR Temperature Sensor: Diagrams Component Connector End Views Exhaust Gas Recirculation (EGR) Temperature Sensor 1 (Diesel) Exhaust Gas Recirculation (EGR) Temperature Sensor 2 (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Temperature Sensor > Component Information > Diagrams > Page 1368 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Temperature Sensor > Component Information > Service and Repair > Exhaust Gas Recirculation Valve Temperature Sensor Replacement - Position 1 EGR Temperature Sensor: Service and Repair Exhaust Gas Recirculation Valve Temperature Sensor Replacement - Position 1 Exhaust Gas Recirculation Valve Temperature Sensor Replacement - Position 1 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Temperature Sensor > Component Information > Service and Repair > Exhaust Gas Recirculation Valve Temperature Sensor Replacement - Position 1 > Page 1371 EGR Temperature Sensor: Service and Repair Exhaust Gas Recirculation Valve Temperature Sensor Replacement - Position 2 Exhaust Gas Recirculation Valve Temperature Sensor Replacement - Position 2 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Exhaust Pressure Differential Sensor Replacement (Pickup) Exhaust Pressure Differential Sensor: Service and Repair Exhaust Pressure Differential Sensor Replacement (Pickup) Exhaust Pressure Differential Sensor Replacement (Pickup) Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the chassis wiring harness electrical connector (1) from the exhaust differential pressure sensor (2). 3. Reposition the exhaust differential pressure sensor pipe assembly hose clamps (3). 4. Remove the exhaust differential pressure sensor pipe assembly hoses from the sensor. 5. Remove the exhaust differential pressure sensor bracket bolts (1). 6. Remove the exhaust differential pressure sensor (2). Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Exhaust Pressure Differential Sensor Replacement (Pickup) > Page 1376 1. Position the exhaust differential pressure sensor (2) to the bracket. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the exhaust differential pressure sensor bracket bolts (1). Tighten the bolts to 9 Nm (80 lb in). 3. Install the exhaust differential pressure sensor pipe assembly hoses to the sensor. 4. Position the exhaust differential pressure sensor pipe assembly hose clamps (3). 5. Connect the chassis wiring harness electrical connector (1) to the exhaust differential pressure sensor (2). 6. Lower the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Exhaust Pressure Differential Sensor Replacement (Pickup) > Page 1377 Exhaust Pressure Differential Sensor: Service and Repair Exhaust Pressure Differential Sensor Replacement (Cab/Chassis) Exhaust Pressure Differential Sensor Replacement (Cab/Chassis) Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the chassis wiring harness electrical connector (1) from the exhaust differential pressure sensor (2). 3. Reposition the exhaust differential pressure sensor pipe assembly hose clamps (3). 4. Remove the exhaust differential pressure sensor pipe assembly hoses from the sensor. 5. Remove the exhaust differential pressure sensor bracket bolts (1). 6. Remove the exhaust differential pressure sensor (2). Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Exhaust Pressure Differential Sensor Replacement (Pickup) > Page 1378 1. Position the exhaust differential pressure sensor (2) to the bracket. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the exhaust differential pressure sensor bracket bolts (1). Tighten the bolts to 9 Nm (80 lb in). 3. Install the exhaust differential pressure sensor pipe assembly hoses to the sensor. 4. Position the exhaust differential pressure sensor pipe assembly hose clamps (3). 5. Connect the chassis wiring harness electrical connector (1) to the exhaust differential pressure sensor (2). 6. Lower the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Exhaust Pressure Differential Sensor Replacement (Pickup) > Page 1379 Exhaust Pressure Differential Sensor: Service and Repair Exhaust Pressure Differential Sensor Pipe Replacement (Pickup) Exhaust Pressure Differential Sensor Pipe Replacement (Pickup) Removal Procedure Caution: The exhaust temperature sensor and exhaust pressure differential sensor line fittings may be difficult to remove when the engine exhaust system temperature is below 48°C (120°F). Excessive force may damage the threads in the exhaust manifold or exhaust pipe. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Reposition the exhaust differential pressure sensor pipe assembly hose clamps (3). 3. Remove the exhaust differential pressure sensor pipe assembly hoses from the sensor. 4. Remove the exhaust differential pressure sensor pipe bracket bolt and nut. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Exhaust Pressure Differential Sensor Replacement (Pickup) > Page 1380 5. Loosen the exhaust differential pressure sensor pipe assembly fittings (1). 6. Remove the exhaust differential pressure sensor pipe assembly. Installation Procedure Note: A special anti-seize compound is used in the sensor or line fittings threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor or line fitting easier to remove. New, or service replacement sensors or line fittings already have the compound applied to the threads. If the sensor or line fittings are removed from an exhaust component and if for any reason the sensor or line fitting are reinstalled, the threads must have anti-seize compound applied before reinstallation. 1. If reinstalling the old temperature sensor or differential pressor sensor line fittings, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Exhaust Pressure Differential Sensor Replacement (Pickup) > Page 1381 Note: Ensure to route the pipe assembly over the frame crossmember. 2. Position and install the exhaust differential pressure sensor pipe assembly to the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Tighten the exhaust differential pressure sensor pipe assembly fittings (1). Tighten the fittings to 45 Nm (33 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Exhaust Pressure Differential Sensor Replacement (Pickup) > Page 1382 4. Position the exhaust differential pressure sensor pipe bracket to the exhaust hanger and install the bolt and nut. Tighten the bracket bolt/nut to 9 Nm (80 lb in). 5. Install the exhaust differential pressure sensor pipe assembly hoses to the sensor. 6. Position the exhaust differential pressure sensor pipe assembly hose clamps (3). 7. Lower the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Exhaust Pressure Differential Sensor Replacement (Pickup) > Page 1383 Exhaust Pressure Differential Sensor: Service and Repair Exhaust Pressure Differential Sensor Pipe Replacement (Cab/Chassis) Exhaust Pressure Differential Sensor Pipe Replacement (Cab/Chassis) Removal Procedure Caution: The exhaust temperature sensor and exhaust pressure differential sensor line fittings may be difficult to remove when the engine exhaust system temperature is below 48°C (120°F). Excessive force may damage the threads in the exhaust manifold or exhaust pipe. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Reposition the exhaust differential pressure sensor pipe assembly hose clamps (3). 3. Remove the exhaust differential pressure sensor pipe assembly hoses from the sensor. 4. Remove the exhaust differential pressure sensor pipe bracket bolt and nut. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Exhaust Pressure Differential Sensor Replacement (Pickup) > Page 1384 5. Loosen the exhaust differential pressure sensor pipe assembly fittings (1). 6. Remove the exhaust differential pressure sensor pipe assembly. Installation Procedure Note: A special anti-seize compound is used in the sensor or line fittings threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor or line fitting easier to remove. New, or service replacement sensors or line fittings already have the compound applied to the threads. If the sensor or line fittings are removed from an exhaust component and if for any reason the sensor or line fitting are reinstalled, the threads must have anti-seize compound applied before reinstallation. 1. If reinstalling the old temperature sensor or differential pressor sensor line fittings, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Exhaust Pressure Differential Sensor Replacement (Pickup) > Page 1385 Note: Ensure to route the pipe assembly over the frame crossmember. 2. Position and install the exhaust differential pressure sensor pipe assembly to the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Tighten the exhaust differential pressure sensor pipe assembly fittings (1). Tighten the fittings to 45 Nm (33 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Exhaust Pressure Differential Sensor Replacement (Pickup) > Page 1386 4. Position the exhaust differential pressure sensor pipe bracket to the exhaust hanger and install the bolt and nut. Tighten the bracket bolt/nut to 9 Nm (80 lb in). 5. Install the exhaust differential pressure sensor pipe assembly hoses to the sensor. 6. Position the exhaust differential pressure sensor pipe assembly hose clamps (3). 7. Lower the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Diagrams Pressure Feedback Exhaust Sensor: Diagrams Component Connector End Views Exhaust Pressure Differential Sensor (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations Accelerator Pedal Position Sensor: Locations Harness Routing Views Brake Clutch Harness Routing 1 - Driver Door Frame 2 - X205 3 - X102 (JL1) 4 - Accelerator Pedal Position (APP) Sensor Connector 5 - Junction Block - Left I/P (except MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 1394 Accelerator Pedal Position Sensor: Diagrams Component Connector End Views Accelerator Pedal Position (APP) Sensor Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 1395 Accelerator Pedal Position Sensor: Description and Operation Accelerator Pedal Position System Description The accelerator pedal position (APP) sensor is mounted inside the accelerator pedal control assembly. The sensor is made up of the two individual sensors within a single housing. Each sensor has a unique functionality to determine pedal position. The accelerator pedal position (APP) system along with the engine control module (ECM) is used to calculate and control the amount of acceleration and deceleration through fuel injector control. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 1396 Accelerator Pedal Position Sensor: Service and Repair Accelerator Pedal Position Sensor Replacement Removal Procedure Caution: Handle the electronic throttle control components carefully. Use cleanliness in order to prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the electronic throttle control components. Do not immerse the electronic throttle control components in cleaning solvents of any type. 1. Remove the connector position assurance (CPA) retainer. 2. Disconnect the accelerator pedal position (APP) sensor electrical connector (1). 3. Remove the accelerator pedal bolts. 4. Remove the accelerator pedal. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 1397 Installation Procedure 1. Position the accelerator pedal to the accelerator pedal bracket. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the accelerator pedal bolts and tighten to 9 Nm (80 lb in).. 3. Connect the APP sensor electrical connector (1). 4. Install the CPA retainer. 5. Connect a scan tool to the diagnostic port in order to test for proper throttle-opening and throttle-closing range. 6. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle, and a wide open throttle (WOT). 7. Verify that the vehicle meets the following conditions: * The vehicle is not in a reduced engine power mode. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 1398 * The ignition is ON. * The engine is OFF. 8. Inspect the carpet fit under the accelerator pedal. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations Air Flow Meter/Sensor: Locations Harness Routing Views Engine Harness Routing - Top (4.3L) 1 - Mega Fuse Ring Terminal 2 - X175 (M30) 3 - J128 4 - J105 5 - J106 6 - J130 (M30 with NQG/NQH) 7 - Engine Control Module (ECM) X1 8 - Engine Control Module (ECM) X2 9 - G103 10 - X112 11 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Connector Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 1402 Air Flow Meter/Sensor: Diagrams Component Connector End Views Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (Diesel) Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (Gas) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 1403 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 1404 Air Flow Meter/Sensor: Service and Repair Mass Airflow Sensor with Intake Air Temperature Sensor Replacement Removal Procedure 1. Disconnect the engine wiring harness electrical connector (1) from the mass air flow (MAF)/intake air temperature (IAT) sensor. 2. Remove the MAF/IAT sensor TORX(R) screws. 3. Remove the MAF/IAT sensor. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 1405 1. Install the MAF/IAT sensor. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the MAF/IAT sensor TORX(R) screws. Tighten the screws to 8 Nm (70 lb in). 3. Connect the engine wiring harness electrical connector (1) to the MAF/IAT sensor. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Diagrams Fuel Pressure Sensor/Switch: Diagrams Component Connector End Views Fuel Rail Pressure (FRP) Sensor (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Diagrams > Page 1409 Fuel Pressure Sensor/Switch: Service and Repair Fuel Injection Fuel Rail Fuel Pressure Sensor Replacement Removal Procedure 1. Remove the exhaust gas recirculation (EGR) valve cooler. Refer to Exhaust Gas Recirculation Valve Cooler Replacement (See: Powertrain Management/Emission Control Systems/Exhaust Gas Recirculation/EGR Cooler/Service and Repair/Exhaust Gas Recirculation Valve Cooler Replacement). 2. Disconnect the engine wiring harness electrical connector (1) from the fuel rail fuel pressure sensor wiring harness extension electrical connector. 3. Remove the fuel rail fuel pressure sensor wiring harness extension clip (3) from the wiring harness bracket. 4. Remove the EGR valve cooler rear bracket bolts and bracket. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Diagrams > Page 1410 5. Disconnect the fuel rail fuel pressure sensor wiring harness extension (1) from the fuel rail fuel pressure sensor. 6. Prior to removal, clean the fuel rail fuel pressure sensor and surrounding area thoroughly with solvent, such as GM P/N 12377981 (Canadian P/N 10953463) or equivalent. 7. Using compressed air, thoroughly blow dry the sensor and surrounding area. 8. Remove the fuel rail fuel pressure sensor (2). Installation Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the fuel rail fuel pressure sensor (2). Tighten the sensor to 70 Nm (52 lb ft). 2. Connect the fuel rail fuel pressure sensor wiring harness extension (1) to the fuel rail fuel pressure sensor. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Diagrams > Page 1411 3. Position the EGR valve cooler rear bracket to the cylinder head and install the bolts. Tighten the bolts to 25 Nm (18 lb ft). 4. Connect the engine wiring harness electrical connector (1) to the fuel rail fuel pressure sensor wiring harness extension electrical connector. 5. Install the fuel rail fuel pressure sensor wiring harness extension clip (3) to the wiring harness bracket. 6. Install the EGR valve cooler. Refer to Exhaust Gas Recirculation Valve Cooler Replacement (See: Powertrain Management/Emission Control Systems/Exhaust Gas Recirculation/EGR Cooler/Service and Repair/Exhaust Gas Recirculation Valve Cooler Replacement). 7. Prime the fuel system. Refer to Fuel System Priming (See: Powertrain Management/Fuel Delivery and Air Induction/Service and Repair/Fuel System Priming). 8. Start the engine. If the engine stalls, repeat the above step. 9. Once the engine starts, inspect for fuel leaks. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Diagrams Fuel Temperature Sensor: Diagrams Component Connector End Views Fuel Temperature Sensor (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Diagrams > Page 1415 Fuel Temperature Sensor: Service and Repair Fuel Temperature Sensor Replacement Removal Procedure 1. Remove the charge air cooler inlet pipe. Refer to Charge Air Cooler Inlet Pipe Replacement (See: Powertrain Management/Fuel Delivery and Air Induction/Turbocharger/Intercooler/Intercooler Duct/Service and Repair/Charge Air Cooler Inlet Pipe Replacement). 2. Disconnect the engine wiring harness electrical connector from the fuel temperature sensor. 3. Remove the fuel temperature sensor (1) from the fuel return pipe. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Diagrams > Page 1416 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the fuel temperature sensor (1) to the fuel return pipe. Tighten the sensor to 22 Nm (16 lb ft). 2. Connect the engine wiring harness electrical connector to the fuel temperature sensor. 3. Prime the fuel system. Refer to Fuel System Priming (See: Powertrain Management/Fuel Delivery and Air Induction/Service and Repair/Fuel System Priming). 4. Start the engine. If the engine stalls, repeat the above step. 5. Once the engine starts, inspect for fuel leaks. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > High Idle Switch > Component Information > Testing and Inspection High Idle Switch: Testing and Inspection High Idle Switch Diagnosis Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions )provide an overview of each diagnostic category. Diagnostic Fault Information Reference Information Schematic Reference Engine Controls Schematics (See: Powertrain Management/Diagrams/Electrical Diagrams) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning)for scan tool information Circuit/System Verification Ignition ON, observe the scan tool High Idle switch parameter while exercising the switch. The reading should change between ON/OFF. Circuit/System Testing 1. Ignition OFF, disconnect the harness connector at the high idle switch. 2. Test for less than 5 ohms between the ground circuit terminal A and ground. ‹› If greater than 5 ohms, test the ground circuit for an open/high resistance. 3. Ignition ON, verify the scan tool High Idle switch parameter is OFF. ‹› If not OFF, test the signal circuit for a short to ground. If the circuit tests normal, replace the ECM. 4. Install a 3A fused jumper wire between the signal circuit terminal C and ground. Verify the scan tool High Idle switch parameter is ON. ‹› If not ON, test the signal circuit for a short to voltage or an open/high resistance. If the circuit tests normal, replace the ECM. 5. If all circuits test normal, test or replace the high idle switch. Component Testing Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > High Idle Switch > Component Information > Testing and Inspection > Page 1420 1. Ignition OFF, disconnect the harness connector at the high idle switch. 2. Test for infinite resistance between the signal terminal C and the ground circuit terminal A with the switch in the open position. ‹› If less than infinite resistance, replace the high idle switch. 3. Test for less than 1 ohm between the signal terminal C and the ground terminal A with the switch in the closed position. ‹› If greater than 1 ohm, replace the high idle switch. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Turbocharger Vane Position Sensor > Component Information > Technical Service Bulletins > Engine - Info on Duramax Turbo Vane Position Sensor Turbocharger Vane Position Sensor: Technical Service Bulletins Engine - Info on Duramax Turbo Vane Position Sensor INFORMATION Bulletin No.: 10-06-04-014 Date: November 03, 2010 Subject: Information on Duramax Turbo Vane Position Sensor Models: 2010-2011 Chevrolet Express Vans, Silverado 2010-2011 GMC Savana Vans, Sierra Equipped with Duramax(TM) Diesel Engine (RPOs LGH, LML) An improvement has been implemented to the turbocharger vane position sensor. Some turbochargers existing in inventory have the old style vane position sensor. If turbochargers, GM P/N 12635325 or 12635167 are being replaced, the original turbo vane sensor should be removed and replaced with the new style sensor, GM P/N 12643471. Turbochargers that are supersessions to these part numbers will have the new style vane position sensor and no action is necessary. Parts Information Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Turbocharger Vane Position Sensor > Component Information > Technical Service Bulletins > Page 1425 Turbocharger Vane Position Sensor: Diagrams Component Connector End Views Turbocharger Vane Position Sensor (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Harness Routing Views Camshaft Position Sensor Jumper Harness Routing (4.8L/5.3L/6.0L/6.2L) 1 - X112 2 - Camshaft Position Sensor Jumper Harness Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 1430 Camshaft Position Sensor: Diagrams Component Connector End Views Camshaft Position (CMP) Actuator Solenoid Valve (LZ1, LY6, L96 or L9H) Camshaft Position (CMP) Sensor (LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 1431 Camshaft Position (CMP) Sensor (Gas except LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 1432 Camshaft Position (CMP) Sensor (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 1433 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 1434 Camshaft Position Sensor: Service Precautions Camshaft Position Actuator Removal and Installation Warning Warning Do not push or pull on the reluctor wheel of the camshaft position (CMP) actuator during removal or installation. The reluctor wheel is retained to the front of the CMP actuator by 3 roll pins. Pushing or pulling on the wheel may dislodge the wheel from the front of the actuator. The actuator return spring is under tension and may rotate the dislodged reluctor wheel, causing personal injury. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 1435 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor Replacement Removal Procedure 1. Remove the cooling fan pulley. Refer to Fan Pulley Replacement (See: Engine, Cooling and Exhaust/Cooling System/Radiator Cooling Fan/Service and Repair). 2. Remove the camshaft position (CMP) sensor bolt. 3. Remove the CMP sensor. Installation Procedure 1. Lubricate the CMP sensor O-ring with clean engine oil. 2. Install the CMP sensor. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 1436 3. Install the CMP sensor bolt. Tighten the bolt to 10 Nm (89 lb in). 4. Install the cooling fan pulley. Refer to Fan Pulley Replacement (See: Engine, Cooling and Exhaust/Cooling System/Radiator Cooling Fan/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams Crankshaft Position Sensor: Diagrams Component Connector End Views Crankshaft Position (CKP) Sensor (LU3) Crankshaft Position (CKP) Sensor (Gas except LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 1440 Crankshaft Position (CKP) Sensor (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 1441 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement Crankshaft Position Sensor Replacement Removal Procedure 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 2. Remove the right wheelhouse panel. Refer to Front Wheelhouse Liner Replacement - Right Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side)Front Wheelhouse Liner Replacement - Right Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side). 3. Disconnect the crankshaft position (CKP) sensor electrical connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 1444 4. Remove the CKP sensor bolt. 5. Remove the CKP sensor. 6. If necessary, remove the CKP sensor spacer bolts. 7. If necessary, remove the CKP sensor spacer. Installation Procedure 1. If necessary, lubricate a NEW CKP spacer O-ring with clean engine oil. 2. If necessary, install the NEW O-ring to the CKP sensor spacer. Note: The crankshaft position sensor spacers are machined with different timing positions. However, if the crankshaft position sensor spacer requires replacement, replace with a grade "C" spacer. 3. If necessary, install the CKP sensor spacer. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. If necessary, install the CKP sensor spacer bolts. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 1445 Tighten the bolts to 10 Nm (89 lb in). 5. Lubricate a NEW CKP sensor O-ring with clean engine oil. 6. Install the NEW O-ring to the CKP sensor. 7. Install the CKP sensor. 8. Install the CKP sensor bolt. Tighten the bolt to 10 Nm (89 lb in). 9. Connect the CKP sensor electrical connector. 10. Install the right wheelhouse panel. Refer to Front Wheelhouse Liner Replacement - Right Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side)Front Wheelhouse Liner Replacement - Right Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side). 11. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 1446 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Exciter Ring and Oil Pump Drive Gear Replacement Crankshaft Position Sensor Exciter Ring and Oil Pump Drive Gear Replacement Removal Procedure 1. Remove the engine front cover. Refer to Engine Front Cover Replacement (See: Engine, Cooling and Exhaust/Engine/Timing Components/Timing Cover/Service and Repair). 2. Remove the upper oil pan. Refer to Upper Oil Pan Replacement (See: Engine, Cooling and Exhaust/Engine/Engine Lubrication/Oil Pan/Service and Repair/Upper Oil Pan Replacement). Caution: Do not use an impact driver to remove or install the oil pump driven gear nut. Use of an impact driver may shear the oil pump drive gear pin in the crankshaft. 3. While holding the secondary oil pump shaft with a hex driver, remove the oil pump driven gear nut. 4. Remove the oil pump driven gear. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 1447 5. Remove the oil pump drive gear and crankshaft sensor reluctor. Do not damage the crankshaft reluctor teeth. Note: Do not remove the reluctor from the oil pump drive gear unless replacing the reluctor or the oil pump drive gear. The reluctor is timed to the gear and once removed the correct timing will be lost. 6. Remove the crankshaft reluctor to oil pump drive gear bolts. 7. Inspect the crankshaft reluctor for the damage, bent teeth, being bent or warped. 8. Inspect the oil pump drive gear for damaged or worn teeth. 9. Inspect the oil pump drive gear crankshaft pin for wear. 10. Inspect the groove of the crankshaft pin in the oil pump drive gear for wear. 11. Replace any parts that are damaged or worn. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 1448 Note: The crankshaft reluctor and the oil pump drive gear are timed at the factory. In order to re-establish proper timing, install knock pins in the oil pump drive gear if the crankshaft reluctor was removed from the oil pump drive gear. The knock pins are available through the parts department. 1. Install the knock pins in the oil pump drive gear to a height of 4.5-5.5 mm (0.177-0.217 in) 2. Install the crankshaft reluctor on the oil pump drive gear. Ensure the reluctor is aligned on the knock pins. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the crankshaft reluctor bolts and tighten to 8 Nm (71 lb in). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 1449 Note: Do not damage the teeth on the crankshaft reluctor. 4. Install the oil pump drive gear and reluctor to the crankshaft. 5. Install the oil pump driven gear. Caution: Do not use an impact driver to remove or install the oil pump driven gear nut. Use of an impact driver may shear the oil pump drive gear pin in the crankshaft. 6. While holding the secondary oil pump shaft with a hex driver, install the oil pump driven gear nut and tighten to 100 Nm (74 lb ft). 7. Install the upper oil pan. Refer to Upper Oil Pan Replacement (See: Engine, Cooling and Exhaust/Engine/Engine Lubrication/Oil Pan/Service and Repair/Upper Oil Pan Replacement). 8. Install the engine front cover. Refer to Engine Front Cover Replacement (See: Engine, Cooling and Exhaust/Engine/Timing Components/Timing Cover/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder Case Replacement Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder Case Replacement Ignition Lock Cylinder Case Replacement Removal Procedure Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). 1. Remove the inflatable restraint steering wheel module coil. Refer to Steering Wheel Inflatable Restraint Module Coil Replacement (See: Restraint Systems/Air Bag Systems/Clockspring Assembly / Spiral Cable/Service and Repair/Removal and Replacement). 2. Remove the ignition/start switch. Refer to Ignition and Start Switch Replacement (See: Service and Repair). 3. Disconnect the park lock cable from the ignition lock cylinder case. 4. Disconnect the passlock and key buzzer from the ignition lock cylinder case. 5. Remove the 3 ignition lock cylinder case screws (2). 6. Remove the ignition lock cylinder case (1) from the vehicle. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder Case Replacement > Page 1455 1. Install the ignition lock cylinder case (1) to the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the 3 ignition lock cylinder case screws (2). Tighten the screws to 7 Nm (62 lb in). 3. Install the park lock cable into the lock cylinder housing. 4. Connect the passlock and key buzzer to the ignition lock cylinder case. 5. Install the ignition/start switch. Refer to Ignition and Start Switch Replacement (See: Service and Repair). 6. Install the inflatable restraint steering wheel module coil. Refer to Steering Wheel Inflatable Restraint Module Coil Replacement (See: Restraint Systems/Air Bag Systems/Clockspring Assembly / Spiral Cable/Service and Repair/Removal and Replacement). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder Case Replacement > Page 1456 Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder Replacement Ignition Lock Cylinder Replacement Removal Procedure Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). 1. Disable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair). 2. Remove the steering column shroud. Refer to Steering Column Shroud Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Column Shroud Replacement). 3. With the key installed hold it in the START position. 4. Install an allen wrench into the hole on top of the ignition lock cylinder case. Push down on the allen wrench to release the tab on the ignition lock cylinder inside the ignition lock cylinder case. 5. Slide the ignition lock cylinder out of the ignition lock cylinder case. Installation Procedure Note: The gears between the ignition/start switch and the ignition lock cylinder case must be in the correct position. Failure to do so will cause a misalignment of the gears in the ignition/start switch and the ignition lock cylinder case, which may result in a NO START or BATTERY DRAIN. 1. Use a screwdriver to rotate the ignition lock cylinder case gear clockwise to the start position allowing it to spring return into the RUN position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder Case Replacement > Page 1457 2. Install the key into the ignition lock cylinder. 3. Align the ignition lock cylinder and install it into the ignition lock cylinder case. 4. Install the steering column shroud. Refer to Steering Column Shroud Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Column Shroud Replacement). 5. Enable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams Knock Sensor: Diagrams Component Connector End Views Knock Sensor (KS) 1 (Gas) Knock Sensor (KS) 2 (Gas) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 1461 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Diagrams Air Bag Deactivation Switch: Diagrams Component Connector End Views Inflatable Restraint I/P Module Disable Switch (C99 or MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Diagrams > Page 1466 Air Bag Deactivation Switch: Service and Repair Instrument Panel Inflatable Restraint Module Switch Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams Impact Sensor: Diagrams Component Connector End Views Inflatable Restraint Front End Sensor - Left (10 Series) Inflatable Restraint Front End Sensor - Right (10 Series) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Page 1470 Inflatable Restraint Front End Sensor (except 10 Series) Inflatable Restraint Side Impact Sensor (SIS) - Left Front (ASF) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Page 1471 Inflatable Restraint Side Impact Sensor (SIS) - Left Rear (Extended or Crew Cab with ASF) Inflatable Restraint Side Impact Sensor (SIS) - Right Front (ASF) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Page 1472 Inflatable Restraint Side Impact Sensor (SIS) - Right Rear (Extended or Crew Cab with ASF) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement Impact Sensor: Service and Repair Inflatable Restraint Front End Sensor Replacement Inflatable Restraint Front End Sensor Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 1475 Impact Sensor: Service and Repair Inflatable Restraint Side Impact Sensor Replacement (Crew Cab/Extended Cab/Regular Cab) Inflatable Restraint Side Impact Sensor Replacement (Crew Cab/Extended Cab/Regular Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 1476 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 1477 Impact Sensor: Service and Repair Inflatable Restraint Side Impact Sensor Replacement (Crew Cab, Rear Door) Inflatable Restraint Side Impact Sensor Replacement (Crew Cab, Rear Door) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 1478 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 1479 Impact Sensor: Service and Repair Inflatable Restraint Side Impact Sensor Replacement (Extended Cab, Rear Door ) Inflatable Restraint Side Impact Sensor Replacement (Extended Cab, Rear Door ) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 1480 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations Seat Belt Buckle Switch: Locations Harness Routing Views Driver Seat Harness Routing 1 - Seat Recline Motor - Driver (AN3) 2 - Seat Lumbar Vertical Motor Position Sensor - Driver (AN3) 3 - Seat Lumbar Vertical Motor - Driver (AN3) 4 - X324 (AN3) 5 - Seat Lumbar Horizontal Motor - Driver (AN3) 6 - Seat Lumbar Horizontal Motor Position Sensor - Driver (AN3) 7 - Seat Recline Position Sensor - Driver (AN3) 8 - Seat Lumbar Switch - Driver (AN3) 9 - Seat Adjuster Switch - Driver (AG1) 10 - Memory Seat Module (MSM) (AN3) 11 - Inflatable Restraint Seat Position Sensor (SPS) - Driver (10 Series) 12 - Seat Adjuster Motor Assembly - Driver (AG1) 13 Seat Belt Buckle - Driver Passenger Seat Harness Routing Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 1484 1 - Seat Frame 2 - X325 (AN3) 3 - Seat Lumbar Vertical Motor - Passenger (AN3) 4 - Seat Adjuster Switch - Passenger (AG2) 5 - Seat Lumbar Switch - Passenger (AN3) 6 - Seat Belt Buckle Passenger 7 - Inflatable Restraint Passenger Presence System (PPS) Module (AL0) 8 - Seat Adjuster Motor Assembly - Passenger (AG2) 9 - Inflatable Restraint Passenger Presence System (PPS) Sensor (AL0) 10 - Seat Recline Motor - Passenger (AN3) 11 - Seat Lumbar Horizontal Motor - Passenger (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 1485 Seat Belt Buckle Switch: Diagrams Component Connector End Views Seat Belt Buckle - Driver Seat Belt Buckle - Passenger X1 (10 Series without MEX) Seat Belt Buckle - Passenger X2 (AL0) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 1486 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Restraints - Passenger Presence System Information Seat Occupant Sensor: Technical Service Bulletins Restraints - Passenger Presence System Information INFORMATION Bulletin No.: 06-08-50-009F Date: December 23, 2010 Subject: Information on Passenger Presence Sensing System (PPS or PSS) Concerns With Custom Upholstery, Accessory Seat Heaters or Other Comfort Enhancing Devices Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Passenger Presence Sensing System Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-08-50-009E (Section 08 - Body and Accessories). Concerns About Safety and Alterations to the Front Passenger Seat Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE THE SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER THE SEAT COVERS OR SEAT-RELATED EQUIPMENT. ANY ALTERATIONS TO SEAT COVERS OR GM ACCESSORIES DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. The front passenger seat in many GM vehicles is equipped with a passenger sensing system that will turn off the right front passenger's frontal airbag under certain conditions, such as when an infant or child seat is present. In some vehicles, the passenger sensing system will also turn off the right front passenger's seat mounted side impact airbag. For the system to function properly, sensors are used in the seat to detect the presence of a properly-seated occupant. The passenger sensing system may not operate properly if the original seat trim is replaced (1) by non-GM covers, upholstery or trim, or (2) by GM covers, upholstery or trim designed for a different vehicle or (3) by GM covers, upholstery or trim that has been altered by a trim shop, or (4) if any object, such as an aftermarket seat heater or a comfort enhancing pad or device is installed under the seat fabric or between the occupant and the seat fabric. Aftermarket Seat Heaters, Custom Upholstery, and Comfort Enhancing Pads or Devices Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE ONLY SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT RELEASED AS GM ACCESSORIES FOR THAT VEHICLE. DO NOT USE ANY OTHER TYPE OF SEAT COVERS OR SEAT-RELATED EQUIPMENT, OR GM ACCESSORIES RELEASED FOR OTHER VEHICLE APPLICATIONS. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ACCESSORIES, INCLUDING ANY WARRANTY REPAIRS MADE NECESSARY BY SUCH USE. Many types of aftermarket accessories are available to customers, upfitting shops, and dealers. Some of these devices sit on top of, or are Velcro(R) strapped to the seat while others such as seat heaters are installed under the seat fabric. Additionally, seat covers made of leather or other materials may have different padding thickness installed that could prevent the Passenger Sensing System from functioning properly. Never alter the vehicle seats. Never add pads or other devices to the seat cushion, as this may interfere with the operation of the Passenger Sensing System and either prevent proper deployment of the passenger airbag or prevent proper suppression of the passenger air bag. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Page 1491 Seat Occupant Sensor: Service and Repair Inflatable Restraint Passenger Presence System Replacement - Front (without HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Page 1492 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Position Sensor > Component Information > Locations Seat Position Sensor: Locations Harness Routing Views Driver Seat Harness Routing 1 - Seat Recline Motor - Driver (AN3) 2 - Seat Lumbar Vertical Motor Position Sensor - Driver (AN3) 3 - Seat Lumbar Vertical Motor - Driver (AN3) 4 - X324 (AN3) 5 - Seat Lumbar Horizontal Motor - Driver (AN3) 6 - Seat Lumbar Horizontal Motor Position Sensor - Driver (AN3) 7 - Seat Recline Position Sensor - Driver (AN3) 8 - Seat Lumbar Switch - Driver (AN3) 9 - Seat Adjuster Switch - Driver (AG1) 10 - Memory Seat Module (MSM) (AN3) 11 - Inflatable Restraint Seat Position Sensor (SPS) - Driver (10 Series) 12 - Seat Adjuster Motor Assembly - Driver (AG1) 13 Seat Belt Buckle - Driver Passenger Seat Harness Routing Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Position Sensor > Component Information > Locations > Page 1496 1 - Seat Frame 2 - X325 (AN3) 3 - Seat Lumbar Vertical Motor - Passenger (AN3) 4 - Seat Adjuster Switch - Passenger (AG2) 5 - Seat Lumbar Switch - Passenger (AN3) 6 - Seat Belt Buckle Passenger 7 - Inflatable Restraint Passenger Presence System (PPS) Module (AL0) 8 - Seat Adjuster Motor Assembly - Passenger (AG2) 9 - Inflatable Restraint Passenger Presence System (PPS) Sensor (AL0) 10 - Seat Recline Motor - Passenger (AN3) 11 - Seat Lumbar Horizontal Motor - Passenger (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Position Sensor > Component Information > Locations > Page 1497 Seat Position Sensor: Diagrams Component Connector End Views Inflatable Restraint Seat Position Sensor - Driver (10 Series except MEX) Inflatable Restraint Seat Position Sensor - Passenger (10 Series except Crew Cab or MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Position Sensor > Component Information > Locations > Page 1498 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Position Sensor > Component Information > Locations > Page 1499 Seat Position Sensor: Service and Repair Inflatable Restraint Seat Position Sensor Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Current Sensor > Component Information > Diagrams Battery Current Sensor: Diagrams Component Connector End Views Battery Current Sensor (10 Series without MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Current Sensor > Component Information > Diagrams > Page 1504 Battery Current Sensor: Service and Repair Battery Current Sensor Replacement Removal Procedure 1. Remove the negative battery cable. Refer to Battery Negative Cable Replacement (V6) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Replacement (V8) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Replacement (Diesel) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 2. Mark the location of the battery current sensor on the battery cable with tape for reference during installation. 3. Remove the tape securing the battery current sensor to the negative battery cable. 4. Mark the location of the negative battery cable clips (1) and remove the clips from the cable. 5. Squeeze the negative battery cable branches together. Important: Note the orientation of the battery current sensor prior to removal. 6. Slide the battery current sensor (2) off of the negative battery cable. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Current Sensor > Component Information > Diagrams > Page 1505 1. Squeeze the negative battery cable branches together. Important: Ensure the battery current sensor is installed in the correct direction and location on the negative battery cable. 2. Slide the NEW battery current sensor (2) up onto the negative battery cable to the location previously marked during removal. 3. Wrap electrical tape around the battery current sensor leg in order to secure the sensor to the negative battery cable. 4. Install the negative battery cable clips (1) to the cable to the locations previously marked during removal. 5. Install the negative battery cable. Refer to Battery Negative Cable Replacement (V6) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Replacement (V8) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Replacement (Diesel) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder Case Replacement Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder Case Replacement Ignition Lock Cylinder Case Replacement Removal Procedure Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). 1. Remove the inflatable restraint steering wheel module coil. Refer to Steering Wheel Inflatable Restraint Module Coil Replacement (See: Restraint Systems/Air Bag Systems/Clockspring Assembly / Spiral Cable/Service and Repair/Removal and Replacement). 2. Remove the ignition/start switch. Refer to Ignition and Start Switch Replacement (See: Service and Repair). 3. Disconnect the park lock cable from the ignition lock cylinder case. 4. Disconnect the passlock and key buzzer from the ignition lock cylinder case. 5. Remove the 3 ignition lock cylinder case screws (2). 6. Remove the ignition lock cylinder case (1) from the vehicle. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder Case Replacement > Page 1511 1. Install the ignition lock cylinder case (1) to the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the 3 ignition lock cylinder case screws (2). Tighten the screws to 7 Nm (62 lb in). 3. Install the park lock cable into the lock cylinder housing. 4. Connect the passlock and key buzzer to the ignition lock cylinder case. 5. Install the ignition/start switch. Refer to Ignition and Start Switch Replacement (See: Service and Repair). 6. Install the inflatable restraint steering wheel module coil. Refer to Steering Wheel Inflatable Restraint Module Coil Replacement (See: Restraint Systems/Air Bag Systems/Clockspring Assembly / Spiral Cable/Service and Repair/Removal and Replacement). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder Case Replacement > Page 1512 Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder Replacement Ignition Lock Cylinder Replacement Removal Procedure Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). 1. Disable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair). 2. Remove the steering column shroud. Refer to Steering Column Shroud Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Column Shroud Replacement). 3. With the key installed hold it in the START position. 4. Install an allen wrench into the hole on top of the ignition lock cylinder case. Push down on the allen wrench to release the tab on the ignition lock cylinder inside the ignition lock cylinder case. 5. Slide the ignition lock cylinder out of the ignition lock cylinder case. Installation Procedure Note: The gears between the ignition/start switch and the ignition lock cylinder case must be in the correct position. Failure to do so will cause a misalignment of the gears in the ignition/start switch and the ignition lock cylinder case, which may result in a NO START or BATTERY DRAIN. 1. Use a screwdriver to rotate the ignition lock cylinder case gear clockwise to the start position allowing it to spring return into the RUN position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder Case Replacement > Page 1513 2. Install the key into the ignition lock cylinder. 3. Align the ignition lock cylinder and install it into the ignition lock cylinder case. 4. Install the steering column shroud. Refer to Steering Column Shroud Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Column Shroud Replacement). 5. Enable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Diagrams Steering Angle Sensor: Diagrams Component Connector End Views Steering Angle Sensor (JL4) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor Replacement Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor Replacement Steering Wheel Position Sensor Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor Replacement > Page 1521 Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor Centering Steering Wheel Position Sensor Centering Removal Procedure Caution: With wheels of the vehicle facing straight ahead, secure the steering wheel utilizing steering column anti-rotation pin, steering column lock, or a strap to prevent rotation. Locking of the steering column will prevent damage and a possible malfunction of the SIR system. The steering wheel must be secured in position before disconnecting the following components: * The steering column * The intermediate shaft(s) * The steering gear After disconnecting these components, do not rotate the steering wheel or move the front tires and wheels. Failure to follow this procedure may cause the SIR coil assembly to become un-centered and cause possible damage to the SIR coil. If you think the SIR coil has became un-centered, refer to your specific SIR coil's centering procedure to re-center SIR Coil. 1. With the wheels of the vehicle in the straight ahead position, secure the steering wheel or the steering column with a steering column anti-rotation pin, a steering column lock, or a strap, as applicable, in order to prevent rotation. Note: Identify the type of steering wheel position sensor from the illustrations shown BEFORE removing the sensor from the steering column. Once you have identified the steering wheel position sensor, follow the instructions listed in the removal procedure. 2. Verify the type of steering wheel position sensor. 3. From the technicians point of view of the FRONT of the sensor (1), the connector will be on the right. Note: If you are reusing the existing sensor, you do not have to align the sensor before removal. Centering is not necessary in order to install the old sensor. 4. Remove the connector from the sensor. 5. Remove the sensor from the adapter and bearing assembly. 6. To install the sensor, proceed to step 1 in the installation procedure. 7. From the technicians point of view, the FRONT of the sensor will have: * A foam ring (2) * A pin hole (1) for the centering the pin-Note the location of the pin hole. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor Replacement > Page 1522 * A flush rotor flange cuff (4) Note: If you are reusing the existing sensor, make an alignment mark (3) on the rotor flange cuff before removing the sensor. Failure to do so will cause misalignment of the old sensor. Replace a misaligned sensor with a new sensor. 8. Make an alignment mark on the flush rotor flange cuff. 9. Remove the connector from the sensor. 10. Remove the sensor from the adapter and bearing assembly. 11. To install the sensor, proceed to step 4 in the installation procedure. 12. From the technicians point of view, the FRONT of the sensor will have: * A raised rotor flange cuff (3) * An alignment mark (2) on the rotor flange cuff for installation * A pin hole (1) for the centering pin-Note the location of the pin hole. 13. Remove the connector from the sensor. 14. Remove the sensor from the adapter and bearing assembly. 15. To install the sensor, proceed to step 8 in the installation procedure. 16. From the technicians point of view, the FRONT of the sensor will have: * A raised rotor flange cuff (3) * An alignment mark (2) on the rotor flange cuff for installation * A pin hole (1) for the centering pin-Note location of the pin hole. * A sensor clip in FRONT of the sensor 17. Remove the connector from the sensor. 18. Remove the sensor clip from the sensor. 19. Remove the sensor from the adapter and bearing assembly. 20. To install the sensor, proceed to step 12 in the installation procedure. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor Replacement > Page 1523 21. From the technicians point of view, the FRONT of the sensor will have: * A flush rotor flange cuff (3) * A pin hole (1) for the centering pin-Note the location of the pin hole. * An alignment mark (2) on the flush rotor flange cuff for installation 22. Remove the connector from the sensor. 23. Remove the sensor from the adapter and bearing assembly. 24. To install the sensor, proceed to step 16 in the installation procedure. 25. From the technicians point of view, the FRONT of the sensor will have: * A flush rotor flange cuff (4) * A pin hole (2) for the centering pin-Note the location of the pin hole. * An alignment mark (3) on the flush rotor flange cuff for installation * A foam ring (1) 26. Remove the connector from the sensor. 27. Remove the sensor from the adapter and bearing assembly. 28. To install the sensor, proceed to step 20 in the installation procedure. Installation Procedure Note: If you are reusing the existing sensor, centering of the old sensor is not necessary. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. 1. From the technicians point of view of the FRONT of the sensor (1), the connector will be on your right. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor Replacement > Page 1524 From the technicians point of view of the BACK of the sensor (2), the connector will be on your left. 2. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 3. Install the connector to the sensor. 4. From the technicians point of view, the FRONT of the sensor will have: * A foam ring (4) * A pin hole (7) for the centering pin-Note the location of the pin hole. * A flush rotor flange cuff (6) * An alignment mark (5) for installation 5. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * A foam ring (3) * An alignment tab (2) for installing the sensor to the adapter and bearing assembly * A view of the inside of the connector Note: If you are reusing the existing sensor, align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 6. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 7. Install the connector to the sensor. 8. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (3) for the centering pin-Note location of the pin hole. * A raised rotor flange cuff (5) * An alignment mark (4) for installation 9. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * An alignment tab (2) for installing the sensor to the adapter and bearing assembly Note: If you are reusing the existing sensor, align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor Replacement > Page 1525 If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 10. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 11. Install the connector to the sensor. 12. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (2) for the centering pin-Note the location of the pin hole. * A raised rotor flange cuff (4) * An alignment mark (3) for installation 13. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Note: If you are reusing the existing sensor, align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 14. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 15. Install the connector to the sensor. 16. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (2) for the centering pin-Note the location of the pin hole. * A flush rotor flange cuff (4) * An alignment mark (3) for installation 17. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Note: If you are reusing the existing sensor, align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 18. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor Replacement > Page 1526 19. Install the connector to the sensor. 20. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (3) for the centering pin-Note location of the pin hole. * A flush rotor flange cuff (5) * An alignment mark (4) for installation * A foam ring (6) 21. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * An alignment tab (2) for installing the sensor to the adapter and bearing assembly Note: If you are reusing the existing sensor, align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 22. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 23. Install the connector to the sensor. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Diagrams Steering Angle Sensor: Diagrams Component Connector End Views Steering Angle Sensor (JL4) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor Replacement Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor Replacement Steering Wheel Position Sensor Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor Replacement > Page 1533 Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor Centering Steering Wheel Position Sensor Centering Removal Procedure Caution: With wheels of the vehicle facing straight ahead, secure the steering wheel utilizing steering column anti-rotation pin, steering column lock, or a strap to prevent rotation. Locking of the steering column will prevent damage and a possible malfunction of the SIR system. The steering wheel must be secured in position before disconnecting the following components: * The steering column * The intermediate shaft(s) * The steering gear After disconnecting these components, do not rotate the steering wheel or move the front tires and wheels. Failure to follow this procedure may cause the SIR coil assembly to become un-centered and cause possible damage to the SIR coil. If you think the SIR coil has became un-centered, refer to your specific SIR coil's centering procedure to re-center SIR Coil. 1. With the wheels of the vehicle in the straight ahead position, secure the steering wheel or the steering column with a steering column anti-rotation pin, a steering column lock, or a strap, as applicable, in order to prevent rotation. Note: Identify the type of steering wheel position sensor from the illustrations shown BEFORE removing the sensor from the steering column. Once you have identified the steering wheel position sensor, follow the instructions listed in the removal procedure. 2. Verify the type of steering wheel position sensor. 3. From the technicians point of view of the FRONT of the sensor (1), the connector will be on the right. Note: If you are reusing the existing sensor, you do not have to align the sensor before removal. Centering is not necessary in order to install the old sensor. 4. Remove the connector from the sensor. 5. Remove the sensor from the adapter and bearing assembly. 6. To install the sensor, proceed to step 1 in the installation procedure. 7. From the technicians point of view, the FRONT of the sensor will have: * A foam ring (2) * A pin hole (1) for the centering the pin-Note the location of the pin hole. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor Replacement > Page 1534 * A flush rotor flange cuff (4) Note: If you are reusing the existing sensor, make an alignment mark (3) on the rotor flange cuff before removing the sensor. Failure to do so will cause misalignment of the old sensor. Replace a misaligned sensor with a new sensor. 8. Make an alignment mark on the flush rotor flange cuff. 9. Remove the connector from the sensor. 10. Remove the sensor from the adapter and bearing assembly. 11. To install the sensor, proceed to step 4 in the installation procedure. 12. From the technicians point of view, the FRONT of the sensor will have: * A raised rotor flange cuff (3) * An alignment mark (2) on the rotor flange cuff for installation * A pin hole (1) for the centering pin-Note the location of the pin hole. 13. Remove the connector from the sensor. 14. Remove the sensor from the adapter and bearing assembly. 15. To install the sensor, proceed to step 8 in the installation procedure. 16. From the technicians point of view, the FRONT of the sensor will have: * A raised rotor flange cuff (3) * An alignment mark (2) on the rotor flange cuff for installation * A pin hole (1) for the centering pin-Note location of the pin hole. * A sensor clip in FRONT of the sensor 17. Remove the connector from the sensor. 18. Remove the sensor clip from the sensor. 19. Remove the sensor from the adapter and bearing assembly. 20. To install the sensor, proceed to step 12 in the installation procedure. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor Replacement > Page 1535 21. From the technicians point of view, the FRONT of the sensor will have: * A flush rotor flange cuff (3) * A pin hole (1) for the centering pin-Note the location of the pin hole. * An alignment mark (2) on the flush rotor flange cuff for installation 22. Remove the connector from the sensor. 23. Remove the sensor from the adapter and bearing assembly. 24. To install the sensor, proceed to step 16 in the installation procedure. 25. From the technicians point of view, the FRONT of the sensor will have: * A flush rotor flange cuff (4) * A pin hole (2) for the centering pin-Note the location of the pin hole. * An alignment mark (3) on the flush rotor flange cuff for installation * A foam ring (1) 26. Remove the connector from the sensor. 27. Remove the sensor from the adapter and bearing assembly. 28. To install the sensor, proceed to step 20 in the installation procedure. Installation Procedure Note: If you are reusing the existing sensor, centering of the old sensor is not necessary. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. 1. From the technicians point of view of the FRONT of the sensor (1), the connector will be on your right. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor Replacement > Page 1536 From the technicians point of view of the BACK of the sensor (2), the connector will be on your left. 2. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 3. Install the connector to the sensor. 4. From the technicians point of view, the FRONT of the sensor will have: * A foam ring (4) * A pin hole (7) for the centering pin-Note the location of the pin hole. * A flush rotor flange cuff (6) * An alignment mark (5) for installation 5. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * A foam ring (3) * An alignment tab (2) for installing the sensor to the adapter and bearing assembly * A view of the inside of the connector Note: If you are reusing the existing sensor, align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 6. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 7. Install the connector to the sensor. 8. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (3) for the centering pin-Note location of the pin hole. * A raised rotor flange cuff (5) * An alignment mark (4) for installation 9. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * An alignment tab (2) for installing the sensor to the adapter and bearing assembly Note: If you are reusing the existing sensor, align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor Replacement > Page 1537 If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 10. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 11. Install the connector to the sensor. 12. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (2) for the centering pin-Note the location of the pin hole. * A raised rotor flange cuff (4) * An alignment mark (3) for installation 13. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Note: If you are reusing the existing sensor, align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 14. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 15. Install the connector to the sensor. 16. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (2) for the centering pin-Note the location of the pin hole. * A flush rotor flange cuff (4) * An alignment mark (3) for installation 17. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Note: If you are reusing the existing sensor, align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 18. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor Replacement > Page 1538 19. Install the connector to the sensor. 20. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (3) for the centering pin-Note location of the pin hole. * A flush rotor flange cuff (5) * An alignment mark (4) for installation * A foam ring (6) 21. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * An alignment tab (2) for installing the sensor to the adapter and bearing assembly Note: If you are reusing the existing sensor, align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 22. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 23. Install the connector to the sensor. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > Page 1544 Tire Pressure Sensor: Testing and Inspection Tire Pressure Indicator Sensor Learn Special Tools J-46079 Tire Pressure Monitor Diagnostic Tool Learn Mode Description The tire pressure monitor (TPM) system uses the instrument panel cluster (IPC), body control module (BCM), remote control door lock receiver (RCDLR), keyless entry transmitter, 4 radio frequency transmitting pressure sensors, and the serial data circuit to perform the TPM learn mode functions. The sensor learn procedure must be performed after every tire rotation, RCDLR replacement, or sensor replacement. Once the learn mode has been enabled, each of the sensors unique identification codes can be learned into the RCDLR memory. When a sensor ID has been learned, the RCDLR sends a serial data message to the BCM to sound a horn chirp. This verifies the sensor has transmitted its ID and the RCDLR has received and learned it. The RCDLR must learn the sensor IDs in the proper sequence to determine correct sensor location. The first learned ID is assigned to the left front location, the second to right front, the third to right rear and the fourth to left rear. The turn signals will individually illuminate indicating which location is to be learned in the proper sequence. Sensor Functions Using J-46079 Each sensor has an internal low frequency coil. When the J-46079 is used in activate mode, it produces a low frequency transmission that activates the sensor. The sensor responds to a low frequency activation by transmitting in learn mode. When the RCDLR receives a learn mode transmission while in TPM learn mode, it will assign that sensors ID to the location on the vehicle relative to the order in which it was learned. Sensor Functions Using Pressure Increase/Decrease Method Each sensor takes a pressure measurement sample once every 30 seconds while in stationary mode. If the tire pressure increases, or decreases by more than 8.3 kPa (1.2 psi) from the last pressure measurement, another measurement will occur immediately to verify the change in pressure. If a pressure change has indeed occurred, the sensor transmits in Learn mode. When the RCDLR receives a Learn mode transmission while in TPM learn mode, it will assign that sensor's ID to the location on the vehicle relative to the order in which it was learned. Learn Mode Cancellation The learn mode will cancel if the ignition is cycled to OFF or if more than 2 minutes has elapsed for any sensor that has not been learned. If the learn mode is cancelled before the first sensor is learned, the original sensor IDs will be maintained. If the learn mode is canceled after the first sensor is learned, the following will occur: * All stored sensor IDs will be invalidated in the RCDLR memory. * If equipped, the DIC will display dashes instead of tire pressures. * DTC C0775 will be set. These conditions will now require the learn procedure to be repeated for the system to function properly. TPM Learn Procedure Note: If using the scan tool to enable the learn mode, the J-46079 must be used to activate the sensors. When this preferred method is used, any stray sensor signals will not affect the learn procedure. In the event a particular sensor's information is displayed on the special tool upon activation but the horn does not chirp, it may be necessary to rotate the wheel valve stem to a different position due to the sensor signal is being blocked by another component. If using the keyless entry transmitter or DIC buttons to enable the learn mode, the J-46079 or Pressure Increase/Decrease Method may be used. Before proceeding with this method, ensure that no other learn procedure is being performed simultaneously or that tire pressures are not being adjusted on another TPM equipped vehicle within close proximity. Stray signals from other TPM equipped vehicles just driving by can be inadvertently learned. If any random horn chirps are heard from the vehicle while performing the learn procedure, most likely a stray sensor has been learned and the procedure will need to be cancelled and repeated. Under these circumstances, performing the TPM Learn Procedure away from other vehicles would be highly recommended. In the event a particular sensor activation does not cause the horn to chirp, it may be necessary to rotate the wheel valve stem to a different position due to the sensor signal is being blocked by another component. Preferred Scan Tool Learn Enable Method 1. Using a scan tool, initiate the TPM Learn Mode. A double horn chirp will sound indicating the Learn Mode has been enabled. The left front turn signal will also be illuminated. 2. Starting with the left front tire, active the sensor by holding the antenna of the J-46079 aimed upward against the tire sidewall close to the wheel rim at the valve stem location. Press and release the Activate button and wait for a horn chirp. Once the horn chirp has sounded, the sensor information is learned and the turn signal in the next location to be learned will illuminate. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > Page 1545 3. After the horn chirp has sounded and the right front turn signal is illuminated, repeat step 2 for the remaining 3 sensors in the following order: 1. Right front 2. Right rear 3. Left rear 4. When the left rear sensor has been learned and a double horn chirp has sounded, the learn process is complete and the RCDLR exits the learn mode. 5. Ignition OFF, adjust all tires to the recommended pressures. Refer to Vehicle Certification, Tire Placard, Anti-Theft, and Service Parts ID Label ( See: Application and ID/Vehicle Certification, Tire Placard, Anti-Theft and Service Parts ID Label). Alternate Keyless Entry Transmitter or DIC Learn Enable Method 1. Ignition ON, initiate the TPM Learn Mode using one of the following procedures: * On vehicles equipped with keyless entry, simultaneously press the keyless entry transmitters lock and unlock buttons until a double horn chirp sounds indicating the Learn Mode has been enabled. The left front turn signal will also be illuminated. * On vehicles not equipped with keyless entry, press and release the driver information center (DIC) INFO button until the TIRE LEARN message appears on the DIC display. Press and hold the SET/RESET button until a double horn chirp sounds indicating the Learn Mode has been enabled. The left front turn signal will also be illuminated. 2. Starting with the left front tire, learn the tire pressure using one of the following methods: * Hold the antenna of the J-46079 aimed upward against the tire sidewall close to the wheel rim at the valve stem location. Press and release the activate button and wait for a horn chirp. Once the horn chirp has sounded, the sensor information is learned and the turn signal in the next location to be learned will illuminate. Warning Over inflating tires may cause personal injury or damage to the tires and wheels. When increasing tire pressure do not exceed the maximum inflation pressure as noted on the tire sidewall. * Increase/decrease the tire pressure for 8-10 seconds then wait for a horn chirp. The horn chirp may occur before or up to 30 seconds after the 8-10 second pressure increase/decrease time period has been reached. Once the horn chirp has sounded, the sensor information is learned and the turn signal in the next location to be learned will illuminate. 3. After the horn chirp has sounded and the right front turn signal is illuminated, repeat step 2 for the remaining 3 sensors in the following order: 1. Right front 2. Right rear 3. Left rear 4. When the left rear sensor has been learned and a double horn chirp has sounded, the learn process is complete and the RCDLR exits the learn mode. 5. Ignition OFF, adjust all tires to the recommended pressures. Refer to Vehicle Certification, Tire Placard, Anti-Theft, and Service Parts ID Label ( See: Application and ID/Vehicle Certification, Tire Placard, Anti-Theft and Service Parts ID Label). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement (Clamp In Style) Tire Pressure Sensor: Service and Repair Tire Pressure Indicator Sensor Replacement (Clamp In Style) Tire Pressure Indicator Sensor Replacement (Clamp In Style) Removal Procedure 1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the tire/wheel assembly from the vehicle. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). Note: Before the tire is removed from the wheel, note the following items to avoid tire pressure sensor damage upon tire dismounting: * Place the sensors cap and valve on a dry clean surface after removal. The cap is aluminum and the valve is nickel plated to prevent corrosion and are not to be substituted with a cap or valve made of any other material. * When separating the tire bead from the wheel, position the bead breaking fixture 90 degrees from the valve stem. * Position the mounting/dismounting head so the tire iron, or pry bar can be inserted slightly clockwise of the sensor body when prying the tire bead up and over the mounting/dismounting head. * Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the out side of the wheel rim. * Repeat items for inner bead. 3. Remove the tire from the wheel. Refer to Tire Dismounting and Mounting (See: Maintenance/Wheels and Tires/Tires/Service and Repair/Removal and Replacement). Note: If any tire sealant is noted upon tire dismounting, remove all residual liquid sealant from the inside of the tire and wheel surfaces. 4. Remove the tire pressure sensor nut. 5. Remove the tire pressure sensor. Installation Procedure 1. Clean any dirt or debris from the grommet sealing area. 2. Insert the sensor in the wheel hole with the air passage facing away from the wheel. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the sensor nut and position the sensor body parallel to the inside wheel surface while torquing. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement (Clamp In Style) > Page 1548 Tighten the sensor nut to 7 Nm (62 lb in). Note: Before reinstalling the tire on the wheel, note the following items to avoid tire pressure sensor damage upon tire mounting: * Position the mounting/dismounting head 180 degrees from the valve stem. * Position the bead transition area 45 degrees counterclockwise of the valve stem. * Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the inside of the wheel rim. * Repeat items for outer bead. 4. Install the tire on the wheel. Refer to Tire Dismounting and Mounting (See: Maintenance/Wheels and Tires/Tires/Service and Repair/Removal and Replacement). Note: A service replacement tire pressure sensor is shipped in OFF mode. In this mode the sensor unique identification code cannot be learned into the remote control door lock receiver (RCDLR) memory. The sensor must be taken out of OFF mode by spinning the tire/wheel assembly above 32 km/h (20 mph) in order to close the sensors internal roll switch for at least 10 seconds. 5. Install the tire/wheel assembly on the vehicle. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 6. Lower the vehicle. 7. Learn the tire pressure sensors. Refer to Tire Pressure Indicator Sensor Learn (See: Instrument Panel, Gauges and Warning Indicators/Tire Monitoring System/Service and Repair/Service Manual Tire Pressure Sensor Learn). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement (Clamp In Style) > Page 1549 Tire Pressure Sensor: Service and Repair Tire Pressure Indicator Sensor Replacement (Snap In Style) Tire Pressure Indicator Sensor Replacement (Snap In Style) Removal Procedure 1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the tire/wheel assembly from the vehicle. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 3. Dismount the tire from the rim. Refer to Tire Dismounting and Mounting (See: Maintenance/Wheels and Tires/Tires/Service and Repair/Removal and Replacement). Note: When servicing the tire pressure sensor always use a new Schrader(R) tire pressure monitor (TPM) and a new TORX screw during installation. 4. Remove the TORX screw (1) from the tire pressure sensor (2) and pull it straight off the tire pressure valve stem (3). Caution: Do not scratch or damage the clear coating on aluminum wheels with the tire changing equipment. Scratching the clear coating could cause the aluminum wheel to corrode and the clear coating to peel from the wheel. 5. Remove the tire pressure valve stem by pulling it through the rim. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement (Clamp In Style) > Page 1550 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Note: * Ensure the flat of the valve, lines up with the flats of the snap in the enclosure. * TPM valves and TORX screws are one-time use only. 1. Assemble the tire pressure sensor (2) to the valve stem and install the new TORX screw (3) and tighten to 1.3 Nm (11.5 lb in). Note: Use and approved tire mounting lubricant. DO NOT use silicon or corrosive base compounds to lubricate the tire bead and the wheel rim. A corrosive type compound can cause tire or rim deterioration. 2. Apply tire soap to the rubber portion of the valve stem (1). 3. Using a tire valve stem mounting tool, pull the valve stem through in a direction parallel to the valve hole on the rim. Note: Snap Fit TPM sensors are still shipped in the OFF mode. However, the TPM no longer needs to be spun to remove it from the OFF mode. The sensor will exit its OFF state when the tire is inflated. The technician can then program the vehicle as normal. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement (Clamp In Style) > Page 1551 4. Mount the tire to the rim. Refer to Tire Dismounting and Mounting (See: Maintenance/Wheels and Tires/Tires/Service and Repair/Removal and Replacement). 5. Install the tire/wheel assembly on the vehicle. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 6. Lower the vehicle. 7. Learn the tire pressure sensors. Refer to Tire Pressure Indicator Sensor Learn (See: Instrument Panel, Gauges and Warning Indicators/Tire Monitoring System/Service and Repair/Service Manual Tire Pressure Sensor Learn). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations Fluid Pressure Sensor/Switch: Locations Disassembled Views Control Valve Body Assembly 1 - Control Valve Body Assembly 2 - Shift Valve Body Assembly 3 - Separator Plate 4 - Main Valve Body Assembly 5 - Transmission Fluid Pressure (TFP) Switch 6 - Main Valve Body Assembly Bolt, M6 x 10 x 50, Flanged Head (23) 7 - Reverse Signal Pipe 8 - Reverse Signal Pipe Bolt, M6 x 10 x 50, Flanged Head 9 - Retaining Clip 10 - Modulated Main Valve Body 11 - Bolt, M6 x 10 x 65 12 Bolt, M6 x 10 x 50 13 - O-Rings 14 - Modulated Main Pressure (MAIN MOD) Solenoid 15 - 6 Speed Pipe Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 1557 Fluid Pressure Sensor/Switch: Diagrams Component Connector End Views Pressure Switch Manifold (PSM) (MW7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 1558 Fluid Pressure Sensor/Switch: Service and Repair Pressure Switch Manifold Replacement Removal Procedure Note: Individual pressure switches cannot be replaced. When any pressure switch needs replacing, the entire assembly must be replaced. Note: The modulated main pressure (MAIN MOD) solenoid has been removed for clarity. 1. Remove the oil pan and transmission internal oil filter. Refer to Oil Pan Replacement (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Fluid Pan/Service and Repair). Warning: Refer to Battery Disconnect Warning (See: Starting and Charging/Battery/Service Precautions). 2. Disconnect the internal wiring harness connector from the transmission fluid pressure (TFP) switch (2). 3. Remove six bolts (1). Remove the TFP switch (2). Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 1559 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Place the new TFP manifold assembly (2) in position and install one bolt (1) in a recessed location to hold in position. Start the remaining five bolts (1) in recessed locations and tighten the bolts by hand. Torque the bolts to 12 Nm (108 lb in). 2. Connect the internal wiring harness connector to the TFP switch. 3. Install the oil pan and transmission internal oil filter. Refer to Oil Pan Replacement (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Fluid Pan/Service and Repair). Note: The FastLearn, adapt, procedure must be performed. This can be done in 1 step using a scan tool. If this procedure is not done, the TCM adaptive values will be at the settings that it learned for the old components and will be in slow adaptive mode. Under these conditions, it will take an unacceptably long time for the adaptive values to converge to levels suitable for the new transmission. 4. Perform the FastLearn procedure. Refer to FastLearn Procedure (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Testing and Inspection/Programming and Relearning). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON Transmission Mode Switch: Customer Interest A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 1568 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 1569 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 1570 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON Transmission Mode Switch: All Technical Service Bulletins A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 1576 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 1577 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 1578 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > Page 1579 Transmission Mode Switch: Diagrams Component Connector End Views Automatic Transmission Internal Mode Switch (MW7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > Page 1580 Transmission Mode Switch: Service and Repair Transmission Internal Mode Switch Replacement Important: The Internal Mode Switch (IMS) is mounted to the manual shift shaft detent lever as an assembly. The components of the detent lever/IMS assembly cannot be individually serviced. When the IMS needs replacing, the entire assembly must be replaced. Replace the IMS. Refer to Manual Shift Shaft, Detent Lever, and Position Switch Assembly Replacement (See: Transmission Position Switch/Sensor/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams Transmission Position Switch/Sensor: Diagrams Component Connector End Views Park/Neutral Position (PNP) Switch (M30) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 1584 Transmission Position Switch/Sensor: Service and Repair Manual Shift Shaft, Detent Lever, and Position Switch Assembly Replacement Removal Procedure 1. Remove the control valve assembly from the transmission. Refer to Control Valve Body Replacement (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Valve Body/Service and Repair). Note: The detent lever/IMS retaining bolt contains patch lock material on the threads. Do not reuse the retaining bolt. 2. Remove the detent lever/IMS retaining bolt (1) using a T27 TORX(R) bit and discard the retaining bolt. Caution: DO NOT mar the transmission case surface around the spherical pin when removing or installing the spherical pin. An unmarred surface is required to maintain the seal between the control valve assembly and the transmission case. Caution: DO NOT twist the spherical pin when removing the pin from the transmission case. Damage to the transmission case can occur. 3. Place a protective plate on the transmission case surface around the spherical pin (3). Remove the spherical pin (3) from the transmission case. 4. Slide the manual shift shaft (5) through the detent lever/IMS assembly (4) and through the manual shift shaft seal. 5. Rotate the detent lever/IMS assembly to disengage the park pawl apply assembly (2). Remove the detent lever/IMS assembly (4). Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 1585 1. Place the new detent lever/IMS assembly (4) in position in the transmission case. Rotate the detent lever/IMS assembly to engage the park pawl apply assembly (2). Reinstall the manual shift shaft (5) through the manual shift shaft seal and through the detent lever/IMS assembly (4). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Push the manual shift shaft (5) into the final position in the transmission case. 3. Install the spherical pin (3) into the transmission case that retains the manual shift shaft. 4. Install the detent lever/IMS retaining bolt (1) using a T27 TORX(R) bit. Tighten the bolt (1) to 10 Nm (92 lb in). 5. Install the control valve assembly. Refer to Control Valve Body Replacement (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Valve Body/Service and Repair). Note: The FastLearn, adapt, procedure must be performed. This can be done in 1 step using a scan tool. If this procedure is not done, the TCM adaptive values will be at the settings that it learned for the old components and will be in slow adaptive mode. Under these conditions, it will take an unacceptably long time for the adaptive values to converge to levels suitable for the new transmission. 6. Perform the FastLearn procedure. Refer to FastLearn Procedure (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Testing and Inspection/Programming and Relearning). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Component Locations Transmission Speed Sensor: Component Locations Disassembled Views Automatic Transmission Case 1 - Automatic Transmission Case 2 - Transmission Case Locating Pin 3 - Transmission Vent Assembly 4 - Transmission Vent Cap 5 - Transmission Vent 6 - Nameplate Rivet 7 - Nameplate 8 Vehicle Speed Sensor Bolt, M6 x 1.0 x 13 9 - Sensor Shipping Cover 10 - Turbine Speed Sensor 11 - Vehicle Speed Sensor O-Ring 12 - Power Take-Off (PTO) Cover Gasket (2) 13 - PTO Cover (2) 14 - PTO Cover Bolt, M10 x 1.5 x 20, Flanged Head, Coated (12) 16 - Manual Shift Shaft 17 Manual Shift Shaft Seal 18 - Manual Shift Shaft Pin 19 - Manual Shift Shaft Detent Lever/Internal Mode Switch (IMS) Assembly 20 - Park Pawl Assembly 21 - Control Valve Body Locating Pin 22 Detent Lever/IMS Bolt 23 - Connector Shipping Cover 24 - Control Valve Body Assembly 25 Control Valve Body Bolt, M6 x 1.0 x 50, Flanged Head (15) 26 - Manual Shift Shaft Detent Spring 27 - Manual Shift Shaft Detent Spring Bolt M6 x 1.0 x 12. Flanged Head (2) 28 - Transmission Wiring Harness Assembly Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Component Locations > Page 1590 Transmission Speed Sensor: Connector Locations Harness Routing Views Engine Chassis Harness Routing - Rear (Diesel) 1 - X300 2 - G300 3 - Automatic Transmission Turbine Speed Sensor (MW7) 4 - Automatic Transmission (MW7) 5 - Vehicle Speed Sensor (VSS) (MW7) 6 - X124 (PTO) 7 - Power Take Off (PTO) Module (PTO) 8 - X175 (MW7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 1591 Transmission Speed Sensor: Diagrams Component Connector End Views Automatic Transmission Input Shaft Speed (ISS) Sensor (M30) Automatic Transmission Turbine Speed Sensor (MW7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 1592 Output Speed Sensor (OSS) (M99) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 1593 Transmission Speed Sensor: Service and Repair Speed Sensor Replacement Removal Procedure Warning: Refer to Battery Disconnect Warning (See: Starting and Charging/Battery/Service Precautions). 1. Be sure the vehicle ignition is turned off. 2. Disconnect the external wiring harness from the speed sensor. 3. Remove the bolt (1) from the speed sensor and carefully remove the speed sensor (2). Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 1594 Note: Do not rotate the sensor in its retaining bracket. Changing the sensor/bracket orientation may cause improper operation. 1. Install a new a O-ring on the speed sensor (2). Lubricate the O-ring with clean transmission fluid. 2. Install the new speed sensor (2) into the speed sensor bore. Align the hole in the retaining bracket with the bolt hole in the speed sensor boss. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the speed sensor bolt (1). Tighten bolt to 12 Nm (108 lb in). 4. Reconnect the external wiring harness to the speed sensor. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams Transmission Temperature Sensor/Switch: Diagrams Component Connector End Views Automatic Transmission Fluid Temperature (TFT) Sensor (M30) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Clutch Pedal Position Sensor / Switch > Component Information > Testing and Inspection Clutch Pedal Position Sensor / Switch: Testing and Inspection Clutch Pedal Position Sensor Learn Important: The clutch pedal position (CPP) sensor learn procedure is required when the following service procedures have been performed regardless of whether DTC P080A is set: * An engine control module (ECM) replacement * A CPP sensor replacement * Any repairs which affect the CPP sensor relationship 1. Install a scan tool. 2. Monitor the ECM for DTCs with a scan tool. If other DTCs are set, except DTC P080A, refer to Diagnostic Trouble Code (DTC) List - Vehicle ( See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle) for the applicable DTC that set. 3. With a scan tool, select Clutch Pedal Position Learn under Module Setup in Manual Transmission, and perform the following instructions displayed on the scan tool screen. Important: The CPP sensor learn procedure cannot be performed more than once per ignition cycle. The clutch pedal needs to be fully depressed and held steady throughout this procedure in order to perform a correct learning. 4. The scan tool will display under CPP Learn Status: Not Learned, In Process, Complete, Fail Low Volt, Fail - High Volt, or Fail Moving. The scan tool will display under CPP Learn Status Complete if the process was successful. 5. If the scan tool indicates that DTC P080A ran and passed this ignition the CPP sensor learn procedure is complete. If the scan tool indicates DTC P080A failed or did not run this ignition, refer to DTC P080A (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P080A/Tremec 5-Speed (TZ0) - Manual Transmission). If any other DTC is set, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle) for the applicable DTC. 6. Turn OFF the ignition for 30 seconds after the learn procedure has successfully completed in order to store the CPP sensor variation values in ECM history. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Clutch Pedal Position Sensor / Switch > Component Information > Testing and Inspection > Page 1602 Clutch Pedal Position Sensor / Switch: Service and Repair Clutch Pedal Engine Start Switch Replacement Removal Procedure 1. Disconnect the clutch pedal position switch electrical connector (1). 2. Remove the plastic retainer (1) tabs from the clutch pedal position switch (2). 3. Remove the clutch pedal position switch (2) from the pushrod. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Clutch Pedal Position Sensor / Switch > Component Information > Testing and Inspection > Page 1603 1. Install the clutch pedal position switch (2) to the pushrod. 2. Install the plastic retainer (1) tabs to the clutch pedal position switch (2). 3. Connect the clutch pedal position switch electrical connector (1). Warning Replacement or reprogramming of the ECM, or replacement of the clutch pedal position sensor (CPPS) or clutch pedal requires that a CPPS learn procedure be performed. Failure to perform the CPPS learn procedure may result in personal injury or damage to the vehicle or its components if the vehicle is in gear and the starter motor is accidentally engaged. 4. Perform the clutch pedal position sensor learn procedure. Refer to DTC P080A (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P080A/Tremec 5-Speed (TZ0) - Manual Transmission) or Clutch Pedal Position Sensor Learn (See: Transmission and Drivetrain/Manual Transmission/Transaxle/Testing and Inspection/Component Tests and General Diagnostics). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Power Take-Off > Power Take-Off Switch > Component Information > Diagrams Power Take-Off Switch: Diagrams Component Connector End Views Power Take-Off (PTO) Switch (PTO) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations Four Wheel Drive Selector Switch: Locations Harness Routing Views Engine Harness Routing - Rear (4.8L/5.3L/6.0L/6.2L except LFA/HP2) 1 - Dash Panel 2 - Transmission 3 - X175 (M30) 4 - Transfer Case Shift Control Switch (NQG) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 1612 Four Wheel Drive Selector Switch: Diagrams Component Connector End Views Transfer Case Shift Control Switch (NQF or NQH) Transfer Case Shift Control Switch (NQG) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 1613 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case Four Wheel Drive Selector Switch: Service and Repair MP 1625/1626-NQF - Transfer Case Transfer Case Shift Control Switch Replacement (Without SLT) Transfer Case Shift Control Switch Replacement (Without SLT) Transfer Case Shift Control Switch Replacement (With SLT) Transfer Case Shift Control Switch Replacement (With SLT) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case > Page 1616 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case > Page 1617 Four Wheel Drive Selector Switch: Service and Repair MP 3023/3024-NQH - Transfer Case Transfer Case Shift Control Switch Replacement (With SLT) Transfer Case Shift Control Switch Replacement (With SLT) Transfer Case Shift Control Switch Replacement (Without SLT) Transfer Case Shift Control Switch Replacement (Without SLT) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case > Page 1618 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams Gear Sensor/Switch: Diagrams Component Connector End Views Transfer Case 2/4 Wheel Drive Actuator Position Sensor (NQH) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair Speed Sensor: Service and Repair Transfer Case Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the speed sensor electrical connector (4). 3. Remove the speed sensor and O-ring. 4. Discard the O-ring. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Page 1625 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the speed sensor with a NEW O-ring. Tighten the sensor to 17 Nm (13 lb ft). 2. Connect the speed sensor electrical connector (4). 3. Lower the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations Power Window Switch: Locations Harness Routing Views Overhead Console Harness Routing 1 - X304 (except MEX) 2 - Inflatable Restraint Passenger Air Bag On/Off Indicator (AL0/C99 except MEX) 3 - Cellular Telephone Microphone (UE1/U3U/UVB) 4 - Roof Beacon Switch (5X7/5Y0/TRW) 5 - Sliding Rear Window Switch (A48) 6 - Dome/Reading Lamps - Front 7 - J322 (TRW/UG1/A48) 8 - J323 9 - X313 (CF5/TRW/5X7/5Y0) 10 - Blunt Cut - Roof Mounted Beacon Provision (TRW) 11 Roof Beacon Relay (TRW) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 1630 Power Window Switch: Diagrams Component Connector End Views Door Lock Switch - Driver (AU3 without AN3 or DL3) Door Lock Switch - Passenger (AU3 without AN3 or DL3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 1631 Door Lock/Window Switch - Driver X1 (AN3 or DL3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 1632 Door Lock/Window Switch - Driver X2 (AN3 or DL3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 1633 Door Lock/Window Switch - Driver X3 (AN3 or DL3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 1634 Door Lock/Window Switch - Driver X4 (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 1635 Door Lock/Window Switch - Driver X7 (AN3 or DL3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 1636 Door Lock/Window Switch - Passenger X1 (AN3 or DL3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 1637 Door Lock/Window Switch - Passenger X2 (AN3 or DL3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 1638 Door Lock/Window Switch - Passenger X3 (AN3 or DL3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 1639 Door Lock/Window Switch - Passenger X4 (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 1640 Door Lock/Window Switch - Passenger X7 (AN3 or DL3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 1641 Sliding Rear Window Switch (A48) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 1642 Window Switch - Driver X1 (A31 without AN3 or DL3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 1643 Window Switch - Driver X2 (A31 without AN3 or DL3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 1644 Window Switch - Left Rear (Crew Cab with A31 or Extended Cab with ABV) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 1645 Window Switch - Passenger (A31 without AN3 or DL3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 1646 Window Switch - Right Rear (Crew Cab with A31 or Extended Cab with ABV) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 1647 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Front Side Door Window and Rear Side Door Window Switch Replacement (with DL8 and without SLT) Power Window Switch: Service and Repair Front Side Door Window and Rear Side Door Window Switch Replacement (with DL8 and without SLT) Front Side Door Window and Rear Side Door Window Switch Replacement (with DL8 and without SLT) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Front Side Door Window and Rear Side Door Window Switch Replacement (with DL8 and without SLT) > Page 1650 Power Window Switch: Service and Repair Rear Side Door Window Switch Replacement (Extended Cab) Rear Side Door Window Switch Replacement (Extended Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Front Side Door Window and Rear Side Door Window Switch Replacement (with DL8 and without SLT) > Page 1651 Power Window Switch: Service and Repair Rear Side Door Window Switch Replacement (Crew Cab) Rear Side Door Window Switch Replacement (Crew Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Front Side Door Window and Rear Side Door Window Switch Replacement (with DL8 and without SLT) > Page 1652 Power Window Switch: Service and Repair Door Lock and Side Window Switch Replacement Driver Side Door Lock and Side Window Switch Replacement - Driver Side Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Front Side Door Window and Rear Side Door Window Switch Replacement (with DL8 and without SLT) > Page 1653 Power Window Switch: Service and Repair Door Lock and Side Window Switch Replacement Passenger Side Door Lock and Side Window Switch Replacement - Passenger Side Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Rain Sensor > Component Information > Diagrams Rain Sensor: Diagrams Component Connector End Views Windshield Outside Moisture Sensor (CE1) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Rain Sensor > Component Information > Service and Repair > Windshield Outside Moisture Sensor Replacement Rain Sensor: Service and Repair Windshield Outside Moisture Sensor Replacement Windshield Outside Moisture Sensor Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Rain Sensor > Component Information > Service and Repair > Windshield Outside Moisture Sensor Replacement > Page 1660 Rain Sensor: Service and Repair Windshield Outside Moisture Sensor Lens Replacement Windshield Outside Moisture Sensor Lens Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Diagrams Washer Fluid Level Switch: Diagrams Component Connector End Views Windshield Washer Fluid Level Switch Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Diagrams > Page 1664 Washer Fluid Level Switch: Service and Repair Windshield Washer Solvent Level Switch Replacement (Chevrolet) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications Alignment: Technical Service Bulletins Steering/Suspension - Wheel Alignment Specifications WARRANTY ADMINISTRATION Bulletin No.: 05-03-07-009C Date: December 09, 2010 Subject: Wheel Alignment Specifications, Requirements and Recommendations for GM Vehicles Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks Supercede: This bulletin is being extensively revised to provide technicians and warranty administrators with an all inclusive guide for wheel alignments. PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM WHEEL ALIGNMENT SERVICE. Please discard Corporate Bulletin Number 05-03-07-009B (Section 03 - Suspension). Purpose The purpose of this bulletin is to provide retail, wholesale and fleet personnel with General Motors' warranty service requirements and recommendations for customer concerns related to wheel alignment. For your convenience, this bulletin updates and centralizes all of GM's Standard Wheel Alignment Service Procedures, Policy Guidelines and bulletins on wheel alignment warranty service. Important PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM WHEEL ALIGNMENT SERVICE. The following five (5) key steps are a summary of this bulletin and are REQUIRED in completing a successful wheel alignment service. 1. Verify the vehicle is in an Original Equipment condition for curb weight, tires, wheels, suspension and steering configurations. Vehicles modified in any of these areas are not covered for wheel alignment warranty. 2. Review the customer concern relative to "Normal Operation" definitions. 3. Verify that vehicle is within the "Mileage Policy" range. 4. Document wheel alignment warranty claims appropriately for labor operations E2000 and E2020. The following information must be documented or attached to the repair order: - Customer concern in detail - What corrected the customer concern? - If a wheel alignment is performed: - Consult SI for proper specifications. - Document the "Before" AND "After" wheel alignment measurements/settings. - Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin) 5. Use the proper wheel alignment equipment (preferred with print-out capability), process and the appropriate calibration maintenance schedules. Important If it is determined that a wheel alignment is necessary under warranty, use the proper labor code for the repair. E2000 for Steering Wheel Angle and/or Front Toe set or E2020 for Wheel Alignment Check/Adjust includes Caster, Camber and Toe set (Wheel alignment labor time for other component repairs is to be charged to the component that causes a wheel alignment operation.). The following flowchart is to help summarize the information detailed in this bulletin and should be used whenever a wheel alignment is performed. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 1670 Verify Original Equipment Condition of the Vehicle - Verify that Original Equipment Tires and Wheels or Official GM Accessory Tires and Wheels are on the vehicle. - Verify that aftermarket suspension "Lift" or "Lowering" Kits or other suspension alterations have NOT been done to the vehicle. - Check for accidental damage to the vehicle; for example, severe pothole or curb impacts, collision damage that may have affected the wheel alignment of the vehicle; e.g., engine cradles, suspension control arms, axles, wheels, wheel covers, tires may show evidence of damage/impact. - Check to be sure vehicle has seen "Normal Use" rather than abuse; e.g., very aggressive driving may show up by looking at the tires and condition of the vehicle. - Check for other additional equipment items that may significantly affect vehicle mass such as large tool boxes, campers, snow plow packages (without the snowplow RPO), etc., especially in trucks and cutaway/incomplete vehicles. Significant additional mass can affect trim height and wheel alignment of the vehicle and may necessitate a customer pay wheel alignment when placed semi-permanently in the vehicle (Upfitter instructions are to realign the vehicle after placement of these types of items. (This typically applies to trucks and incomplete vehicles that can be upfit with equipment such as the above.) Customer Concerns, "Normal Operation" Conditions and "Mileage Policy" Possible Concerns The following are typical conditions that may require wheel alignment warranty service: 1. Lead/Pull: defined as "at a constant highway speed on a typical straight road, the amount of effort required at the steering wheel to maintain the vehicle's straight heading." Important Please evaluate for the condition with hands-on the steering wheel. Follow the "Vehicle Leads/Pulls" diagnostic tree located in SI to determine the cause of a lead/pull concern. Lead/Pull concerns can be due to road crown or road slope, tires, wheel alignment or even in rare circumstances a steering gear issue. Lead/pull concerns due to road crown are considered "Normal Operation" and are NOT a warrantable condition -- the customer should be advised that this is "Normal Operation." Important Some customers may comment on a "Lead/Pull" when they hold the steering wheel in a level condition. If so, this is more likely a "steering wheel angle" concern because the customer is "steering" the vehicle to obtain a "level" steering wheel. 2. Steering wheel angle to the left or right (counter-clockwise or clockwise, respectively): Defined as the steering wheel angle (clocking) deviation from "level" while maintaining a straight heading on a typical straight road. 3. Irregular or Premature tire wear: Slight to very slight "feathering" or "edge" wear on the shoulders of tires is NOT considered unusual and should even out with a tire rotation; if the customer is concerned about a "feathering" condition of the tires, the customer could be advised to rotate the tires earlier than the next scheduled mileage/maintenance interval (but no later than the next interval). Be sure to understand the customer's driving habits as this will also heavily influence the tire wear performance; tire wear from aggressive or abusive driving habits is NOT a warrantable condition. Important Slight or mild feathering, cupping, edge or heel/toe wear of tire tread shoulders is "normal" and can show up very early in a tire/vehicle service mileage; in fact, some new tires can show evidence of feathering from the factory. These issues do NOT affect the overall performance and tread life of the tire. Dealer personnel should always check the customer's maintenance records to ensure that tire inflation pressure is being maintained to placard and that the tires are being rotated (modified-X pattern) at the proper mileage intervals. Wheel alignments are NOT to be performed for the types of "Normal" Tire Feathering shown in Figures 1-4 below. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 1671 Figure 1: Full Tread View - "NORMAL" Tire "Feathering" Wear on the Shoulder/Adjacent/Center Ribs Figure 2: Tire Shoulder View Example 1 - "NORMAL" Tire "Feathering" Wear on the Shoulder Figure 3: Tire Shoulder View Example 2 - "NORMAL" Tire "Feathering" Wear Figure 4: Detail Side View of Tire Shoulder Area - "NORMAL" Tire "Feathering" Wear Important When a wheel alignment is deemed necessary for tire wear, be sure to document on the repair order, in as much detail as possible, the severity and type of tire wear (e.g., severe center wear or severe inside or outside shoulder wear) and the position of the tire on the vehicle (RF, LF, LR, RR). Please note the customer's concern with the wear such as, noise, appearance, wear life, etc. A field product report with pictures of the tire wear condition is recommended. Refer to Corporate Bulletin Number 02-00-89-002J and #07-00-89-036C. 4. Other repairs that affect wheel alignment; e.g., certain component replacement such as suspension control arm replacement, engine cradle adjustment/replace, steering gear replacement, steering tie rod replace, suspension strut/shock, steering knuckle, etc. may require a wheel alignment. Important If other components or repairs are identified as affecting the wheel alignment, policy calls for the wheel alignment labor time to be charged to the replaced/repaired component's labor operation time rather than the wheel alignment labor operations. Important Vibration type customer concerns are generally NOT due to wheel alignment except in the rare cases; e.g., extreme diagonal wear across the tread. In general, wheel alignments are NOT to be performed as an investigation/correction for vibration concerns. "Normal Operation" Conditions Vehicle Lead/Pull Due to Road Crown or Slope: As part of "Normal Operation," vehicles will follow side-to-side or left to right road crown or slope. Be sure to verify from the customer the types of roads they are driving as they may not recognize the influence of road crown on vehicle lead/pull and steering wheel angle. If a vehicle requires significant steering effort to prevent it from "climbing" the road crown there may be an issue to be looked into further. Important Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 1672 A wheel alignment will generally NOT correct vehicles that follow the road crown since this is within "Normal Operation." Mileage Policy The following mileage policy applies for E2020 and E2000 labor operations: Note Wheel Alignment is NOT covered under the New Vehicle Limited Warranty for Express and Savana Cutaway vehicles as these vehicles require Upfitters to set the wheel alignment after completing the vehicles. - 0-800 km (0-500 mi): E2000/E2020 claims ONLY allowed with Call Center Authorization. Due to the tie down during shipping, the vehicle's suspension requires some time to reach normal operating position. For this reason, new vehicles are generally NOT to be aligned until they have accumulated at least 800 km (500 mi). A field product report should accompany any claim within this mileage range. - 801-12,000 km (501-7,500 mi): - If a vehicle came from the factory with incorrect alignment settings, any resulting off-angle steering wheel, lead/pull characteristics or the rare occurrence of excessive tire wear would be apparent early in the life of the vehicle. The following policy applies: - Vehicles 100% Factory Set/Measured for Caster/Camber/Toe - Escalade/ESV/EXT, Tahoe/Suburban, Yukon/XL/Denali, Silverado/Sierra, Express/Savana, Corvette and Colorado/Canyon: E2000/E2020 Claims: Call Center Authorization Required - All Vehicles NOT 100% Factory Set/Measured for Caster/Camber/Toe as noted above: E2000/E2020 Claims: Dealer Service Manager Authorization Required - 12,001 km and beyond (7,501 miles and beyond): During this period, customers are responsible for the wheel alignment expense or dealers may provide on a case-by case basis a one-time customer enthusiasm claim up to 16,000 km (10,000 mi). In the event that a defective component required the use of the subject labor operations, the identified defective component labor operation will include the appropriate labor time for a wheel alignment as an add condition to the component repair. Important Only one wheel alignment labor operation claim (E2000 or E2020) may be used per VIN. Warranty Documentation Requirements When a wheel alignment service has been deemed necessary, the following items will need to be clearly documented on/with the repair order: - Customer concern in detail - What corrected the customer concern? - If a wheel alignment is performed: - Consult SI for proper specifications. - Document the "Before" AND "After" wheel alignment measurements/settings. - Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin) 1. Document the customer concern in as much detail as possible on the repair order and in the warranty administration system. Preferred examples: - Steering wheel is off angle in the counterclockwise direction by approximately x degrees or clocking position. - Vehicle lead/pulls to the right at approximately x-y mph. Vehicle will climb the road crown. Severe, Moderate or Slight. - RF and LF tires are wearing on the outside shoulders with severe feathering. Important In the event of a lead/pull or steering wheel angle concern, please note the direction of lead/pull (left or right) or direction of steering wheel angle (clockwise or counterclockwise) on the repair order and within the warranty claim verbatim. Important In the event of a tire wear concern, please note the position on the vehicle and where the wear is occurring on the tire; i.e., the RF tire is wearing on the inside shoulder. 2. Document the technician's findings on cause and correction of the issue. Examples: - Reset LF toe from 0.45 degrees to 0.10 degrees and RF toe from -0.25 degrees to 0.10 degrees to correct the steering wheel angle from 5 degrees counterclockwise to 0 degrees. - Reset LF camber from 0.25 degrees to -0.05 degrees to correct the cross-camber condition of +0.30 degrees to 0.00 degrees on the vehicle. - Front Sum toe was found to be 0.50 degrees, reset to 0.20 degrees. 3. Print-out the "Before" and "After" wheel alignment measurements/settings and attach them to the Repair Order or if print-out capability is not Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 1673 available, measurements may also be clearly and legibly handwritten into the Wheel Alignment Repair Order Questionnaire attached to this bulletin. 4. Attach the Wheel Alignment Repair Order Questionnaire below along with the print-out of "Before" and "After" wheel alignment measurements to the Repair Order and retain for use by GM. Wheel Alignment Equipment and Process Wheel alignments must be performed with a quality machine that will give accurate results when performing checks. "External Reference" (image-based camera technology) is preferred. Please refer to Corporate Bulletin Number 05-00-89-029B: General Motors Dealership Critical Equipment Requirements and Recommendations. Requirements: - Computerized four wheel alignment system. - Computer capable of printing before and after alignment reports. - Computer capable of time and date stamp printout. - Racking system must have jacking capability - Racking system must be capable of level to 1.6 mm (1/16 in) - Appropriate wheel stops and safety certification - Built-in turn plates and slip plates - Wheel clamps capable of attaching to 20" or larger wheels - Racking capable of accepting any GM passenger car or light duty truck - Operator properly trained and ASE-certified (U.S. only) in wheel alignment Recommendations: Racking should have front and rear jacking capability. Equipment Maintenance and Calibration: Alignment machines must be regularly calibrated in order to give correct information. Most manufacturers recommend the following: - Alignment machines with "internal reference" sensors should be checked (and calibrated, if necessary) every six months. - Alignment machines with "external reference" (image-based camera technology) should be checked (and calibrated, if necessary) once a year. - Racks must be kept level to within 1.6 mm (1/16 in). - If any instrument that is part of the alignment machine is dropped or damaged in some way, check the calibration immediately. Check with the manufacturer of your specific equipment for their recommended service/calibration schedule. Wheel Alignment Process When performing wheel alignment measurement and/or adjustment, the following steps should be taken: Preliminary Steps: 1. Verify that the vehicle has a full tank of fuel (compensate as necessary). 2. Inspect the wheels and the tires for damage. 3. Inspect the tires for the proper inflation and irregular tire wear. 4. Inspect the wheel bearings for excessive play. 5. Inspect all suspension and steering parts for looseness, wear, or damage. 6. Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or suspension components. 7. Inspect the vehicle trim height. 8. Compensate for frame angle on targeted vehicles (refer to Wheel Alignment Specifications in SI). Satisfactory vehicle operation may occur over a wide range of alignment angles. However, if the wheel alignment angles are not within the range of specifications, adjust the wheel alignment to the specifications. Refer to Wheel Alignment Specifications in SI. Give consideration to excess loads, such as tool boxes, sample cases, etc. Follow the wheel alignment equipment manufacturer's instructions. Measure/Adjust: Important Prior to making any adjustments to wheel alignment on a vehicle, technicians must verify that the wheel alignment specifications loaded into their wheel alignment machine are up-to-date by comparing these to the wheel alignment specifications for the appropriate model and model year in SI. Using incorrect and/or outdated specifications may result in unnecessary adjustments, irregular and/or premature tire wear and repeat customer concerns Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 1674 Important When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear wheel alignment angles first in order to obtain proper front wheel alignment angles. Perform the following steps in order to measure the front and rear alignment angles: 1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment angles and record the readings. If necessary, adjust the wheel alignment to vehicle specification and record the before and after measurements. Refer to Wheel Alignment Specifications in SI. Important Technicians must refer to SI for the correct wheel alignment specifications. SI is the only source of GM wheel alignment specifications that is kept up-to-date throughout the year. Test drive vehicle to ensure proper repair. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 1675 Frame Angle Measurement (Express / Savana Only) ........ Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 1676 What corrected the customer concern and was the repair verified? Please Explain: ............. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Trim Height Specifications Alignment: Specifications Trim Height Specifications Trim Height Specifications Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Trim Height Specifications > Page 1679 Alignment: Specifications Wheel Alignment Specifications Wheel Alignment Specifications Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Trim Height Specifications > Page 1680 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Caster Description Alignment: Description and Operation Caster Description Caster Description Caster is the tilting of the uppermost point of the steering axis either forward or backward, when viewed from the side of the vehicle. A backward tilt is positive (+) and a forward tilt is negative (-). Caster influences directional control of the steering but does not affect the tire wear. Caster is affected by the vehicle height, therefore it is important to keep the body at its designed height. Overloading the vehicle or a weak or sagging rear spring will affect caster. When the rear of the vehicle is lower than its designated trim height, the front suspension moves to a more positive caster. If the rear of the vehicle is higher than its designated trim height, the front suspension moves to a less positive caster. With too little positive caster, steering may be touchy at high speed and wheel returnability may be diminished when coming out of a turn. If one wheel has more positive caster than the other, that wheel will pull toward the center of the vehicle. This condition will cause the vehicle to pull or lead to the side with the least amount of positive caster. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Caster Description > Page 1683 Alignment: Description and Operation Camber Description Camber Description Camber is the tilting of the wheels from the vertical when viewed from the front of the vehicle. When the wheels tilt outward at the top, the camber is positive (+). When the wheel tilts inward at the top, the camber is negative (-). The amount of tilt is measured in degrees from the vertical. Camber settings influence the directional control and the tire wear. Too much positive camber will result in premature wear on the outside of the tire and cause excessive wear on the suspension parts. Too much negative camber will result in premature wear on the inside of the tire and cause excessive wear on the suspension parts. Unequal side-to-side camber of 1 degree or more will cause the vehicle to pull or lead to the side with the most positive camber. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Caster Description > Page 1684 Alignment: Description and Operation Toe Description Toe Description Toe is a measurement of how much the front and/or rear wheels are turned in or out from a straight-ahead position. When the wheels are turned in, toe is positive (+). When the wheels are turned out, toe is negative (-). The actual amount of toe is normally only a fraction of a degree. The purpose of toe is to ensure that the wheels roll parallel. Toe also offsets the small deflections of the wheel support system that occur when the vehicle is rolling forward. In other words, with the vehicle standing still and the wheels set with toe-in, the wheels tend to roll parallel on the road when the vehicle is moving. Improper toe adjustment will cause premature tire wear and cause steering instability. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Caster Description > Page 1685 Alignment: Description and Operation Setback Description Setback Description Setback applies to both the front and the rear wheels. Setback is the amount that one wheel may be aligned behind the other wheel. Setback may be the result of a road hazard or a collision. The first clue is a caster difference from side-to-side of more than 1 degree. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Caster Description > Page 1686 Alignment: Description and Operation Caster Description Caster Description Caster is the tilting of the uppermost point of the steering axis either forward or backward, when viewed from the side of the vehicle. A backward tilt is positive (+) and a forward tilt is negative (-). Caster influences directional control of the steering but does not affect the tire wear. Caster is affected by the vehicle height, therefore it is important to keep the body at its designed height. Overloading the vehicle or a weak or sagging rear spring will affect caster. When the rear of the vehicle is lower than its designated trim height, the front suspension moves to a more positive caster. If the rear of the vehicle is higher than its designated trim height, the front suspension moves to a less positive caster. With too little positive caster, steering may be touchy at high speed and wheel returnability may be diminished when coming out of a turn. If one wheel has more positive caster than the other, that wheel will pull toward the center of the vehicle. This condition will cause the vehicle to pull or lead to the side with the least amount of positive caster. Camber Description Camber Description Camber is the tilting of the wheels from the vertical when viewed from the front of the vehicle. When the wheels tilt outward at the top, the camber is positive (+). When the wheel tilts inward at the top, the camber is negative (-). The amount of tilt is measured in degrees from the vertical. Camber settings influence the directional control and the tire wear. Too much positive camber will result in premature wear on the outside of the tire and cause excessive wear on the suspension parts. Too much negative camber will result in premature wear on the inside of the tire and cause excessive wear on the suspension parts. Unequal side-to-side camber of 1 degree or more will cause the vehicle to pull or lead to the side with the most positive camber. Toe Description Toe Description Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Caster Description > Page 1687 Toe is a measurement of how much the front and/or rear wheels are turned in or out from a straight-ahead position. When the wheels are turned in, toe is positive (+). When the wheels are turned out, toe is negative (-). The actual amount of toe is normally only a fraction of a degree. The purpose of toe is to ensure that the wheels roll parallel. Toe also offsets the small deflections of the wheel support system that occur when the vehicle is rolling forward. In other words, with the vehicle standing still and the wheels set with toe-in, the wheels tend to roll parallel on the road when the vehicle is moving. Improper toe adjustment will cause premature tire wear and cause steering instability. Setback Description Setback Description Setback applies to both the front and the rear wheels. Setback is the amount that one wheel may be aligned behind the other wheel. Setback may be the result of a road hazard or a collision. The first clue is a caster difference from side-to-side of more than 1 degree. Thrust Angles Description Thrust Angles Description The front wheels aim or steer the vehicle. The rear wheels control tracking. This tracking action relates to the thrust angle (3). The thrust angle is the path that the rear wheels take. Ideally, the thrust angle is geometrically aligned with the body centerline (2). In the illustration, toe-in is shown on the left rear wheel, moving the thrust line (1) off center. The resulting deviation from the centerline is the thrust angle. If the thrust angle is not set properly the vehicle may "dog track", the steering wheel may not be centered or it could be perceived as a bent axle. Thrust angle can be checked during a wheel alignment. Positive thrust angle means the thrust line is pointing to the right hand side (RHS) of the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Caster Description > Page 1688 Negative thrust angle means the thrust line is pointing to the left hand side (LHS) of the vehicle. If the thrust angle is out of specification, moving the axle to body relationship will change the thrust angle reading. If the vehicle is out in the Positive (+) direction-moving the RHS forward and/or LHS rearward will move the thrust angle towards zero degrees. If the vehicle is out in the Negative (-) direction-moving the RHS rearward and/or LHS forward will move the thrust angle towards zero degrees. Lead/Pull Description Lead/Pull Description At a constant highway speed on a typical straight road, lead/pull is the amount of effort required at the steering wheel to maintain the vehicle's straight path. Important: Vehicles will tend to lead/pull in the direction of the road slope as part of normal operation. Lead/pull is usually caused by the following factors: * Road slope * Variability in tire construction * Wheel alignment (front cross caster and camber) * Unbalanced steering gear * Electronic Power Steering (EPS) steering position and torque sensors not calibrated correctly, if equipped. Wander Description Wander Description Wander is the undesired drifting or deviation of a vehicle to either side from a straight path with hand pressure on the steering wheel. Wander is a symptom of the vehicle's sensitivity to external disturbances, such as road crown and crosswind, and accentuated by poor on-center steering feel. Scrub Radius Description Scrub Radius Description Ideally, the scrub radius is as small as possible. Normally, the SAI angle and the centerline of the tire and the wheel intersect below the road surface, causing a positive scrub radius. With struts, the SAI angle is much larger than the long arm/short arm type of suspension. This allows the SAI angle to intersect the camber angle above the road surface, forming a negative scrub radius. The smaller the scrub radius, the better the directional stability. Installing aftermarket wheels that have additional offset will dramatically increase the scrub radius. The newly installed wheels may cause the centerline of the tires to move further away from the spindle. This will increase the scrub radius. A large amount of scrub radius can cause severe shimmy after hitting a bump. Four-wheel drive vehicles with large tires use a steering damper to compensate for an increased scrub radius. Scrub radius is not directly measurable by the conventional methods. Scrub radius is projected geometrically by engineers during the design phase of the suspension. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Page 1689 Alignment: Testing and Inspection Trim Height Inspection Note: Before performing any of the following adjustment procedures, inspect the entire suspension system for worn or damaged suspension components. Replace those components before any measurements or adjustments are performed. Also check for any collision damage. Trim Height Measurements Trim height is a predetermined measurement relating to vehicle ride height. Incorrect trim heights can cause the vehicle to bottom over bumps, damage to the suspension components, and symptoms similar to wheel alignment problems. Check the trim heights when diagnosing suspension concerns and before checking the wheel alignment. Perform the following before measuring the trim heights: * Ensure the vehicle is on a level surface, such as an alignment rack. * Set the tire pressures to the pressure shown on the certification label. Refer to Vehicle Certification, Tire Placard, Anti-Theft, and Service Parts ID Label (See: Application and ID/Vehicle Certification, Tire Placard, Anti-Theft and Service Parts ID Label). * Ensure that the suspension is fully supporting the vehicle. * If the vehicle is equipped with automatic level control, ensure that the system is functioning properly. * Check for installed after market accessories or modifications that could affect trim height measurements: - Tire and wheel sizes other than production - Lifting or lowering kits - Wheel Opening Flares - Ground Effects * Ensure that the passenger and rear compartments are empty, except for the spare tire. * Check the fuel level. Add additional weight if necessary to simulate a full tank of fuel. (One U.S. gallon of gasoline weighs approximate 6.5 lbs. One liter of gasoline weighs 0.70 kg.) * Close all doors, lift gate/trunk and the hood. * Remove the alignment rack floating pins. Z Height Measurement Note: For vehicles equipped with torsion bars, check the Z height before performing the alignment. The Z height dimension measurement determines the proper ride height for the front end of the vehicle. Vehicles equipped with torsion bars use adjust arms in order to adjust the Z height dimension. Vehicles without torsion bars have no adjustment and could require replacement of suspension components. 1. Jounce the front suspension of the vehicle by pushing the vehicle down and lifting up. 2. Allow the vehicle to settle and take a measurement. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Page 1690 Note: Perform steps 3-9 for both sides of the vehicle. 3. Point A is the contact surface of the steering knuckle for the levels. 4. Set the top edge of the level on the reference surface of the steering knuckle (C) and extend the level directly under the front end of the front attachment bolt of the lower control arm (A). 5. While keeping the level in contact with the knuckle reference surface, adjust the level up/down until the bubble indicates it is horizontally level. 6. Measure the distance between the center of the bolt and the top of the level for your first measurement 7. Keep the top edge of the level on the reference surface of the steering knuckle (C) and move the level directly under the rear end of the rear attachment bolt of the lower control arm (B). 8. Measure the distance between the center of the bolt and the top of the level for your second measurement. 9. Average the measurements between the step 6 and step 8. 10. Record the measurement. Z Height Adjustment Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Page 1691 1. For vehicles equipped with a torsion bar suspension, turn the bolt (1) that contacts the torsion bar adjusting arm as needed. 2. For vehicles without torsion bars, replace worn or damaged components as necessary. D Height Measurement 1. Jounce the rear suspension of the vehicle by pushing the vehicle down and lifting up. 2. Allow the vehicle to settle and take a measurement. 3. Measure between the axle bracket and jounce bumper mount bracket as shown in graphic. 4. If any of these measurements are out of specifications, inspect for the following conditions: * Worn or damaged suspension components * Collision damage Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Wheel Alignment Measurement Alignment: Service and Repair Wheel Alignment Measurement Wheel Alignment Measurement Steering and vibration complaints are not always the result of improper alignment. One possible cause is wheel and tire imbalance. Another possibility is tire lead due to worn or improperly manufactured tires. Lead/pull is defined as follows: At a constant highway speed on a typical straight road, lead/pull is the amount of effort required at the steering wheel to maintain the vehicle's straight path. Lead is the vehicle deviation from a straight path on a level road without pressure on the steering wheel. Refer to Radial Tire Lead/Pull Correction (See: Wheels and Tires/Testing and Inspection/Symptom Related Diagnostic Procedures/Radial Tire Lead/Pull Correction) in order to determine if the vehicle has a tire lead problem. Before performing any adjustment affecting wheel alignment, perform the following inspections in order to ensure correct alignment readings: * Inspect for visible damage to the suspension components and replace as necessary. * Inspect the tires for the proper inflation and irregular tire wear. Refer to Vehicle Certification, Tire Placard, Anti-Theft, and Service Parts ID Label (See: Application and ID/Vehicle Certification, Tire Placard, Anti-Theft and Service Parts ID Label) and Tire Diagnosis - Irregular or Premature Wear (See: Wheels and Tires/Testing and Inspection/Symptom Related Diagnostic Procedures/Tire Diagnosis - Irregular or Premature Wear). * Inspect the runout of the wheels and the tires. Refer to Tire and Wheel Runout Specifications (See: Body and Frame/Testing and Inspection/Vibration Diagnosis and Correction/Specifications/Tire and Wheel Runout Specifications). * Inspect the wheel bearings for backlash and excessive play. Refer to Wheel Bearings Diagnosis (See: Steering and Suspension/Suspension/Testing and Inspection/Component Tests and General Diagnostics/Wheel Bearings Diagnosis). * Inspect the ball joints for looseness or wear. * Inspect the tie rod ends for looseness or wear. * Inspect the control arms and stabilizer shaft for looseness or wear. * Inspect the steering gear for looseness at the frame. Refer to Fastener Tightening Specifications (See: Specifications/Mechanical Specifications/Steering/System Specifications/Power Steering). * Inspect the struts/shock absorbers for wear, leaks, and any noticeable noises. Refer to Suspension Strut and Shock Absorber Testing - On Vehicle (See: Steering and Suspension/Suspension/Testing and Inspection/Component Tests and General Diagnostics/Suspension Strut and Shock Absorber Testing - On Vehicle). * Inspect the vehicle trim height. Refer to Trim Height Inspection (See: Steering and Suspension/Suspension/Testing and Inspection/Component Tests and General Diagnostics/Trim Height Inspection). * Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or suspension components. * Inspect the fuel level. The fuel tank should be full or the vehicle should have a compensating load added. Give consideration to excess loads, such as tool boxes, sample cases, etc. If normally carried in the vehicle, these items should remain in the vehicle during alignment adjustments. Give consideration also to the condition of the equipment being used for the alignment. Follow the equipment manufacturer's instructions. Satisfactory vehicle operation may occur over a wide range of alignment settings. However, if the setting exceeds the service allowable specifications, correct the alignment to the service preferred specifications. Refer to Wheel Alignment Specifications (See: Specifications/Wheel Alignment Specifications). Perform the following steps in order to measure the front and rear alignment angles: 1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment angles and record the readings. Note: * Record the "Before" and "After" alignment measurements. * When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear toe adjustment first in order to obtain proper front alignment angles. 4. Adjust alignment angles to vehicle specification, if necessary. Refer to Wheel Alignment Specifications (See: Specifications/Wheel Alignment Specifications). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Wheel Alignment Measurement > Page 1694 Alignment: Service and Repair Front Caster and Camber Adjustment Front Caster and Camber Adjustment Note: Caster measurements are now relative to ground. 1. The caster and camber adjustments are made by rotating the offset cam bolt and the cam in the slotted frame bracket in order to reposition the control arm. Note: Before adjusting the caster and camber angles, jounce the front bumper 3 times to allow the vehicle to return to normal height. Measure and adjust the caster and the camber with the vehicle at curb height. The front suspension Z dimension is indicated in Trim Heights. Refer to Trim Height Inspection (See: Steering and Suspension/Suspension/Testing and Inspection/Component Tests and General Diagnostics/Trim Height Inspection). 2. For an accurate reading, do not push or pull on the tires during the alignment process. 3. Determine the caster angle (2). 4. Determine the positive camber (2) or negative camber (3) angle. 5. Remove the pinned adjusting cam insert. Do not reinstall the cam insert. 6. Loosen the upper control arm cam adjustment bolts. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 7. Adjust the caster and the camber angle by turning the cam bolts until the specifications have been met. When the adjustments are complete, hold Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Wheel Alignment Measurement > Page 1695 the cam bolt head in order to ensure the cam bolt position does not change while tightening the nut. Tighten the cam nuts to 190 Nm (140 lb ft). 8. Verify that the caster and the camber are still within specifications. Refer to Wheel Alignment Specifications (See: Specifications/Wheel Alignment Specifications). When the caster and camber are within specifications, adjust the toe. Refer to Wheel Alignment - Steering Wheel Angle and/or Front Toe Adjustment (See: Wheel Alignment - Steering Wheel Angle and/or Front Toe Adjustment). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Wheel Alignment Measurement > Page 1696 Alignment: Service and Repair Wheel Alignment - Steering Wheel Angle and/or Front Toe Adjustment Wheel Alignment - Steering Wheel Angle and/or Front Toe Adjustment 1. Loosen the jam nut on the inner tie rod (1). 2. Rotate the inner tie rod (2) to the required toe specification setting. Refer to Wheel Alignment Specifications (See: Specifications/Wheel Alignment Specifications). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the jam nut (1) on the tie rod and tighten to 75 Nm (55 lb ft). 4. Check the toe setting after tightening. 5. Re-adjust the toe setting if necessary. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications During engine cranking, the pressure should be at least 10 MPa. With the engine running at idle the pressure should be close to the Desired Fuel Rail Pressure. As the engine speed increase, the Desired Fuel Rail Pressure and the Actual Fuel Rail Pressure should be within 2 MPa of each other. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 1701 Fuel Pressure: Service Precautions Relieving Fuel Pressure Warning Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis Fuel Pressure: Testing and Inspection Fuel System Diagnosis Fuel System Diagnosis Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Circuit/System Description Fuel is drawn by the fuel injection pump from the tank to the engine through the fuel supply lines. Fuel flows to the fuel filter/heater element housing , which combines a water separator, a prime pump, fuel heater element and a filter element. A mechanical fuel injection pump at the front of the engine valley includes the fuel supply pump and the high-pressure pump. The small section of the fuel pump assembly is the supply pump, which creates a vacuum to pull fuel from the fuel tank to the high-pressure pump. The vacuum varies with engine load and speed as indicated by the table below. The pump is engine-driven by the camshaft gear. From the high-pressure pump, the pressurized fuel flows to the left fuel rail. A balance pipe from the center of the left rail then feeds the right fuel rail. Each fuel rail supplies one bank of 4 fuel injectors. The fuel rail pressure sensor is mounted in the end of the right fuel rail. Fuel is used to cool and lubricate the fuel injectors and fuel injection pump. The fuel return system is designed to return this fuel to the fuel tank. If the high side fuel pressure becomes excessive, the fuel rail pressure relief valve releases the fuel into the fuel return system. The return fuel travels through the fuel cooler and then to the fuel tank. Diagnostic Aids An Engine Cranks but Will Not Run or Hard Start symptom may exist if air is being drawn into the fuel injection system due to the following conditions: * Fuel contamination-Refer to Contaminants-in-Fuel Diagnosis (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Contaminants-in-Fuel Diagnosis). * Deformed or cut O-rings at the fuel supply line connections * Improperly seated fuel supply line fittings * Porous or weathered rubber fuel supply lines * Fuel filter vent screw not tighten or cross threaded * Fuel filter not tighten properly Reference Information Special Tools * J-23738-A MityVac * EN-47969 Fuel Supply Diagnostic Hose * CH-48027 Digital Pressure Gauge * J 44581 Fuel Line Disconnect Tool Circuit/System Verification Observe the Actual Fuel Rail Pressure parameter with a scan tool. During engine cranking, the pressure should be at least 10 MPa. With the engine running at idle the pressure should be close to the Desired Fuel Rail Pressure. As the engine speed increase, the Desired Fuel Rail Pressure and the Actual Fuel Rail Pressure should be within 2 MPa of each other. Circuit/System Testing Note: Ensure that a sufficient amount of fuel is in the fuel tank to run the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis > Page 1704 1. Install the CH-48027 to the fuel system service port on the right front side of the engine. 2. Prime the fuel system until 10 psi is indicated on the CH-48027 . Fuel pressure should not drop below 2 psi in less than one minute. ‹› If fuel pressure drops below 2 psi in less than one minute, go to step 4. Note: It may be necessary to remove engine components for the visual inspections. 3. Attempt to start and idle the engine. Observe the CH-48027 during idle. The vacuum should be between 1-3 in Hg. ‹› If more than 3 in Hg is observed at idle, visually inspect the following items: * Fuel filter element for a restriction * Hoses and lines that are flattening when the engine is running, or have kinks that would restrict the flow of fuel ‹› If engine did not start and no vacuum was observed, refer to Fuel Injection Pump Replacement (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair). 4. Disconnect the fuel supply line at the engine and install a J-23738-A using the J 44581 to the engine side of the fuel supply line. 5. Apply vacuum to the fuel supply pipe until 25 in Hg has been reached. Wait for at least one minute to allow the fuel system to stabilize. Vacuum should not drop below 8 in Hg within 10 minutes. ‹› If vacuum cannot be obtained or the vacuum drops below 8 in Hg within 10 minutes, repair the air leak at fuel filter/heater element housing connections or at the fuel hoses/pipes on the engine supply line. 6. Remove both hoses from the fuel filter/heater element housing assembly. Cap the suction side port of the fuel filter/heater element housing assembly. Apply 25 in Hg to the discharge port of the fuel filter/heater element housing assembly. Vacuum should not drop below 8 in Hg within 10 minutes. ‹› If vacuum drops below 8 in Hg within 10 minutes, replace the fuel filter/heater element housing assembly. Note: The engine may start and then stall after briefly running. 7. Remove the J-23738-A from the fuel filter/heater element housing assembly. Install the removed fuel filter/heater element housing assembly, and cap off the fuel supply pipe on the engine. Crank the engine in 15-second intervals while observing the CH-48027 . More than 5 in Hg vacuum should be observed during cranking. ‹› If less than 5 in Hg was observed on the vacuum gauge during cranking, replace the fuel injection pump. Note: The engine may start, and then stall after briefly running. 8. Install the fuel supply line at the engine, and disconnect the chassis fuel supply line at the fuel tank. Install a J-23738-A to the supply hose at the fuel tank using the J 44581 . 9. Apply vacuum to the supply hose at the fuel tank until 25 in Hg has been reached. Wait for a least one minute for the fuel system to stabilize. Vacuum should not drop below 8 in Hg within 10 minutes. ‹› If vacuum cannot be obtained, or the vacuum drops below 8 in Hg within 10 minutes, repair the air leak in the fuel supply line between the engine and fuel tank, or the connection of the supply line to the engine. 10. Install all components and lines that were previously removed or disconnected. 11. Install the EN-47969 on the fuel supply line at the engine. Create a vertical loop in the hose to observe the incoming fuel for air bubbles. 12. Open the bleed screw on top of the fuel filter/heater element housing. Prime the system until fuel appears at the bleed screw. Continue to prime the fuel system until the engine starts and runs. 13. Run the engine for at least 10 minutes to allow the fuel system to stabilize, and purge any air from the system. Note: Changes in engine speed can cause an increase of air bubbles that enter the EN-47969 . An air pocket at the top of the EN-47969 loop is considered a normal condition. 14. At a stabilized idle, observe the fuel entering the EN-47969 for air bubbles. ‹› If air bubbles were observed entering the transparent hose, test the fuel sender for leaks. Refer to Fuel Sender Assembly Replacement (See: Instrument Panel, Gauges and Warning Indicators/Fuel Gauge Sender/Service and Repair). 15. Install the fuel sender, fuel tank, and all fuel system connections and components that were previously disconnected. Leave the EN-47969 connected to the fuel supply line. Prime the fuel system 30 times to remove the air from the fuel hoses. Continue to prime the fuel system until the engine starts and runs. Observe the fuel entering the transparent hose. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis > Page 1705 ‹› If air bubbles are still present, refer to Diagnostic Aids. ‹› If no air bubbles are present , remove the EN-47969 and run the engine to ensure no fuel leaks exist. Repair Instructions Perform the Diagnostic Repair Verification (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. * Fuel Injection Pump Replacement (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair) * Fuel Sender Assembly Replacement (See: Instrument Panel, Gauges and Warning Indicators/Fuel Gauge Sender/Service and Repair) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis > Page 1706 Fuel Pressure: Testing and Inspection Fuel System Diagnosis - High Pressure Side Fuel System Diagnosis - High Pressure Side Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Circuit/System Description High Pressure System The fuel injection pump at the front of the engine valley includes a fuel supply pump and a high-pressure pump. Fuel is drawn by the fuel supply pump from the primary fuel tank and delivered to the high-pressure pump. The pump is engine-driven by the camshaft gear. High pressure fuel is regulated by the fuel pressure regulator mounted on the fuel injection pump. From the high-pressure pump, the fuel moves to the left and right fuel rails through high pressure metal lines. Each fuel rail distributes high pressure fuel to one bank of 4 fuel injectors. The fuel pressure relief valve is location on the left rail, and relieves excessive fuel pressure which returns to the fuel tank. Return System The fuel return system routes fuel from the fuel injectors, the pressure relief valve, and the fuel injection pump. The return fuel travels to the fuel cooler and then to the fuel tank. This fuel is used to cool and lubricate the injection pump and the injectors. Diagnostic Aids * The fuel return volumes vary based on the American Petroleum Institute (API) rating of the diesel fuel. * A fuel injector may have high fuel return flow only at higher engine temperatures. Reference Information Special Tools * J 45873 Fuel Return Volume Test Kit * J-45873-30 Injector Flow Test Adapter Circuit/System Verification With the engine running at idle the Actual Fuel Pressure should be close to the Desired Fuel Rail Pressure. During engine cranking the Actual Fuel Pressure should be at least 10 MPa. Inspect the fuel return hoses and lines for external leaks or damage. Circuit/System Testing Important: If you were not referred to this test from another diagnostic, do not perform this procedure. Only perform this test when the fuel is more than 18°C (65°F). Important: Before replacing the fuel pressure relief valve, ensure that the break-away torque is within specifications. Refer to Fastener Tightening Specifications (See: Powertrain Management/Specifications). 1. Remove the fuel pressure relief valve return hose and plug the hose to prevent fuel leakage. 2. Install a section of rubber fuel hose on the fuel pressure relief valve connection and place loose end of hose into a clean fuel container. Important: Fuel that is contaminated with gasoline may cause permanent damage to the fuel pressure relief valve. Refer to Contaminants-in-Fuel Diagnosis (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Contaminants-in-Fuel Diagnosis). * If the engine cranks but does not start, crank engine for 15 seconds. Observe for fuel leaking from fuel pressure relief valve. ‹› If fuel leaks from the fuel pressure relief valve, replace the pressure relief valve. Refer to Fuel Pressure Relief Valve Replacement (See: Fuel Filter/Fuel Pressure Release/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis > Page 1707 * If the engine starts and runs, idle the engine while commanding the fuel rail pressure to 180 MPa with a scan tool. Observe for fuel leaking from fuel pressure relief valve. ‹› If fuel leaks from the fuel pressure relief valve, replace the pressure relief valve. Refer to Fuel Pressure Relief Valve Replacement (See: Fuel Filter/Fuel Pressure Release/Service and Repair). Important: Always replace the fuel return hose retaining clips on the fuel injectors with new clips after removing. 3. Remove the fuel return hose from the fuel injectors of the right cylinder bank. Refer to Fuel Injection Fuel Return Pipe Replacement - Right Side (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Return Line/Service and Repair/Fuel Injection Fuel Return Pipe Replacement - Right Side). 4. Connect the yellow hoses from the J 45873 to the J-45873-30 . 5. Connect the J-45873-30 with yellow hoses to each fuel injector return port of the right cylinder bank, and install the retaining clips. 6. Install the 4 yellow hoses in the J 45873 graduated cylinders in numerical order. 7. Connect the fuel return hoses to the J-45873-30 to prevent leakage. ‹› If the engine starts and runs, idle the engine until fuel start dripping into all the graduated cylinders and yellow hoses are full of fuel. Important: The engine cranking speed must be more than 150 RPM during the cranking portion of this test. ‹› If the engine does not start, crank the engine in 15-second intervals, with 1 minute cooling time between intervals, until fuel starts to flow into all of the graduated cylinders. 8. Elevate the 4 yellow hoses to retain the fuel in the hoses, and empty the 4 graduated cylinders into a suitable container. 9. Install the 4 yellow hoses in the J 45873 graduated cylinders in numerical order. ‹› If the engine starts and runs, idle the engine for 15 seconds. ‹› If the engine does not start, crank the engine for 15 seconds. Important: During replacement of the injectors, inspect the inlet and outlet fittings for corrosion or contamination. Refer to Contaminants-in-Fuel Diagnosis (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Contaminants-in-Fuel Diagnosis). 10. Measure the quantity of fuel in each of the graduated cylinders. Refer to Fuel System Specifications (See: Powertrain Management/Fuel Delivery and Air Induction/Specifications) for the desired quantities. ‹› If high return flows were recorded, replace those fuel injectors that had high return flow and retest the fuel return flow, referring to Fuel System Specifications (See: Powertrain Management/Fuel Delivery and Air Induction/Specifications). Replace any additional high return flow injectors and proceed to the next number step. 11. Install and connect all fuel system components that were previously removed or disconnected. 12. Remove the fuel return pipes from the fuel injectors of the left cylinder bank and repeat the fuel return flow test previously preformed on the right cylinder bank. ‹› If high return flows were recorded, replace those fuel injectors that had high return flow and retest the fuel return flow, referring to Fuel System Specifications (See: Powertrain Management/Fuel Delivery and Air Induction/Specifications). Replace any additional high return flow injectors and proceed to the next number step. 13. Install and connect all fuel system components that were previously removed or disconnected. 14. Start and idle the engine. You may have to prime the fuel system before the engine will start. Command the fuel pressure control to 180 MPa with a scan tool. The actual fuel pressure should be the same as the commanded pressure. ‹› If the engine does not start or the fuel pressure is less than 145 MPa when commanded, replace the fuel injection pump. 15. Command the fuel pressure control to 180 MPa with a scan tool. The fuel pressure should be able to reach 145 MPa when commanded. ‹› If the fuel pressure is less than the specified value, refer to Fuel System Diagnosis (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Fuel System Diagnosis). 16. Operate the vehicle in order to verify the repairs. Repair Instructions Perform the Diagnostic Repair Verification (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis > Page 1708 * Fuel Injection Pump Replacement (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair) * Fuel Pressure Relief Valve Replacement (See: Fuel Filter/Fuel Pressure Release/Service and Repair) * Fuel Injector Replacement (Right) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Injector/Service and Repair/Removal and Replacement/Fuel Injector Replacement (Right))Fuel Injector Replacement (Left) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Injector/Service and Repair/Removal and Replacement/Fuel Injector Replacement (Left)) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Idle Speed............................................................................................................................................ ......................................................................680 RPM Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 1712 Idle Speed: Service and Repair High Idle Switch Programming Before Programming a Control Module Important: DO NOT program a control module unless you are directed by a service procedure or you are directed by a General Motors Corporation service bulletin. Programming a control module at any other time will not permanently correct a customer's concern. Ensure the following conditions are met before programming a control module: * Vehicle system voltage - There is no charging system concern. All charging system concerns must be repaired before programming a control module. - Battery voltage is greater than 12 volts but less than 16 volts. The battery must be charged before programming the control module if the battery voltage is low. - A battery charger is NOT connected to the vehicle's battery. Incorrect system voltage or voltage fluctuations from a battery charger, may cause programming failure or control module damage. - Turn OFF or disable any system that may put a load on the vehicle's battery. * Twilight sentinel * Interior lights * Daytime running lights (DRL)-Applying the parking brake, on most vehicles, disables the DRL system. Refer to the Owner's Manual. * HVAC systems * Engine cooling fans, etc. * The ignition switch is in the proper position. The scan tool prompts you to turn ON the ignition, with the engine OFF. DO NOT change the position of the ignition switch during the programming procedure, unless instructed to do so. * All tool connections are secure. - The connection at the data link connector (DLC) - Voltage supply circuits * DO NOT disturb the tool harnesses while programming. If an interruption occurs during the programming procedure, programming failure or control module damage may occur. High Idle Switch Programming * Using the Tech 2, select Module Setup/PTO Options * Use soft keys to select desired settings. * When setting selections are complete, select Reprogram. Important: The ECM will not operate under the new value until the it has powered down once. * Turn OFF the ignition until communication with the ECM is lost, as indicated on the scan tool. * Start the vehicle and confirm the new settings by operating the high idle switch. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > Customer Interest for Air Cleaner Fresh Air Duct/Hose: > 08-06-04-054B > Jan > 11 > Diesel Engine - Low Power/MIL ON/DTC P0101 Air Cleaner Fresh Air Duct/Hose: Customer Interest Diesel Engine - Low Power/MIL ON/DTC P0101 TECHNICAL Bulletin No.: 08-06-04-054B Date: January 24, 2011 Subject: Snow or Ice Ingestion into Air Cleaner Element, Malfunction Indicator Lamp (MIL) Illuminated, Engine Power is Reduced Message Displayed, DTC P0101 Set (Perform Repair as Outlined) Models: 2007-2010 Chevrolet Silverado 2500/3500 Series 2007-2010 GMC Sierra 2500/3500 Series Equipped with Duramax(TM) Diesel Engine (RPO LMM) Supercede: This bulletin is being revised to provide a procedure to relocate the OAT sensor, if equipped with RPO CJ2. Please discard Corporate Bulletin 08-06-04-054A (Section 06 - Engine / Propulsion System). Condition Some customers may comment on the malfunction indicator lamp (MIL) being illuminated and an Engine Power is Reduced message being displayed. The technician may observe DTC P0101 set as current or in history. Cause This condition may be caused by snow being ingested into the air cleaner housing and accumulating in the air cleaner element, resulting in restricted airflow into the engine. Correction 1. Verify the condition by questioning the customer as to when the condition occurs (such as during or right after a snow storm). ‹› If the condition occurs as described above, proceed to Step 2. ‹› If the condition does not occur as described above, refer to Diagnostic Trouble Code (DTC) List Vehicle in SI. 2. Remove the air cleaner element. Refer to Air Cleaner Element Replacement in SI. 3. Inspect the air cleaner element for the following conditions: 1. Packed snow 2. Frozen ice 3. A soaking wet condition that would indicate previous snow ingestion 4. Excessive debris and contamination as a result of the ingestion ‹› If any of the above conditions are observed, replace the air cleaner element. Remove any snow or ice that may have accumulated in the air intake duct. Note Winter covers for trucks that are equipped with the Duramax(TM) Diesel Engine are included with vehicle orders that ship to the following areas: All of Canada, and the following states: Alaska, Colorado, Idaho, Maine, Michigan, Minnesota, Montana, New Hampshire, New York, North Dakota, South Dakota, Vermont, Wisconsin, Wyoming. These vehicles should not need a new cover. 4. Install the grille opening section ONLY (if using the 2 piece cover) of the winter front cover following the usage guidelines provided in the Owners Manual for the appropriate type winter cover. ‹› If the customer does not have a cover, obtain and install the grille opening section ONLY , GM P/N 25822811 (GMC) or GM P/N 25822812 (Chevrolet). 5. The grille opening cover MUST BE installed to ensure a complete repair, BEFORE ENCOUNTERING SNOW. This repair allows warm air to be circulated into the air cleaner. Additional Information to Advise Customer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > Customer Interest for Air Cleaner Fresh Air Duct/Hose: > 08-06-04-054B > Jan > 11 > Diesel Engine - Low Power/MIL ON/DTC P0101 > Page 1722 Important If the vehicle is driven in a snow storm before installing the winter cover and the customer chooses to resolve the issue, they must follow this procedure using the following steps: 1. Remove ANY ice or snow that may have accumulated in the air intake duct, BEFORE REPLACING the air cleaner element. 2. INSTALL the winter cover BEFORE continuing to drive the truck. 3. Turn OFF the ignition, and all electrical accessories and components. 4. Remove the key from the vehicle, THEN open and close the door. 5. WAIT for 2 minutes to allow the engine control module (ECM) to power down. This can be verified by watching for the instrument panel cluster (IPC) gage needles to drop slightly. 1. Allowing the ECM to power down will let DTC P0101 revert to a History DTC and the vehicle should return to full power if the issue has been eliminated. 2. Advise the customer to take the vehicle to the dealer as soon as possible to verify the condition has been eliminated. Ambient (Outside) Air Temperature Sensor Relocation For vehicles equipped with Automatic Temperature Control HVAC (RPO CJ2), the ambient (outside) air temperature sensor needs to be relocated using the following procedure: 1. Remove the radiator grille. Refer to the Radiator Grille Replacement procedure in SI. 2. Remove the ambient air sensor from its current location by carefully lifting the sensor from the radiator support cross bar. 3. Remove the harness clip nearest to the sensor. 4. Reinstall the ambient air sensor to the new location using the existing hole (1) in the lower section of the radiator support. 5. Reinstall the harness clip to the existing hole (2) in the radiator support. 6. Reinstall the radiator grille. Parts Information Warranty Information Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > Customer Interest for Air Cleaner Fresh Air Duct/Hose: > 08-06-04-054B > Jan > 11 > Diesel Engine - Low Power/MIL ON/DTC P0101 > Page 1723 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > Customer Interest for Air Cleaner Fresh Air Duct/Hose: > 08-06-04-054A > Jan > 10 > Engine - Reduced Power/MIL ON/DTC P0101 Air Cleaner Fresh Air Duct/Hose: Customer Interest Engine - Reduced Power/MIL ON/DTC P0101 TECHNICAL Bulletin No.: 08-06-04-054A Date: January 07, 2010 Subject: Snow or Ice Ingestion into Air Cleaner Element, Malfunction Indicator Lamp (MIL) Illuminated, Engine Power is Reduced Message Displayed, DTC P0101 Set (Perform Repair as Outlined) Models: 2007-2010 Chevrolet Silverado 2500/3500 Series 2007-2010 GMC Sierra 2500/3500 Series Equipped with Duramax(TM) Diesel Engine (RPO LMM) Please Refer to GMVIS Supercede: This bulletin is being revised to remove the graphic, update the Parts and Correction information and add information to advise a customer. Please discard Corporate Bulletin 08-06-04-054 (Section 06 - Engine / Propulsion System). Condition Some customers may comment on the malfunction indicator lamp (MIL) being illuminated and an Engine Power is Reduced message being displayed. The technician may observe DTC P0101 set as current or in history. Cause This condition may be caused by snow being ingested into the air cleaner housing and accumulating in the air cleaner element, resulting in restricted airflow into the engine. Correction 1. Verify the condition by questioning the customer as to when the condition occurs (such as during or right after a snow storm). ‹› If the condition occurs as described above, proceed to Step 2. ‹› If the condition does not occur as described above, refer to Diagnostic Trouble Code (DTC) List Vehicle in SI. 2. Remove the air cleaner element. Refer to Air Cleaner Element Replacement in SI. 3. Inspect the air cleaner element for the following conditions: 1. Packed snow 2. Frozen ice 3. A soaking wet condition that would indicate previous snow ingestion 4. Excessive debris and contamination as a result of the ingestion ‹› If any of the above conditions are observed, replace the air cleaner element. Remove any snow or ice that may have accumulated in the air intake duct. Note Winter covers for trucks that are equipped with the Duramax(TM) Diesel Engine are included with vehicle orders that ship to the following areas: All of Canada, and the following states: Alaska, Colorado, Idaho, Maine, Michigan, Minnesota, Montana, New Hampshire, New York, North Dakota, South Dakota, Vermont, Wisconsin, Wyoming. These vehicles should not need a new cover. 4. Install the grille opening section ONLY (if using the 2 piece cover) of the winter front cover following the usage guidelines provided in the Owners Manual for the appropriate type winter cover. ‹› If the customer does not have a cover, obtain and install the grille opening section ONLY, GM P/N 25822811 (GMC) or GM P/N 25822812 (Chevrolet). 5. The grille opening cover MUST BE installed to ensure a complete repair, BEFORE ENCOUNTERING SNOW. This repair allows warm air to be circulated into the air cleaner. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > Customer Interest for Air Cleaner Fresh Air Duct/Hose: > 08-06-04-054A > Jan > 10 > Engine - Reduced Power/MIL ON/DTC P0101 > Page 1728 Additional Information to Advise Customer Important If the vehicle is driven in a snow storm before installing the winter cover and the customer chooses to resolve the issue, they must follow this procedure using the following steps: 1. Remove ANY ice or snow that may have accumulated in the air intake duct, BEFORE REPLACING the air cleaner element. 2. INSTALL the winter cover BEFORE continuing to drive the truck. 3. Turn OFF the ignition, and all electrical accessories and components. 4. Remove the key from the vehicle, THEN open and close the door. 5. WAIT for 2 minutes to allow the engine control module (ECM) to power down. This can be verified by watching for the instrument panel cluster (IPC) gage needles to drop slightly. 1. Allowing the ECM to power down will let DTC P0101 revert to a History DTC and the vehicle should return to full power if the issue has been eliminated. 2. Advise the customer to take the vehicle to the dealer as soon as possible to verify the condition has been eliminated. Parts Information Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Cleaner Fresh Air Duct/Hose: > 08-06-04-054B > Jan > 11 > Diesel Engine - Low Power/MIL ON/DTC P0101 Air Cleaner Fresh Air Duct/Hose: All Technical Service Bulletins Diesel Engine - Low Power/MIL ON/DTC P0101 TECHNICAL Bulletin No.: 08-06-04-054B Date: January 24, 2011 Subject: Snow or Ice Ingestion into Air Cleaner Element, Malfunction Indicator Lamp (MIL) Illuminated, Engine Power is Reduced Message Displayed, DTC P0101 Set (Perform Repair as Outlined) Models: 2007-2010 Chevrolet Silverado 2500/3500 Series 2007-2010 GMC Sierra 2500/3500 Series Equipped with Duramax(TM) Diesel Engine (RPO LMM) Supercede: This bulletin is being revised to provide a procedure to relocate the OAT sensor, if equipped with RPO CJ2. Please discard Corporate Bulletin 08-06-04-054A (Section 06 - Engine / Propulsion System). Condition Some customers may comment on the malfunction indicator lamp (MIL) being illuminated and an Engine Power is Reduced message being displayed. The technician may observe DTC P0101 set as current or in history. Cause This condition may be caused by snow being ingested into the air cleaner housing and accumulating in the air cleaner element, resulting in restricted airflow into the engine. Correction 1. Verify the condition by questioning the customer as to when the condition occurs (such as during or right after a snow storm). ‹› If the condition occurs as described above, proceed to Step 2. ‹› If the condition does not occur as described above, refer to Diagnostic Trouble Code (DTC) List Vehicle in SI. 2. Remove the air cleaner element. Refer to Air Cleaner Element Replacement in SI. 3. Inspect the air cleaner element for the following conditions: 1. Packed snow 2. Frozen ice 3. A soaking wet condition that would indicate previous snow ingestion 4. Excessive debris and contamination as a result of the ingestion ‹› If any of the above conditions are observed, replace the air cleaner element. Remove any snow or ice that may have accumulated in the air intake duct. Note Winter covers for trucks that are equipped with the Duramax(TM) Diesel Engine are included with vehicle orders that ship to the following areas: All of Canada, and the following states: Alaska, Colorado, Idaho, Maine, Michigan, Minnesota, Montana, New Hampshire, New York, North Dakota, South Dakota, Vermont, Wisconsin, Wyoming. These vehicles should not need a new cover. 4. Install the grille opening section ONLY (if using the 2 piece cover) of the winter front cover following the usage guidelines provided in the Owners Manual for the appropriate type winter cover. ‹› If the customer does not have a cover, obtain and install the grille opening section ONLY , GM P/N 25822811 (GMC) or GM P/N 25822812 (Chevrolet). 5. The grille opening cover MUST BE installed to ensure a complete repair, BEFORE ENCOUNTERING SNOW. This repair allows warm air to be circulated into the air cleaner. Additional Information to Advise Customer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Cleaner Fresh Air Duct/Hose: > 08-06-04-054B > Jan > 11 > Diesel Engine - Low Power/MIL ON/DTC P0101 > Page 1734 Important If the vehicle is driven in a snow storm before installing the winter cover and the customer chooses to resolve the issue, they must follow this procedure using the following steps: 1. Remove ANY ice or snow that may have accumulated in the air intake duct, BEFORE REPLACING the air cleaner element. 2. INSTALL the winter cover BEFORE continuing to drive the truck. 3. Turn OFF the ignition, and all electrical accessories and components. 4. Remove the key from the vehicle, THEN open and close the door. 5. WAIT for 2 minutes to allow the engine control module (ECM) to power down. This can be verified by watching for the instrument panel cluster (IPC) gage needles to drop slightly. 1. Allowing the ECM to power down will let DTC P0101 revert to a History DTC and the vehicle should return to full power if the issue has been eliminated. 2. Advise the customer to take the vehicle to the dealer as soon as possible to verify the condition has been eliminated. Ambient (Outside) Air Temperature Sensor Relocation For vehicles equipped with Automatic Temperature Control HVAC (RPO CJ2), the ambient (outside) air temperature sensor needs to be relocated using the following procedure: 1. Remove the radiator grille. Refer to the Radiator Grille Replacement procedure in SI. 2. Remove the ambient air sensor from its current location by carefully lifting the sensor from the radiator support cross bar. 3. Remove the harness clip nearest to the sensor. 4. Reinstall the ambient air sensor to the new location using the existing hole (1) in the lower section of the radiator support. 5. Reinstall the harness clip to the existing hole (2) in the radiator support. 6. Reinstall the radiator grille. Parts Information Warranty Information Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Cleaner Fresh Air Duct/Hose: > 08-06-04-054B > Jan > 11 > Diesel Engine - Low Power/MIL ON/DTC P0101 > Page 1735 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Cleaner Fresh Air Duct/Hose: > 08-06-04-054A > Jan > 10 > Engine - Reduced Power/MIL ON/DTC P0101 Air Cleaner Fresh Air Duct/Hose: All Technical Service Bulletins Engine - Reduced Power/MIL ON/DTC P0101 TECHNICAL Bulletin No.: 08-06-04-054A Date: January 07, 2010 Subject: Snow or Ice Ingestion into Air Cleaner Element, Malfunction Indicator Lamp (MIL) Illuminated, Engine Power is Reduced Message Displayed, DTC P0101 Set (Perform Repair as Outlined) Models: 2007-2010 Chevrolet Silverado 2500/3500 Series 2007-2010 GMC Sierra 2500/3500 Series Equipped with Duramax(TM) Diesel Engine (RPO LMM) Please Refer to GMVIS Supercede: This bulletin is being revised to remove the graphic, update the Parts and Correction information and add information to advise a customer. Please discard Corporate Bulletin 08-06-04-054 (Section 06 - Engine / Propulsion System). Condition Some customers may comment on the malfunction indicator lamp (MIL) being illuminated and an Engine Power is Reduced message being displayed. The technician may observe DTC P0101 set as current or in history. Cause This condition may be caused by snow being ingested into the air cleaner housing and accumulating in the air cleaner element, resulting in restricted airflow into the engine. Correction 1. Verify the condition by questioning the customer as to when the condition occurs (such as during or right after a snow storm). ‹› If the condition occurs as described above, proceed to Step 2. ‹› If the condition does not occur as described above, refer to Diagnostic Trouble Code (DTC) List Vehicle in SI. 2. Remove the air cleaner element. Refer to Air Cleaner Element Replacement in SI. 3. Inspect the air cleaner element for the following conditions: 1. Packed snow 2. Frozen ice 3. A soaking wet condition that would indicate previous snow ingestion 4. Excessive debris and contamination as a result of the ingestion ‹› If any of the above conditions are observed, replace the air cleaner element. Remove any snow or ice that may have accumulated in the air intake duct. Note Winter covers for trucks that are equipped with the Duramax(TM) Diesel Engine are included with vehicle orders that ship to the following areas: All of Canada, and the following states: Alaska, Colorado, Idaho, Maine, Michigan, Minnesota, Montana, New Hampshire, New York, North Dakota, South Dakota, Vermont, Wisconsin, Wyoming. These vehicles should not need a new cover. 4. Install the grille opening section ONLY (if using the 2 piece cover) of the winter front cover following the usage guidelines provided in the Owners Manual for the appropriate type winter cover. ‹› If the customer does not have a cover, obtain and install the grille opening section ONLY, GM P/N 25822811 (GMC) or GM P/N 25822812 (Chevrolet). 5. The grille opening cover MUST BE installed to ensure a complete repair, BEFORE ENCOUNTERING SNOW. This repair allows warm air to be circulated into the air cleaner. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Cleaner Fresh Air Duct/Hose: > 08-06-04-054A > Jan > 10 > Engine - Reduced Power/MIL ON/DTC P0101 > Page 1740 Additional Information to Advise Customer Important If the vehicle is driven in a snow storm before installing the winter cover and the customer chooses to resolve the issue, they must follow this procedure using the following steps: 1. Remove ANY ice or snow that may have accumulated in the air intake duct, BEFORE REPLACING the air cleaner element. 2. INSTALL the winter cover BEFORE continuing to drive the truck. 3. Turn OFF the ignition, and all electrical accessories and components. 4. Remove the key from the vehicle, THEN open and close the door. 5. WAIT for 2 minutes to allow the engine control module (ECM) to power down. This can be verified by watching for the instrument panel cluster (IPC) gage needles to drop slightly. 1. Allowing the ECM to power down will let DTC P0101 revert to a History DTC and the vehicle should return to full power if the issue has been eliminated. 2. Advise the customer to take the vehicle to the dealer as soon as possible to verify the condition has been eliminated. Parts Information Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Air Cleaner Outlet Duct Replacement Air Cleaner Fresh Air Duct/Hose: Service and Repair Air Cleaner Outlet Duct Replacement Air Cleaner Outlet Duct Replacement Removal Procedure 1. Loosen the outlet duct clamps at the air cleaner assembly and the turbocharger. 2. Remove the air cleaner outlet duct. Installation Procedure Note: The air cleaner outlet duct must be fully seated against the positive stop feature on the turbocharger inlet and also must be fully seated against the positive stop features on both sides of the air cleaner assembly. 1. Install the air cleaner outlet duct. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Air Cleaner Outlet Duct Replacement > Page 1743 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Tighten the outlet duct clamps at the turbocharger and the air cleaner assembly. Tighten the clamps to 4 Nm (35 lb in). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Air Cleaner Outlet Duct Replacement > Page 1744 Air Cleaner Fresh Air Duct/Hose: Service and Repair Air Intake Pipe Replacement Air Intake Pipe Replacement Removal Procedure 1. Remove the water outlet tube. Refer to Water Outlet Tube Replacement (LU3) (See: Engine, Cooling and Exhaust/Cooling System/Coolant Outlet/Service and Repair)Water Outlet Tube Replacement (LMM) (See: Engine, Cooling and Exhaust/Cooling System/Coolant Outlet/Service and Repair). 2. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (See: Air Cleaner Outlet Duct Replacement). Note: It is not necessary to completely remove the PCV hose/pipe from the engine when removing the air intake pipe. 3. Remove the positive crankcase ventilation (PCV) hose/pipe from the air intake pipe. Refer to Positive Crankcase Ventilation Hose/Pipe/Tube Replacement (See: Powertrain Management/Emission Control Systems/Positive Crankcase Ventilation/PCV Valve Hose/Service and Repair). 4. Disconnect the engine wiring harness electrical connector from the turbocharger control solenoid valve. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Air Cleaner Outlet Duct Replacement > Page 1745 5. Remove the engine wiring harness clip (1) from the bracket on the turbocharger. 6. Reposition the turbocharger control solenoid valve wiring harness extension out of the way. Note: The clamp for the air intake pipe uses reverse threads. 7. Loosen the air intake pipe to turbocharger clamp (1). 8. Remove the air intake pipe (2) from the turbocharger. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Air Cleaner Outlet Duct Replacement > Page 1746 1. Clean the mating surfaces on the air intake pipe and the turbocharger. 2. Align the arrow (2) on the air intake pipe to the arrow (1) on the turbocharger. 3. Install the air intake pipe (2) into the turbocharger. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Note: The clamp for the air intake pipe uses reverse threads. 4. Tighten the air intake pipe to turbocharger clamp (1). Tighten the clamp to 4.6 Nm (41 lb in). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Air Cleaner Outlet Duct Replacement > Page 1747 5. Route the turbocharger control solenoid valve wiring harness extension into position. 6. Install the engine wiring harness clip (1) to the bracket on the turbocharger. 7. Connect the engine wiring harness electrical connector to the turbocharger control solenoid valve. 8. Install the PCV hose/pipe to the air intake pipe. Refer to Positive Crankcase Ventilation Hose/Pipe/Tube Replacement (See: Powertrain Management/Emission Control Systems/Positive Crankcase Ventilation/PCV Valve Hose/Service and Repair). 9. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (See: Air Cleaner Outlet Duct Replacement). 10. Install the water outlet tube. Refer to Water Outlet Tube Replacement (LU3) (See: Engine, Cooling and Exhaust/Cooling System/Coolant Outlet/Service and Repair)Water Outlet Tube Replacement (LMM) (See: Engine, Cooling and Exhaust/Cooling System/Coolant Outlet/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 08-06-04-054B > Jan > 11 > Diesel Engine - Low Power/MIL ON/DTC P0101 Air Filter Element: Customer Interest Diesel Engine - Low Power/MIL ON/DTC P0101 TECHNICAL Bulletin No.: 08-06-04-054B Date: January 24, 2011 Subject: Snow or Ice Ingestion into Air Cleaner Element, Malfunction Indicator Lamp (MIL) Illuminated, Engine Power is Reduced Message Displayed, DTC P0101 Set (Perform Repair as Outlined) Models: 2007-2010 Chevrolet Silverado 2500/3500 Series 2007-2010 GMC Sierra 2500/3500 Series Equipped with Duramax(TM) Diesel Engine (RPO LMM) Supercede: This bulletin is being revised to provide a procedure to relocate the OAT sensor, if equipped with RPO CJ2. Please discard Corporate Bulletin 08-06-04-054A (Section 06 - Engine / Propulsion System). Condition Some customers may comment on the malfunction indicator lamp (MIL) being illuminated and an Engine Power is Reduced message being displayed. The technician may observe DTC P0101 set as current or in history. Cause This condition may be caused by snow being ingested into the air cleaner housing and accumulating in the air cleaner element, resulting in restricted airflow into the engine. Correction 1. Verify the condition by questioning the customer as to when the condition occurs (such as during or right after a snow storm). ‹› If the condition occurs as described above, proceed to Step 2. ‹› If the condition does not occur as described above, refer to Diagnostic Trouble Code (DTC) List Vehicle in SI. 2. Remove the air cleaner element. Refer to Air Cleaner Element Replacement in SI. 3. Inspect the air cleaner element for the following conditions: 1. Packed snow 2. Frozen ice 3. A soaking wet condition that would indicate previous snow ingestion 4. Excessive debris and contamination as a result of the ingestion ‹› If any of the above conditions are observed, replace the air cleaner element. Remove any snow or ice that may have accumulated in the air intake duct. Note Winter covers for trucks that are equipped with the Duramax(TM) Diesel Engine are included with vehicle orders that ship to the following areas: All of Canada, and the following states: Alaska, Colorado, Idaho, Maine, Michigan, Minnesota, Montana, New Hampshire, New York, North Dakota, South Dakota, Vermont, Wisconsin, Wyoming. These vehicles should not need a new cover. 4. Install the grille opening section ONLY (if using the 2 piece cover) of the winter front cover following the usage guidelines provided in the Owners Manual for the appropriate type winter cover. ‹› If the customer does not have a cover, obtain and install the grille opening section ONLY , GM P/N 25822811 (GMC) or GM P/N 25822812 (Chevrolet). 5. The grille opening cover MUST BE installed to ensure a complete repair, BEFORE ENCOUNTERING SNOW. This repair allows warm air to be circulated into the air cleaner. Additional Information to Advise Customer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 08-06-04-054B > Jan > 11 > Diesel Engine - Low Power/MIL ON/DTC P0101 > Page 1756 Important If the vehicle is driven in a snow storm before installing the winter cover and the customer chooses to resolve the issue, they must follow this procedure using the following steps: 1. Remove ANY ice or snow that may have accumulated in the air intake duct, BEFORE REPLACING the air cleaner element. 2. INSTALL the winter cover BEFORE continuing to drive the truck. 3. Turn OFF the ignition, and all electrical accessories and components. 4. Remove the key from the vehicle, THEN open and close the door. 5. WAIT for 2 minutes to allow the engine control module (ECM) to power down. This can be verified by watching for the instrument panel cluster (IPC) gage needles to drop slightly. 1. Allowing the ECM to power down will let DTC P0101 revert to a History DTC and the vehicle should return to full power if the issue has been eliminated. 2. Advise the customer to take the vehicle to the dealer as soon as possible to verify the condition has been eliminated. Ambient (Outside) Air Temperature Sensor Relocation For vehicles equipped with Automatic Temperature Control HVAC (RPO CJ2), the ambient (outside) air temperature sensor needs to be relocated using the following procedure: 1. Remove the radiator grille. Refer to the Radiator Grille Replacement procedure in SI. 2. Remove the ambient air sensor from its current location by carefully lifting the sensor from the radiator support cross bar. 3. Remove the harness clip nearest to the sensor. 4. Reinstall the ambient air sensor to the new location using the existing hole (1) in the lower section of the radiator support. 5. Reinstall the harness clip to the existing hole (2) in the radiator support. 6. Reinstall the radiator grille. Parts Information Warranty Information Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 08-06-04-054B > Jan > 11 > Diesel Engine - Low Power/MIL ON/DTC P0101 > Page 1757 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 08-06-04-054A > Jan > 10 > Engine - Reduced Power/MIL ON/DTC P0101 Air Filter Element: Customer Interest Engine - Reduced Power/MIL ON/DTC P0101 TECHNICAL Bulletin No.: 08-06-04-054A Date: January 07, 2010 Subject: Snow or Ice Ingestion into Air Cleaner Element, Malfunction Indicator Lamp (MIL) Illuminated, Engine Power is Reduced Message Displayed, DTC P0101 Set (Perform Repair as Outlined) Models: 2007-2010 Chevrolet Silverado 2500/3500 Series 2007-2010 GMC Sierra 2500/3500 Series Equipped with Duramax(TM) Diesel Engine (RPO LMM) Please Refer to GMVIS Supercede: This bulletin is being revised to remove the graphic, update the Parts and Correction information and add information to advise a customer. Please discard Corporate Bulletin 08-06-04-054 (Section 06 - Engine / Propulsion System). Condition Some customers may comment on the malfunction indicator lamp (MIL) being illuminated and an Engine Power is Reduced message being displayed. The technician may observe DTC P0101 set as current or in history. Cause This condition may be caused by snow being ingested into the air cleaner housing and accumulating in the air cleaner element, resulting in restricted airflow into the engine. Correction 1. Verify the condition by questioning the customer as to when the condition occurs (such as during or right after a snow storm). ‹› If the condition occurs as described above, proceed to Step 2. ‹› If the condition does not occur as described above, refer to Diagnostic Trouble Code (DTC) List Vehicle in SI. 2. Remove the air cleaner element. Refer to Air Cleaner Element Replacement in SI. 3. Inspect the air cleaner element for the following conditions: 1. Packed snow 2. Frozen ice 3. A soaking wet condition that would indicate previous snow ingestion 4. Excessive debris and contamination as a result of the ingestion ‹› If any of the above conditions are observed, replace the air cleaner element. Remove any snow or ice that may have accumulated in the air intake duct. Note Winter covers for trucks that are equipped with the Duramax(TM) Diesel Engine are included with vehicle orders that ship to the following areas: All of Canada, and the following states: Alaska, Colorado, Idaho, Maine, Michigan, Minnesota, Montana, New Hampshire, New York, North Dakota, South Dakota, Vermont, Wisconsin, Wyoming. These vehicles should not need a new cover. 4. Install the grille opening section ONLY (if using the 2 piece cover) of the winter front cover following the usage guidelines provided in the Owners Manual for the appropriate type winter cover. ‹› If the customer does not have a cover, obtain and install the grille opening section ONLY, GM P/N 25822811 (GMC) or GM P/N 25822812 (Chevrolet). 5. The grille opening cover MUST BE installed to ensure a complete repair, BEFORE ENCOUNTERING SNOW. This repair allows warm air to be circulated into the air cleaner. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 08-06-04-054A > Jan > 10 > Engine - Reduced Power/MIL ON/DTC P0101 > Page 1762 Additional Information to Advise Customer Important If the vehicle is driven in a snow storm before installing the winter cover and the customer chooses to resolve the issue, they must follow this procedure using the following steps: 1. Remove ANY ice or snow that may have accumulated in the air intake duct, BEFORE REPLACING the air cleaner element. 2. INSTALL the winter cover BEFORE continuing to drive the truck. 3. Turn OFF the ignition, and all electrical accessories and components. 4. Remove the key from the vehicle, THEN open and close the door. 5. WAIT for 2 minutes to allow the engine control module (ECM) to power down. This can be verified by watching for the instrument panel cluster (IPC) gage needles to drop slightly. 1. Allowing the ECM to power down will let DTC P0101 revert to a History DTC and the vehicle should return to full power if the issue has been eliminated. 2. Advise the customer to take the vehicle to the dealer as soon as possible to verify the condition has been eliminated. Parts Information Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 08-06-04-054B > Jan > 11 > Diesel Engine - Low Power/MIL ON/DTC P0101 Air Filter Element: All Technical Service Bulletins Diesel Engine - Low Power/MIL ON/DTC P0101 TECHNICAL Bulletin No.: 08-06-04-054B Date: January 24, 2011 Subject: Snow or Ice Ingestion into Air Cleaner Element, Malfunction Indicator Lamp (MIL) Illuminated, Engine Power is Reduced Message Displayed, DTC P0101 Set (Perform Repair as Outlined) Models: 2007-2010 Chevrolet Silverado 2500/3500 Series 2007-2010 GMC Sierra 2500/3500 Series Equipped with Duramax(TM) Diesel Engine (RPO LMM) Supercede: This bulletin is being revised to provide a procedure to relocate the OAT sensor, if equipped with RPO CJ2. Please discard Corporate Bulletin 08-06-04-054A (Section 06 - Engine / Propulsion System). Condition Some customers may comment on the malfunction indicator lamp (MIL) being illuminated and an Engine Power is Reduced message being displayed. The technician may observe DTC P0101 set as current or in history. Cause This condition may be caused by snow being ingested into the air cleaner housing and accumulating in the air cleaner element, resulting in restricted airflow into the engine. Correction 1. Verify the condition by questioning the customer as to when the condition occurs (such as during or right after a snow storm). ‹› If the condition occurs as described above, proceed to Step 2. ‹› If the condition does not occur as described above, refer to Diagnostic Trouble Code (DTC) List Vehicle in SI. 2. Remove the air cleaner element. Refer to Air Cleaner Element Replacement in SI. 3. Inspect the air cleaner element for the following conditions: 1. Packed snow 2. Frozen ice 3. A soaking wet condition that would indicate previous snow ingestion 4. Excessive debris and contamination as a result of the ingestion ‹› If any of the above conditions are observed, replace the air cleaner element. Remove any snow or ice that may have accumulated in the air intake duct. Note Winter covers for trucks that are equipped with the Duramax(TM) Diesel Engine are included with vehicle orders that ship to the following areas: All of Canada, and the following states: Alaska, Colorado, Idaho, Maine, Michigan, Minnesota, Montana, New Hampshire, New York, North Dakota, South Dakota, Vermont, Wisconsin, Wyoming. These vehicles should not need a new cover. 4. Install the grille opening section ONLY (if using the 2 piece cover) of the winter front cover following the usage guidelines provided in the Owners Manual for the appropriate type winter cover. ‹› If the customer does not have a cover, obtain and install the grille opening section ONLY , GM P/N 25822811 (GMC) or GM P/N 25822812 (Chevrolet). 5. The grille opening cover MUST BE installed to ensure a complete repair, BEFORE ENCOUNTERING SNOW. This repair allows warm air to be circulated into the air cleaner. Additional Information to Advise Customer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 08-06-04-054B > Jan > 11 > Diesel Engine - Low Power/MIL ON/DTC P0101 > Page 1768 Important If the vehicle is driven in a snow storm before installing the winter cover and the customer chooses to resolve the issue, they must follow this procedure using the following steps: 1. Remove ANY ice or snow that may have accumulated in the air intake duct, BEFORE REPLACING the air cleaner element. 2. INSTALL the winter cover BEFORE continuing to drive the truck. 3. Turn OFF the ignition, and all electrical accessories and components. 4. Remove the key from the vehicle, THEN open and close the door. 5. WAIT for 2 minutes to allow the engine control module (ECM) to power down. This can be verified by watching for the instrument panel cluster (IPC) gage needles to drop slightly. 1. Allowing the ECM to power down will let DTC P0101 revert to a History DTC and the vehicle should return to full power if the issue has been eliminated. 2. Advise the customer to take the vehicle to the dealer as soon as possible to verify the condition has been eliminated. Ambient (Outside) Air Temperature Sensor Relocation For vehicles equipped with Automatic Temperature Control HVAC (RPO CJ2), the ambient (outside) air temperature sensor needs to be relocated using the following procedure: 1. Remove the radiator grille. Refer to the Radiator Grille Replacement procedure in SI. 2. Remove the ambient air sensor from its current location by carefully lifting the sensor from the radiator support cross bar. 3. Remove the harness clip nearest to the sensor. 4. Reinstall the ambient air sensor to the new location using the existing hole (1) in the lower section of the radiator support. 5. Reinstall the harness clip to the existing hole (2) in the radiator support. 6. Reinstall the radiator grille. Parts Information Warranty Information Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 08-06-04-054B > Jan > 11 > Diesel Engine - Low Power/MIL ON/DTC P0101 > Page 1769 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 08-06-04-054A > Jan > 10 > Engine - Reduced Power/MIL ON/DTC P0101 Air Filter Element: All Technical Service Bulletins Engine - Reduced Power/MIL ON/DTC P0101 TECHNICAL Bulletin No.: 08-06-04-054A Date: January 07, 2010 Subject: Snow or Ice Ingestion into Air Cleaner Element, Malfunction Indicator Lamp (MIL) Illuminated, Engine Power is Reduced Message Displayed, DTC P0101 Set (Perform Repair as Outlined) Models: 2007-2010 Chevrolet Silverado 2500/3500 Series 2007-2010 GMC Sierra 2500/3500 Series Equipped with Duramax(TM) Diesel Engine (RPO LMM) Please Refer to GMVIS Supercede: This bulletin is being revised to remove the graphic, update the Parts and Correction information and add information to advise a customer. Please discard Corporate Bulletin 08-06-04-054 (Section 06 - Engine / Propulsion System). Condition Some customers may comment on the malfunction indicator lamp (MIL) being illuminated and an Engine Power is Reduced message being displayed. The technician may observe DTC P0101 set as current or in history. Cause This condition may be caused by snow being ingested into the air cleaner housing and accumulating in the air cleaner element, resulting in restricted airflow into the engine. Correction 1. Verify the condition by questioning the customer as to when the condition occurs (such as during or right after a snow storm). ‹› If the condition occurs as described above, proceed to Step 2. ‹› If the condition does not occur as described above, refer to Diagnostic Trouble Code (DTC) List Vehicle in SI. 2. Remove the air cleaner element. Refer to Air Cleaner Element Replacement in SI. 3. Inspect the air cleaner element for the following conditions: 1. Packed snow 2. Frozen ice 3. A soaking wet condition that would indicate previous snow ingestion 4. Excessive debris and contamination as a result of the ingestion ‹› If any of the above conditions are observed, replace the air cleaner element. Remove any snow or ice that may have accumulated in the air intake duct. Note Winter covers for trucks that are equipped with the Duramax(TM) Diesel Engine are included with vehicle orders that ship to the following areas: All of Canada, and the following states: Alaska, Colorado, Idaho, Maine, Michigan, Minnesota, Montana, New Hampshire, New York, North Dakota, South Dakota, Vermont, Wisconsin, Wyoming. These vehicles should not need a new cover. 4. Install the grille opening section ONLY (if using the 2 piece cover) of the winter front cover following the usage guidelines provided in the Owners Manual for the appropriate type winter cover. ‹› If the customer does not have a cover, obtain and install the grille opening section ONLY, GM P/N 25822811 (GMC) or GM P/N 25822812 (Chevrolet). 5. The grille opening cover MUST BE installed to ensure a complete repair, BEFORE ENCOUNTERING SNOW. This repair allows warm air to be circulated into the air cleaner. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 08-06-04-054A > Jan > 10 > Engine - Reduced Power/MIL ON/DTC P0101 > Page 1774 Additional Information to Advise Customer Important If the vehicle is driven in a snow storm before installing the winter cover and the customer chooses to resolve the issue, they must follow this procedure using the following steps: 1. Remove ANY ice or snow that may have accumulated in the air intake duct, BEFORE REPLACING the air cleaner element. 2. INSTALL the winter cover BEFORE continuing to drive the truck. 3. Turn OFF the ignition, and all electrical accessories and components. 4. Remove the key from the vehicle, THEN open and close the door. 5. WAIT for 2 minutes to allow the engine control module (ECM) to power down. This can be verified by watching for the instrument panel cluster (IPC) gage needles to drop slightly. 1. Allowing the ECM to power down will let DTC P0101 revert to a History DTC and the vehicle should return to full power if the issue has been eliminated. 2. Advise the customer to take the vehicle to the dealer as soon as possible to verify the condition has been eliminated. Parts Information Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 1775 Air Filter Element: Service and Repair Air Cleaner Element Replacement Removal Procedure 1. Loosen the screw holding the air cleaner housing door in place. 2. Remove the air cleaner housing door. 3. Remove the air filter element. Installation Procedure 1. Stand facing the front fender on the passenger side of the vehicle. Insert the element into the housing. Place the palm of your hand on the inboard end of the element, and press the element into position. 2. Press both downward and inboard until the outboard end of the element clicks into place inboard of the locating tab. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 1776 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the air cleaner housing door and tighten the screw. Tighten the screw to 4 Nm (35 lb in). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair Fuel Pressure Relief Valve Replacement Removal Procedure 1. Remove the glow plug module and bracket. Refer to Glow Plug Control Module Replacement (See: Powertrain Management/Glow Plug System/Glow Plug Control Module/Service and Repair). 2. Remove the fuel pressure relief valve from the left fuel rail. Installation Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the fuel pressure relief valve to the left fuel rail. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Page 1781 Tighten the valve to 100 Nm (74 lb ft). 2. Install the glow plug module and bracket. Refer to Glow Plug Control Module Replacement (See: Powertrain Management/Glow Plug System/Glow Plug Control Module/Service and Repair). 3. Prime the fuel system. Refer to Fuel System Priming (See: Powertrain Management/Fuel Delivery and Air Induction/Service and Repair/Fuel System Priming). 4. Start the engine. If the engine stalls, repeat the above step. 5. Once the engine starts, inspect for fuel leaks. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications The minimum compression in any one cylinder is 2069 kPa (300 psi). There should not be more than 345 kPa (50 psi) difference between a suspect cylinder and the average compression of all 8 cylinders. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 1785 Compression Check: Testing and Inspection Engine Compression Test Special Tools * J 26999 - Compression Gauge * EN-47603 - Compression Gauge Adapter For equivalent regional tools, refer to Special Tools (See: Engine, Cooling and Exhaust/Engine/Tools and Equipment/Special Tools). 1. Ensure that the vehicle's batteries are in good condition, and fully charged. 2. Operate the vehicle until the engine is at normal operating temperature. 3. Shut off engine. 4. Disconnect glow plug nut; remove all 8 glow plugs. All 8 glow plugs must be removed from the engine during each cylinder test to obtain valid test results. 5. Prior to taking a compression reading, verify the cranking speed is greater than 140 RPM. If the cranking speed is below 140 RPM, repair the slow cranking speed condition before continuing with the compression test. Refer to Engine Cranks Slowly (See: Starting and Charging/Testing and Inspection/Symptom Related Diagnostic Procedures/Engine Cranks Slowly). 6. Install the EN-47603 - adapter in the glow plug hole for the cylinder that is being checked. Caution: Do not add oil to any cylinder during a compression test as extensive engine damage may result. 7. Connect the J 26999 - gauge to the EN-47603 - adapter. Caution: Do not crank the engine using the ignition switch, as the fuel injectors and the glow plug circuits will be energized and engine damage may result. 8. Using a remote start switch, crank the engine for 6 compression strokes, puffs, for the cylinder being tested. 9. Observe the J 26999 - gauge and note the reading as the compression test is being performed. A normal cylinder reading will be indicated if compression builds up quickly and evenly to the specified level. An abnormal reading will be indicated if compression is low on the first compression stroke, starts increasing on the following compression strokes but does not reach the specified level. 10. Record the compression reading for the cylinder just tested. 11. Disconnect the J 26999 gauge from the EN-47603 - adapter and remove adapter from the glow plug hole. 12. Repeat steps 8 through 13 for all remaining cylinders. All 8 cylinders must be tested to obtain valid test results. Record the readings. 13. The minimum compression in any one cylinder is 2069 kPa (300 psi). There should not be more than 345 kPa (50 psi) difference between a suspect cylinder and the average compression of all 8 cylinders. Note: Cylinder to cylinder variation may be at the high end of the specification on engines with less than 20,000 km (12,427 miles). * Normal-Compression builds up quickly and evenly to the specified compression for each cylinder. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 1786 * Piston Rings Leaking-Compression is low on the first stroke. Compression builds up with the following strokes but does not reach normal. * Valves Leaking-Compression is low on the first stroke. Compression usually does not build up on the following strokes. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications Valve Clearance Adjustment Specifications Valve Lash ........................................................................................................................................... ...................................................... 0.3 mm (0.012 in) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Adjustments > On Vehicle Valve Clearance: Adjustments On Vehicle Valve Clearance Adjustment 1. Remove the fan clutch. Refer to Fan Clutch Replacement (Diesel) (See: Engine, Cooling and Exhaust/Cooling System/Radiator Cooling Fan/Fan Clutch/Service and Repair). 2. Remove the upper valve rocker arm covers. Refer to Valve Rocker Arm Upper Cover Replacement - Left Side (See: Engine, Cooling and Exhaust/Engine/Cylinder Head Assembly/Valve Cover/Service and Repair/Valve Rocker Arm Upper Cover Replacement - Left Side) and Valve Rocker Arm Upper Cover Replacement - Right Side (See: Engine, Cooling and Exhaust/Engine/Cylinder Head Assembly/Valve Cover/Service and Repair/Valve Rocker Arm Upper Cover Replacement - Right Side). 3. Rotate the crankshaft in order to bring the number 1 cylinder to top dead center (TDC) of the compression stroke. The number 1 cylinder is the front cylinder on the right bank. The mark on the crankshaft balancer should be aligned with the mark on the engine. 4. Loosen the valve adjusting screws. 5. Insert a feeler gauge between the tip of the rocker arm and the valve bridge. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Adjustments > On Vehicle > Page 1792 6. Adjust the valve lash to 0.3 mm (0.012 in). Refer to Valve Clearance Adjustment Specifications (See: ) to determine which valves can be adjusted when the engine is at TDC. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 7. Tighten the lock nut. Tighten nut to 22 Nm (16 lb ft). 8. Rotate the crankshaft one revolution in order to bring the number 1 cylinder to TDC of the exhaust stroke. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Adjustments > On Vehicle > Page 1793 9. Loosen the valve adjusting screws. 10. Insert a feeler gauge between the tip of the rocker arm and the valve bridge. 11. Adjust the valve clearance to 0.3 mm (0.012 in). Refer to Valve Clearance Adjustment Specifications (See: ) to determine which valves can be adjusted when the engine is at TDC. 12. Tighten the lock nut. Tighten nut to 22 Nm (16 lb ft). 13. Install the upper valve rocker arm covers. Refer to Valve Rocker Arm Upper Cover Replacement - Left Side (See: Engine, Cooling and Exhaust/Engine/Cylinder Head Assembly/Valve Cover/Service and Repair/Valve Rocker Arm Upper Cover Replacement - Left Side) and Valve Rocker Arm Upper Cover Replacement - Right Side (See: Engine, Cooling and Exhaust/Engine/Cylinder Head Assembly/Valve Cover/Service and Repair/Valve Rocker Arm Upper Cover Replacement - Right Side). 14. Install the fan clutch. Refer to Fan Clutch Replacement (Diesel) (See: Engine, Cooling and Exhaust/Cooling System/Radiator Cooling Fan/Fan Clutch/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Adjustments > On Vehicle > Page 1794 Valve Clearance: Adjustments Off Vehicle Valve Clearance Adjustment 1. Rotate the crankshaft to bring the number 1 cylinder at the top dead center of the compression stroke. The number 1 cylinder is the front cylinder on the right bank. The mark on the crankshaft balancer should be aligned with the mark on the engine. 2. Loosen the valve adjusting screws. 3. Insert a feeler gauge between the tip of the rocker arm and the valve bridge. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Adjustments > On Vehicle > Page 1795 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Adjust the valve lash to 0.3 mm (0.012 in). Refer to Valve Clearance Adjustment Specifications (See: ) to determine which valves that can be adjusted when the engine is at Top Dead Center. Tighten the valve lash lock nut to 22 Nm (16 lb ft). 5. Rotate the crankshaft one revolution to bring the number 1 cylinder at Top Dead Center of the exhaust stroke. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Adjustments > On Vehicle > Page 1796 6. Adjust the valve lash to 0.3 mm (0.012 in). Refer to Valve Clearance Adjustment Specifications (See: ) to determine which valves that can be adjusted when the engine is at Top Dead Center. Tighten the valve lash lock nut to 22 Nm (16 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Customer Interest: > 05-06-01-018B > Feb > 11 > Diesel Engine - Drive Belt Chirp/Squeal at Cold Idle Drive Belt: Customer Interest Diesel Engine - Drive Belt Chirp/Squeal at Cold Idle TECHNICAL Bulletin No.: 05-06-01-018B Date: February 09, 2011 Subject: Accessory Drive Belt Chirp, Squeal or Squeak Type Noise at Cold Idle (Replace A/C Compressor/Power Steering Pump Mounting Bracket or Enlarge Bracket Bolt Holes) Models: 2004-2010 Chevrolet Silverado 2006-2010 Chevrolet Express 2004-2010 GMC Sierra 2006-2010 GMC Savana Equipped with 6.6L Duramax(R) Diesel Engine (VINs D, 2 - RPOs LBZ, LLY, LMM) Supercede: This bulletin is being revised to add model years and RPOs. Please discard Corporate Bulletin Number 05-06-01-018A (Section 06 - Engine/Propulsion System). Condition Important It should be noted that a chirp type noise on engine shutdown is normal for a diesel engine due to higher engine compression and the rapid stopping of the crankshaft. No repairs should be attempted for this condition. Some customers may comment on an accessory drive belt chirp, squeal, or squeak type noise at idle, especially on a cold start. The noise may be reduced or go away after the engine warms up. Cause Some 2004/2005 Silverado or Sierra trucks, with a 6.6L LLY engine produced before June, 2004, may have an A/C compressor/power steering pump mounting bracket and power steering rear mounting bracket that are machined slightly out of specification, causing a misaligned power steering pump. If the power steering pump is misaligned, it will force the accessory drive belt to run farther inboard on the fan pulley. When the belt leaves the fan pulley, the belt will not align properly to the crankshaft pulley grooves and create a chirp or squeak type noise at the point of interference. Vehicles built after June 2004 will already have the new A/C compressor/power steering pump mounting bracket installed, but still may exhibit belt noise caused by the power steering pump rear mounting bracket. Correction Vehicles built prior to June 2004, replace the A/C compressor/power steering pump mounting bracket. Vehicles built after June 2004, enlarge the rear power steering pump bracket bolt holes. 1. Follow the published service information (SI) diagnostics for drive belt chirping. The diagnostic chart for the drive belt chirping will ask to inspect for a misaligned accessory drive pulley. Important Remove the top section of the radiator shroud and TCM/cover to gain access to check alignment and measure the power steering pulley on the power steering pump shaft. 2. Verify that the power steering pulley is properly pressed onto the power steering pump shaft. Refer to SI for the power steering pulley replacement. If the pulley needs to be realigned on the power steering pump shaft, follow the published SI procedures for the power steering pulley replacement. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Customer Interest: > 05-06-01-018B > Feb > 11 > Diesel Engine - Drive Belt Chirp/Squeal at Cold Idle > Page 1805 3. If the noise was not fully eliminated by the procedure in step 2, the power steering pulley may be adjusted with an allowable maximum variance of 1.0 mm (0.039 in) to the front from the flush position on the shaft to assist in eliminating any remaining belt noise. Refer to graphic illustration number 1 and number 2. Ensure that the power steering pump pulley illustration number 1 is flush against the power steering pump shaft illustration number 2, with an allowable variance of 1.0 mm (0.039 in). 4. If the noise was not fully eliminated by the procedure in step 3, and there are no other concerns found, follow the published SI diagnostics for drive belt chirping. Then, if the vehicle was built prior to June 2004 go to step 5. If the vehicle was built after June 2004, go to step 6. 5. Vehicles Built Prior to June 2004: 1. Replace the A/C compressor/power steering pump mounting bracket with P/N 97362175. Refer to graphic illustration number 1. Follow the published SI procedures for the Air Conditioning (A/C) Compressor and Power Steering Pump Mounting Bracket Replacement. 2. With the new A/C compressor/power steering pump mounting bracket installed, reposition the power steering pump to gain access to drill larger holes into the rear mounting bracket using a 14 mm (1/2") drill bit. Drilling the bolt holes larger will ensure proper alignment of the bracket when installing the bolts. Refer to graphic illustration number 2. 3. Install the power steering pump to the A/C compressor/power steering pump bracket. Refer to graphic illustration numbers 4, 2, and 1. Important Power steering pump front mounting bolts must always be tightened first to ensure correct pulley alignment. 4. Refer to graphic illustration number 4 and tighten the front power steering pump mounting bolts. Tighten Tighten the bolts to 50 Nm (37 lb ft). 5. Refer to graphic illustration number 2 and tighten the rear power steering bracket bolts. Tighten Tighten the bolts to 50 Nm (37 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Customer Interest: > 05-06-01-018B > Feb > 11 > Diesel Engine - Drive Belt Chirp/Squeal at Cold Idle > Page 1806 6. Vehicles Built After June 2004: 1. Remove the front and rear power steering bracket bolts from the A/C compressor/power steering pump bracket. Refer to graphic illustration numbers 4, 2, and 1. 2. Reposition the power steering pump to gain access to drill larger holes into the rear mounting bracket using a 14 mm (1/2 in) drill bit. Drilling the bolt holes larger will ensure proper alignment of the bracket when installing the bolts. Refer to graphic illustration number 2. 3. Install the power steering pump to A/C compressor/power steering pump bracket. Refer to graphic illustration numbers 4, 2, and 1. Important Power steering pump front mounting bolts must always be tightened first to ensure correct pulley alignment. 4. Refer to graphic illustration number 4 and tighten the front power steering pump mounting bolts. Tighten Tighten the bolts to 50 Nm (37 lb ft). 5. Refer to graphic illustration number 2 and tighten the rear bracket bolts. Tighten Tighten the bolts to 50 Nm (37 lb ft). Dual Generator System New belts are not available for dual generator systems. If a belt chirp noise is occurring on a dual generator system, please complete a Field Product Report (FPR). The instructions for completing a FPR can be found in Service Bulletin Number 02-00-89-002G. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Customer Interest: > 05-06-01-018B > Feb > 11 > Diesel Engine - Drive Belt Chirp/Squeal at Cold Idle > Page 1807 Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 05-06-01-018B > Feb > 11 > Diesel Engine - Drive Belt Chirp/Squeal at Cold Idle Drive Belt: All Technical Service Bulletins Diesel Engine - Drive Belt Chirp/Squeal at Cold Idle TECHNICAL Bulletin No.: 05-06-01-018B Date: February 09, 2011 Subject: Accessory Drive Belt Chirp, Squeal or Squeak Type Noise at Cold Idle (Replace A/C Compressor/Power Steering Pump Mounting Bracket or Enlarge Bracket Bolt Holes) Models: 2004-2010 Chevrolet Silverado 2006-2010 Chevrolet Express 2004-2010 GMC Sierra 2006-2010 GMC Savana Equipped with 6.6L Duramax(R) Diesel Engine (VINs D, 2 - RPOs LBZ, LLY, LMM) Supercede: This bulletin is being revised to add model years and RPOs. Please discard Corporate Bulletin Number 05-06-01-018A (Section 06 - Engine/Propulsion System). Condition Important It should be noted that a chirp type noise on engine shutdown is normal for a diesel engine due to higher engine compression and the rapid stopping of the crankshaft. No repairs should be attempted for this condition. Some customers may comment on an accessory drive belt chirp, squeal, or squeak type noise at idle, especially on a cold start. The noise may be reduced or go away after the engine warms up. Cause Some 2004/2005 Silverado or Sierra trucks, with a 6.6L LLY engine produced before June, 2004, may have an A/C compressor/power steering pump mounting bracket and power steering rear mounting bracket that are machined slightly out of specification, causing a misaligned power steering pump. If the power steering pump is misaligned, it will force the accessory drive belt to run farther inboard on the fan pulley. When the belt leaves the fan pulley, the belt will not align properly to the crankshaft pulley grooves and create a chirp or squeak type noise at the point of interference. Vehicles built after June 2004 will already have the new A/C compressor/power steering pump mounting bracket installed, but still may exhibit belt noise caused by the power steering pump rear mounting bracket. Correction Vehicles built prior to June 2004, replace the A/C compressor/power steering pump mounting bracket. Vehicles built after June 2004, enlarge the rear power steering pump bracket bolt holes. 1. Follow the published service information (SI) diagnostics for drive belt chirping. The diagnostic chart for the drive belt chirping will ask to inspect for a misaligned accessory drive pulley. Important Remove the top section of the radiator shroud and TCM/cover to gain access to check alignment and measure the power steering pulley on the power steering pump shaft. 2. Verify that the power steering pulley is properly pressed onto the power steering pump shaft. Refer to SI for the power steering pulley replacement. If the pulley needs to be realigned on the power steering pump shaft, follow the published SI procedures for the power steering pulley replacement. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 05-06-01-018B > Feb > 11 > Diesel Engine - Drive Belt Chirp/Squeal at Cold Idle > Page 1813 3. If the noise was not fully eliminated by the procedure in step 2, the power steering pulley may be adjusted with an allowable maximum variance of 1.0 mm (0.039 in) to the front from the flush position on the shaft to assist in eliminating any remaining belt noise. Refer to graphic illustration number 1 and number 2. Ensure that the power steering pump pulley illustration number 1 is flush against the power steering pump shaft illustration number 2, with an allowable variance of 1.0 mm (0.039 in). 4. If the noise was not fully eliminated by the procedure in step 3, and there are no other concerns found, follow the published SI diagnostics for drive belt chirping. Then, if the vehicle was built prior to June 2004 go to step 5. If the vehicle was built after June 2004, go to step 6. 5. Vehicles Built Prior to June 2004: 1. Replace the A/C compressor/power steering pump mounting bracket with P/N 97362175. Refer to graphic illustration number 1. Follow the published SI procedures for the Air Conditioning (A/C) Compressor and Power Steering Pump Mounting Bracket Replacement. 2. With the new A/C compressor/power steering pump mounting bracket installed, reposition the power steering pump to gain access to drill larger holes into the rear mounting bracket using a 14 mm (1/2") drill bit. Drilling the bolt holes larger will ensure proper alignment of the bracket when installing the bolts. Refer to graphic illustration number 2. 3. Install the power steering pump to the A/C compressor/power steering pump bracket. Refer to graphic illustration numbers 4, 2, and 1. Important Power steering pump front mounting bolts must always be tightened first to ensure correct pulley alignment. 4. Refer to graphic illustration number 4 and tighten the front power steering pump mounting bolts. Tighten Tighten the bolts to 50 Nm (37 lb ft). 5. Refer to graphic illustration number 2 and tighten the rear power steering bracket bolts. Tighten Tighten the bolts to 50 Nm (37 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 05-06-01-018B > Feb > 11 > Diesel Engine - Drive Belt Chirp/Squeal at Cold Idle > Page 1814 6. Vehicles Built After June 2004: 1. Remove the front and rear power steering bracket bolts from the A/C compressor/power steering pump bracket. Refer to graphic illustration numbers 4, 2, and 1. 2. Reposition the power steering pump to gain access to drill larger holes into the rear mounting bracket using a 14 mm (1/2 in) drill bit. Drilling the bolt holes larger will ensure proper alignment of the bracket when installing the bolts. Refer to graphic illustration number 2. 3. Install the power steering pump to A/C compressor/power steering pump bracket. Refer to graphic illustration numbers 4, 2, and 1. Important Power steering pump front mounting bolts must always be tightened first to ensure correct pulley alignment. 4. Refer to graphic illustration number 4 and tighten the front power steering pump mounting bolts. Tighten Tighten the bolts to 50 Nm (37 lb ft). 5. Refer to graphic illustration number 2 and tighten the rear bracket bolts. Tighten Tighten the bolts to 50 Nm (37 lb ft). Dual Generator System New belts are not available for dual generator systems. If a belt chirp noise is occurring on a dual generator system, please complete a Field Product Report (FPR). The instructions for completing a FPR can be found in Service Bulletin Number 02-00-89-002G. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 05-06-01-018B > Feb > 11 > Diesel Engine - Drive Belt Chirp/Squeal at Cold Idle > Page 1815 Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 08-06-01-008A > Jul > 09 > Engine - Drive Belt Misalignment Diagnostics Drive Belt: All Technical Service Bulletins Engine - Drive Belt Misalignment Diagnostics INFORMATION Bulletin No.: 08-06-01-008A Date: July 27, 2009 Subject: Diagnosing Accessory Drive Belt / Serpentine Belt Noise and Availability and Use of Kent-Moore EN-49228 Laser Alignment Tool - Drive Belt Models: 2010 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add a model year and update the Tool Information. Please discard Corporate Bulletin Number 08-06-01-008 (Section 06 - Engine). Background Several aftermarket companies offer laser alignment tools for accessory drive systems that can be very helpful in eliminating drive belt noise as a result of misaligned pulleys. Typically pricing ranges from $160 - $200. EN-49228 Laser Alignment Tool - Drive Belt The GM Tool program has now made available a competitive, simple to use and time-saving laser tool to assist in achieving precise alignment of the drive belt pulleys. This optional tool removes the guesswork from proper pulley alignment and may serve to reduce comebacks from: - Drive Belt Noise - Accelerated Drive Belt Wear - Drive Belt Slippage Instructions The instructions below are specific only to the truck Gen IV V-8 family of engines. These instructions are only for illustrative purposes to show how the tool may be used. Universal instructions are included in the box with the Laser Alignment Tool - Drive Belt. Caution - Do not look directly into the beam projected from the laser. - Use caution when shining the laser on highly polished or reflective surfaces. Laser safety glasses help reduce laser beam glare in many circumstances. - Always use laser safety glasses when using the laser. Laser safety glasses are not designed to protect eyes from direct laser exposure. 1. Observe and mark the serpentine belt orientation. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 08-06-01-008A > Jul > 09 > Engine - Drive Belt Misalignment Diagnostics > Page 1820 2. Remove the serpentine belt from the accessory drive system. 3. Install the tool onto the power steering pulley. Position the legs of the tool into the outer grooves of the pulley, farthest from the front of the engine. 4. Install the retaining cord around the pulley and to the legs of the tool. 5. Put on the laser safety glasses provided with the tool. 6. Depress the switch on the rear of the tool to activate the light beam. 7. Rotate the power steering pulley as required to project the light beam onto the crankshaft balancer pulley grooves. 8. Inspect for proper power steering pulley alignment. - If the laser beam projects onto the second rib or raised area (1), the pulleys are aligned properly. - If the laser beam projects more than one-quarter rib 0.9 mm (0.035 in) mis-alignment, adjust the position of the power steering pulley as required. - Refer to SI for Power Steering Pulley Removal and Installation procedures. 9. Install the serpentine belt to the accessory drive system in the original orientation. 10. Operate the vehicle and verify that the belt noise concern is no longer present. Tool Information Please visit the GM service tool website for pricing information or to place your order for this tool. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: > 08-06-01-008A > Jul > 09 > Engine - Drive Belt Misalignment Diagnostics > Page 1821 Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Drive Belt: > 08-06-01-008A > Jul > 09 > Engine - Drive Belt Misalignment Diagnostics Drive Belt: All Technical Service Bulletins Engine - Drive Belt Misalignment Diagnostics INFORMATION Bulletin No.: 08-06-01-008A Date: July 27, 2009 Subject: Diagnosing Accessory Drive Belt / Serpentine Belt Noise and Availability and Use of Kent-Moore EN-49228 Laser Alignment Tool - Drive Belt Models: 2010 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add a model year and update the Tool Information. Please discard Corporate Bulletin Number 08-06-01-008 (Section 06 - Engine). Background Several aftermarket companies offer laser alignment tools for accessory drive systems that can be very helpful in eliminating drive belt noise as a result of misaligned pulleys. Typically pricing ranges from $160 - $200. EN-49228 Laser Alignment Tool - Drive Belt The GM Tool program has now made available a competitive, simple to use and time-saving laser tool to assist in achieving precise alignment of the drive belt pulleys. This optional tool removes the guesswork from proper pulley alignment and may serve to reduce comebacks from: - Drive Belt Noise - Accelerated Drive Belt Wear - Drive Belt Slippage Instructions The instructions below are specific only to the truck Gen IV V-8 family of engines. These instructions are only for illustrative purposes to show how the tool may be used. Universal instructions are included in the box with the Laser Alignment Tool - Drive Belt. Caution - Do not look directly into the beam projected from the laser. - Use caution when shining the laser on highly polished or reflective surfaces. Laser safety glasses help reduce laser beam glare in many circumstances. - Always use laser safety glasses when using the laser. Laser safety glasses are not designed to protect eyes from direct laser exposure. 1. Observe and mark the serpentine belt orientation. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Drive Belt: > 08-06-01-008A > Jul > 09 > Engine - Drive Belt Misalignment Diagnostics > Page 1827 2. Remove the serpentine belt from the accessory drive system. 3. Install the tool onto the power steering pulley. Position the legs of the tool into the outer grooves of the pulley, farthest from the front of the engine. 4. Install the retaining cord around the pulley and to the legs of the tool. 5. Put on the laser safety glasses provided with the tool. 6. Depress the switch on the rear of the tool to activate the light beam. 7. Rotate the power steering pulley as required to project the light beam onto the crankshaft balancer pulley grooves. 8. Inspect for proper power steering pulley alignment. - If the laser beam projects onto the second rib or raised area (1), the pulleys are aligned properly. - If the laser beam projects more than one-quarter rib 0.9 mm (0.035 in) mis-alignment, adjust the position of the power steering pulley as required. - Refer to SI for Power Steering Pulley Removal and Installation procedures. 9. Install the serpentine belt to the accessory drive system in the original orientation. 10. Operate the vehicle and verify that the belt noise concern is no longer present. Tool Information Please visit the GM service tool website for pricing information or to place your order for this tool. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Drive Belt: > 08-06-01-008A > Jul > 09 > Engine - Drive Belt Misalignment Diagnostics > Page 1828 Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Page 1829 Drive Belt: Diagrams Drive Belt Replacement Equipped with a single generator. Equipped with dual generators. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Page 1830 Drive Belt: Service Precautions Belt Dressing Caution Caution: Do not use belt dressing on the drive belt. Belt dressing causes the breakdown of the composition of the drive belt. Failure to follow this recommendation will damage the drive belt. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Page 1831 Drive Belt: Description and Operation Drive Belt System Description The drive belt system consists of the following components: * The drive belt * The drive belt tensioner * The drive belt idler pulley * The crankshaft balancer pulley * The accessory drive component mounting brackets * The accessory drive components - The power steering pump, if belt driven - The generator - The A/C compressor, if equipped - The engine cooling fan, if belt driven - The water pump, if belt driven - The vacuum pump, if equipped - The air compressor, if equipped The drive belt system may use 1 belt or 2 belts. The drive belt is thin so that it can bend backwards and has several ribs to match the grooves in the pulleys. The drive belts are made of different types of rubbers, chloroprene or EPDM, and have different layers or plys containing either fiber cloth or cords for reinforcement. Both sides of the drive belt may be used to drive the different accessory drive components. When the back side of the drive belt is used to drive a pulley, the pulley is smooth. The drive belt is pulled by the crankshaft balancer pulley across the accessory drive component pulleys. The spring loaded drive belt tensioner keeps constant tension on the drive belt to prevent the drive belt from slipping. The drive belt tensioner arm will move when loads are applied to the drive belt by the accessory drive components and the crankshaft. The drive belt system may have an idler pulley, which is used to add wrap to the adjacent pulleys. Some systems use an idler pulley in place of an accessory drive component when the vehicle is not equipped with the accessory. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping, Squeal, and Whine Diagnosis Drive Belt: Testing and Inspection Drive Belt Chirping, Squeal, and Whine Diagnosis Drive Belt Chirping, Squeal, and Whine Diagnosis Diagnostic Aids * A chirping or squeal noise may be intermittent due to moisture on the drive belts or the pulleys. It may be necessary to spray a small amount of water on the drive belts in order to duplicate the customers concern. If spraying water on the drive belt duplicates the symptom, cleaning the belt pulleys may be the probable solution. * If the noise is intermittent, verify the accessory drive components by varying their loads making sure they are operated to their maximum capacity. An overcharged A/C system, power steering system with a pinched hose or wrong fluid, or a generator failing are suggested items to inspect. * A chirping, squeal or whine noise may be caused by a loose or improper installation of a body or suspension component. Other items of the vehicle may also cause the noise. * The drive belts will not cause a whine noise. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. The noise may not be engine related. This step is to verify that the engine is making the noise. If the engine is not making the noise do not proceed further with this table. 3. The noise may be an internal engine noise. Removing the drive belts one at a time and operating the engine for a brief period will verify the noise is related to the drive belt. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belts removed. 4. Inspect all drive belt pulleys for pilling. Pilling is the small balls or pills or it can be strings in the drive belt grooves from the accumulation of rubber dust. 6. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found refer to that accessory drive component for the proper installation procedure for that pulley. 10. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed. 12. Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating properly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley. 14. This test is to verify that the drive belt tensioner operates properly. If the drive belt tensioner is not operating properly, proper belt tension may not be achieved to keep the drive belt from slipping which could cause a squeal noise. 15. This test is to verify that the drive belt is not too long, which would prevent the drive belt tensioner from working properly. Also if an incorrect length drive belt was installed, it may not be routed properly and may be turning an accessory drive component in the wrong direction. 16. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found refer to that accessory drive component for the proper installation procedure for that pulley. 17. This test is to verify that the pulleys are the correct diameter or width. Using a known good vehicle compare the pulley sizes. 19. Replacing the drive belt when it is not damaged or there is not excessive pilling will only be a temporary repair. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping, Squeal, and Whine Diagnosis > Page 1834 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping, Squeal, and Whine Diagnosis > Page 1835 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping, Squeal, and Whine Diagnosis > Page 1836 Drive Belt: Testing and Inspection Drive Belt Rumbling and Vibration Diagnosis Drive Belt Rumbling and Vibration Diagnosis Diagnostic Aids The accessory drive components can have an affect on engine vibration. Vibration from the engine operating may cause a body component or another part of the vehicle to make rumbling noise. Vibration can be caused by, but not limited to the air conditioning (A/C) system over charged, the power steering system restricted or the incorrect fluid, or an extra load on the generator. To help identify an intermittent or an improper condition, vary the loads on the accessory drive components. The drive belt may have a rumbling condition that can not be seen or felt. Sometimes replacing the drive belt may be the only repair for the symptom. If replacing the drive belt, completing the diagnostic table, and the noise is only heard when the drive belts are installed, there might be an accessory drive component with a failure. Varying the load on the different accessory drive components may aid in identifying which component is causing the rumbling noise. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This test is to verify that the symptom is present during diagnosing. Other vehicle components may cause a similar symptom. 3. This test is to verify that one of the drive belts is causing the rumbling noise or vibration. Rumbling noise may be confused with an internal engine noise due to the similarity in the description. Remove only one drive belt at a time if the vehicle has multiple drive belts. When removing the drive belts the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belts removed. 4. Inspecting the drive belts is to ensure that they are not causing the noise. Small cracks across the ribs of the drive belt will not cause the noise. Belt separation is identified by the plys of the belt separating and may be seen at the edge of the belt our felt as a lump in the belt. 5. Small amounts of pilling is normal condition and acceptable. When the pilling is severe the drive belt does not have a smooth surface for proper operation. 9. Inspecting of the fasteners can eliminate the possibility that the wrong bolt, nut, spacer, or washer was installed. 11. This step should only be performed if the water pump is driven by the drive belt. Inspect the water pump shaft for being bent. Also inspect the water pump bearings for smooth operation and excessive play. Compare the water pump with a known good water pump. 12. Accessory drive component brackets that are bent, cracked, or loose may put extra strain on that accessory component causing it to vibrate. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping, Squeal, and Whine Diagnosis > Page 1837 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping, Squeal, and Whine Diagnosis > Page 1838 Drive Belt: Testing and Inspection Drive Belt Falls Off and Excessive Wear Diagnosis Drive Belt Falls Off and Excessive Wear Diagnosis Diagnostic Aids If the drive belt repeatedly falls off the drive belt pulleys, this is because of pulley misalignment. An extra load that is quickly applied on released by an accessory drive component may cause the drive belt to fall off the pulleys. Verify the accessory drive components operate properly. If the drive belt is the incorrect length, the drive belt tensioner may not keep the proper tension on the drive belt. Excessive wear on a drive belt is usually caused by an incorrect installation or the wrong drive belt for the application. Minor misalignment of the drive belt pulleys will not cause excessive wear, but will probably cause the drive belt to make a noise or to fall off. Excessive misalignment of the drive belt pulleys will cause excessive wear but may also make the drive belt fall off. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This inspection is to verify the condition of the drive belt. Damage may of occurred to the drive belt when the drive belt fell off. The drive belt may of been damaged, which caused the drive belt to fall off. Inspect the belt for cuts, tears, sections of ribs missing, or damaged belt plys. 4. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found refer to that accessory drive component for the proper installation procedure of that pulley. 5. Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating properly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley. 6. Accessory drive component brackets that are bent or cracked will let the drive belt fall off. 7. Inspection of the fasteners can eliminate the possibility that a wrong bolt, nut , spacer, or washer was installed. Missing, loose, or the wrong fasteners may cause pulley misalignment from the bracket moving under load. Over tightening of the fasteners may cause misalignment of the accessory component bracket. 13. The inspection is to verify the drive belt is correctly installed on all of the drive belt pulleys. Wear on the drive belt may be caused by mis-positioning the drive belt by one groove on a pulley. 14. The installation of a drive belt that is too wide or too narrow will cause wear on the drive belt. The drive belt ribs should match all of the grooves on all of the pulleys. 15. This inspection is to verify the drive belt is not contacting any parts of the engine or body while the engine is operating. There should be sufficient clearance when the drive belt accessory drive components load varies. The drive belt should not come in contact with an engine or a body component when snapping the throttle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping, Squeal, and Whine Diagnosis > Page 1839 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Page 1840 Drive Belt: Service and Repair Drive Belt Replacement Removal Procedure 1. Remove the upper fan shroud. Refer to Engine Coolant Fan Upper Shroud Replacement (LMM Diesel) (See: Engine, Cooling and Exhaust/Cooling System/Fan Shroud/Service and Repair)Engine Coolant Fan Upper Shroud Replacement (Mechanical) (See: Engine, Cooling and Exhaust/Cooling System/Fan Shroud/Service and Repair). 2. Remove the 3 engine cooling fan shroud bolts (1). 3. Position the engine cooling fan shroud (1) forward to the radiator. 4. Install a 1/2 inch breaker bar into the tensioner opening and rotate the tensioner counterclockwise. 5. Remove the belt from the tensioner. 6. Slowly release the tension on the tensioner arm. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Page 1841 7. Remove the drive belt from the drive pulleys , if equipped with a single generator. 8. Remove the drive belt from the drive pulleys, if equipped with dual generators. 9. Inspect the drive belt for excessive cracking or any visible damage and replace if necessary. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Page 1842 1. Install the drive belt, if equipped with dual generators. 2. Route the drive belt over and/or around all the drive pulleys except for the tensioner. 3. Install the drive belt, if equipped with a single generator. 4. Route the drive belt over and/or around all the drive pulleys except for the tensioner. 5. Install a 1/2 inch breaker bar into the tensioner opening and rotate the tensioner counterclockwise. 6. Install the belt over and/or around the tensioner. 7. Slowly release the tension on the tensioner arm. 8. Inspect the drive belt for proper installation on and/or around all pulleys. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Page 1843 9. Position the engine cooling fan shroud on the 3 mounting brackets (1). 10. Install the bolts. Loosely tighten the top mounting bolt at the oil filler neck. 11. Center the engine cooling fan shroud to the fan blade in 3 places (1). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Note: Maintain a 6 mm (0.25 in) minimum clearance at all 3 places. 12. Fully tighten the 3 engine cooling fan shroud bolts (1). Tighten the bolts to 8 Nm (71 lb in). 13. Install the upper fan shroud. Refer to Engine Coolant Fan Upper Shroud Replacement (LMM Diesel) (See: Engine, Cooling and Exhaust/Cooling System/Fan Shroud/Service and Repair)Engine Coolant Fan Upper Shroud Replacement (Mechanical) (See: Engine, Cooling and Exhaust/Cooling System/Fan Shroud/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > Customer Interest for Air Cleaner Fresh Air Duct/Hose: > 08-06-04-054B > Jan > 11 > Diesel Engine - Low Power/MIL ON/DTC P0101 Air Cleaner Fresh Air Duct/Hose: Customer Interest Diesel Engine - Low Power/MIL ON/DTC P0101 TECHNICAL Bulletin No.: 08-06-04-054B Date: January 24, 2011 Subject: Snow or Ice Ingestion into Air Cleaner Element, Malfunction Indicator Lamp (MIL) Illuminated, Engine Power is Reduced Message Displayed, DTC P0101 Set (Perform Repair as Outlined) Models: 2007-2010 Chevrolet Silverado 2500/3500 Series 2007-2010 GMC Sierra 2500/3500 Series Equipped with Duramax(TM) Diesel Engine (RPO LMM) Supercede: This bulletin is being revised to provide a procedure to relocate the OAT sensor, if equipped with RPO CJ2. Please discard Corporate Bulletin 08-06-04-054A (Section 06 - Engine / Propulsion System). Condition Some customers may comment on the malfunction indicator lamp (MIL) being illuminated and an Engine Power is Reduced message being displayed. The technician may observe DTC P0101 set as current or in history. Cause This condition may be caused by snow being ingested into the air cleaner housing and accumulating in the air cleaner element, resulting in restricted airflow into the engine. Correction 1. Verify the condition by questioning the customer as to when the condition occurs (such as during or right after a snow storm). ‹› If the condition occurs as described above, proceed to Step 2. ‹› If the condition does not occur as described above, refer to Diagnostic Trouble Code (DTC) List Vehicle in SI. 2. Remove the air cleaner element. Refer to Air Cleaner Element Replacement in SI. 3. Inspect the air cleaner element for the following conditions: 1. Packed snow 2. Frozen ice 3. A soaking wet condition that would indicate previous snow ingestion 4. Excessive debris and contamination as a result of the ingestion ‹› If any of the above conditions are observed, replace the air cleaner element. Remove any snow or ice that may have accumulated in the air intake duct. Note Winter covers for trucks that are equipped with the Duramax(TM) Diesel Engine are included with vehicle orders that ship to the following areas: All of Canada, and the following states: Alaska, Colorado, Idaho, Maine, Michigan, Minnesota, Montana, New Hampshire, New York, North Dakota, South Dakota, Vermont, Wisconsin, Wyoming. These vehicles should not need a new cover. 4. Install the grille opening section ONLY (if using the 2 piece cover) of the winter front cover following the usage guidelines provided in the Owners Manual for the appropriate type winter cover. ‹› If the customer does not have a cover, obtain and install the grille opening section ONLY , GM P/N 25822811 (GMC) or GM P/N 25822812 (Chevrolet). 5. The grille opening cover MUST BE installed to ensure a complete repair, BEFORE ENCOUNTERING SNOW. This repair allows warm air to be circulated into the air cleaner. Additional Information to Advise Customer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > Customer Interest for Air Cleaner Fresh Air Duct/Hose: > 08-06-04-054B > Jan > 11 > Diesel Engine - Low Power/MIL ON/DTC P0101 > Page 1854 Important If the vehicle is driven in a snow storm before installing the winter cover and the customer chooses to resolve the issue, they must follow this procedure using the following steps: 1. Remove ANY ice or snow that may have accumulated in the air intake duct, BEFORE REPLACING the air cleaner element. 2. INSTALL the winter cover BEFORE continuing to drive the truck. 3. Turn OFF the ignition, and all electrical accessories and components. 4. Remove the key from the vehicle, THEN open and close the door. 5. WAIT for 2 minutes to allow the engine control module (ECM) to power down. This can be verified by watching for the instrument panel cluster (IPC) gage needles to drop slightly. 1. Allowing the ECM to power down will let DTC P0101 revert to a History DTC and the vehicle should return to full power if the issue has been eliminated. 2. Advise the customer to take the vehicle to the dealer as soon as possible to verify the condition has been eliminated. Ambient (Outside) Air Temperature Sensor Relocation For vehicles equipped with Automatic Temperature Control HVAC (RPO CJ2), the ambient (outside) air temperature sensor needs to be relocated using the following procedure: 1. Remove the radiator grille. Refer to the Radiator Grille Replacement procedure in SI. 2. Remove the ambient air sensor from its current location by carefully lifting the sensor from the radiator support cross bar. 3. Remove the harness clip nearest to the sensor. 4. Reinstall the ambient air sensor to the new location using the existing hole (1) in the lower section of the radiator support. 5. Reinstall the harness clip to the existing hole (2) in the radiator support. 6. Reinstall the radiator grille. Parts Information Warranty Information Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > Customer Interest for Air Cleaner Fresh Air Duct/Hose: > 08-06-04-054B > Jan > 11 > Diesel Engine - Low Power/MIL ON/DTC P0101 > Page 1855 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > Customer Interest for Air Cleaner Fresh Air Duct/Hose: > 08-06-04-054A > Jan > 10 > Engine - Reduced Power/MIL ON/DTC P0101 Air Cleaner Fresh Air Duct/Hose: Customer Interest Engine - Reduced Power/MIL ON/DTC P0101 TECHNICAL Bulletin No.: 08-06-04-054A Date: January 07, 2010 Subject: Snow or Ice Ingestion into Air Cleaner Element, Malfunction Indicator Lamp (MIL) Illuminated, Engine Power is Reduced Message Displayed, DTC P0101 Set (Perform Repair as Outlined) Models: 2007-2010 Chevrolet Silverado 2500/3500 Series 2007-2010 GMC Sierra 2500/3500 Series Equipped with Duramax(TM) Diesel Engine (RPO LMM) Please Refer to GMVIS Supercede: This bulletin is being revised to remove the graphic, update the Parts and Correction information and add information to advise a customer. Please discard Corporate Bulletin 08-06-04-054 (Section 06 - Engine / Propulsion System). Condition Some customers may comment on the malfunction indicator lamp (MIL) being illuminated and an Engine Power is Reduced message being displayed. The technician may observe DTC P0101 set as current or in history. Cause This condition may be caused by snow being ingested into the air cleaner housing and accumulating in the air cleaner element, resulting in restricted airflow into the engine. Correction 1. Verify the condition by questioning the customer as to when the condition occurs (such as during or right after a snow storm). ‹› If the condition occurs as described above, proceed to Step 2. ‹› If the condition does not occur as described above, refer to Diagnostic Trouble Code (DTC) List Vehicle in SI. 2. Remove the air cleaner element. Refer to Air Cleaner Element Replacement in SI. 3. Inspect the air cleaner element for the following conditions: 1. Packed snow 2. Frozen ice 3. A soaking wet condition that would indicate previous snow ingestion 4. Excessive debris and contamination as a result of the ingestion ‹› If any of the above conditions are observed, replace the air cleaner element. Remove any snow or ice that may have accumulated in the air intake duct. Note Winter covers for trucks that are equipped with the Duramax(TM) Diesel Engine are included with vehicle orders that ship to the following areas: All of Canada, and the following states: Alaska, Colorado, Idaho, Maine, Michigan, Minnesota, Montana, New Hampshire, New York, North Dakota, South Dakota, Vermont, Wisconsin, Wyoming. These vehicles should not need a new cover. 4. Install the grille opening section ONLY (if using the 2 piece cover) of the winter front cover following the usage guidelines provided in the Owners Manual for the appropriate type winter cover. ‹› If the customer does not have a cover, obtain and install the grille opening section ONLY, GM P/N 25822811 (GMC) or GM P/N 25822812 (Chevrolet). 5. The grille opening cover MUST BE installed to ensure a complete repair, BEFORE ENCOUNTERING SNOW. This repair allows warm air to be circulated into the air cleaner. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > Customer Interest for Air Cleaner Fresh Air Duct/Hose: > 08-06-04-054A > Jan > 10 > Engine - Reduced Power/MIL ON/DTC P0101 > Page 1860 Additional Information to Advise Customer Important If the vehicle is driven in a snow storm before installing the winter cover and the customer chooses to resolve the issue, they must follow this procedure using the following steps: 1. Remove ANY ice or snow that may have accumulated in the air intake duct, BEFORE REPLACING the air cleaner element. 2. INSTALL the winter cover BEFORE continuing to drive the truck. 3. Turn OFF the ignition, and all electrical accessories and components. 4. Remove the key from the vehicle, THEN open and close the door. 5. WAIT for 2 minutes to allow the engine control module (ECM) to power down. This can be verified by watching for the instrument panel cluster (IPC) gage needles to drop slightly. 1. Allowing the ECM to power down will let DTC P0101 revert to a History DTC and the vehicle should return to full power if the issue has been eliminated. 2. Advise the customer to take the vehicle to the dealer as soon as possible to verify the condition has been eliminated. Parts Information Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Cleaner Fresh Air Duct/Hose: > 08-06-04-054B > Jan > 11 > Diesel Engine - Low Power/MIL ON/DTC P0101 Air Cleaner Fresh Air Duct/Hose: All Technical Service Bulletins Diesel Engine - Low Power/MIL ON/DTC P0101 TECHNICAL Bulletin No.: 08-06-04-054B Date: January 24, 2011 Subject: Snow or Ice Ingestion into Air Cleaner Element, Malfunction Indicator Lamp (MIL) Illuminated, Engine Power is Reduced Message Displayed, DTC P0101 Set (Perform Repair as Outlined) Models: 2007-2010 Chevrolet Silverado 2500/3500 Series 2007-2010 GMC Sierra 2500/3500 Series Equipped with Duramax(TM) Diesel Engine (RPO LMM) Supercede: This bulletin is being revised to provide a procedure to relocate the OAT sensor, if equipped with RPO CJ2. Please discard Corporate Bulletin 08-06-04-054A (Section 06 - Engine / Propulsion System). Condition Some customers may comment on the malfunction indicator lamp (MIL) being illuminated and an Engine Power is Reduced message being displayed. The technician may observe DTC P0101 set as current or in history. Cause This condition may be caused by snow being ingested into the air cleaner housing and accumulating in the air cleaner element, resulting in restricted airflow into the engine. Correction 1. Verify the condition by questioning the customer as to when the condition occurs (such as during or right after a snow storm). ‹› If the condition occurs as described above, proceed to Step 2. ‹› If the condition does not occur as described above, refer to Diagnostic Trouble Code (DTC) List Vehicle in SI. 2. Remove the air cleaner element. Refer to Air Cleaner Element Replacement in SI. 3. Inspect the air cleaner element for the following conditions: 1. Packed snow 2. Frozen ice 3. A soaking wet condition that would indicate previous snow ingestion 4. Excessive debris and contamination as a result of the ingestion ‹› If any of the above conditions are observed, replace the air cleaner element. Remove any snow or ice that may have accumulated in the air intake duct. Note Winter covers for trucks that are equipped with the Duramax(TM) Diesel Engine are included with vehicle orders that ship to the following areas: All of Canada, and the following states: Alaska, Colorado, Idaho, Maine, Michigan, Minnesota, Montana, New Hampshire, New York, North Dakota, South Dakota, Vermont, Wisconsin, Wyoming. These vehicles should not need a new cover. 4. Install the grille opening section ONLY (if using the 2 piece cover) of the winter front cover following the usage guidelines provided in the Owners Manual for the appropriate type winter cover. ‹› If the customer does not have a cover, obtain and install the grille opening section ONLY , GM P/N 25822811 (GMC) or GM P/N 25822812 (Chevrolet). 5. The grille opening cover MUST BE installed to ensure a complete repair, BEFORE ENCOUNTERING SNOW. This repair allows warm air to be circulated into the air cleaner. Additional Information to Advise Customer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Cleaner Fresh Air Duct/Hose: > 08-06-04-054B > Jan > 11 > Diesel Engine - Low Power/MIL ON/DTC P0101 > Page 1866 Important If the vehicle is driven in a snow storm before installing the winter cover and the customer chooses to resolve the issue, they must follow this procedure using the following steps: 1. Remove ANY ice or snow that may have accumulated in the air intake duct, BEFORE REPLACING the air cleaner element. 2. INSTALL the winter cover BEFORE continuing to drive the truck. 3. Turn OFF the ignition, and all electrical accessories and components. 4. Remove the key from the vehicle, THEN open and close the door. 5. WAIT for 2 minutes to allow the engine control module (ECM) to power down. This can be verified by watching for the instrument panel cluster (IPC) gage needles to drop slightly. 1. Allowing the ECM to power down will let DTC P0101 revert to a History DTC and the vehicle should return to full power if the issue has been eliminated. 2. Advise the customer to take the vehicle to the dealer as soon as possible to verify the condition has been eliminated. Ambient (Outside) Air Temperature Sensor Relocation For vehicles equipped with Automatic Temperature Control HVAC (RPO CJ2), the ambient (outside) air temperature sensor needs to be relocated using the following procedure: 1. Remove the radiator grille. Refer to the Radiator Grille Replacement procedure in SI. 2. Remove the ambient air sensor from its current location by carefully lifting the sensor from the radiator support cross bar. 3. Remove the harness clip nearest to the sensor. 4. Reinstall the ambient air sensor to the new location using the existing hole (1) in the lower section of the radiator support. 5. Reinstall the harness clip to the existing hole (2) in the radiator support. 6. Reinstall the radiator grille. Parts Information Warranty Information Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Cleaner Fresh Air Duct/Hose: > 08-06-04-054B > Jan > 11 > Diesel Engine - Low Power/MIL ON/DTC P0101 > Page 1867 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Cleaner Fresh Air Duct/Hose: > 08-06-04-054A > Jan > 10 > Engine - Reduced Power/MIL ON/DTC P0101 Air Cleaner Fresh Air Duct/Hose: All Technical Service Bulletins Engine - Reduced Power/MIL ON/DTC P0101 TECHNICAL Bulletin No.: 08-06-04-054A Date: January 07, 2010 Subject: Snow or Ice Ingestion into Air Cleaner Element, Malfunction Indicator Lamp (MIL) Illuminated, Engine Power is Reduced Message Displayed, DTC P0101 Set (Perform Repair as Outlined) Models: 2007-2010 Chevrolet Silverado 2500/3500 Series 2007-2010 GMC Sierra 2500/3500 Series Equipped with Duramax(TM) Diesel Engine (RPO LMM) Please Refer to GMVIS Supercede: This bulletin is being revised to remove the graphic, update the Parts and Correction information and add information to advise a customer. Please discard Corporate Bulletin 08-06-04-054 (Section 06 - Engine / Propulsion System). Condition Some customers may comment on the malfunction indicator lamp (MIL) being illuminated and an Engine Power is Reduced message being displayed. The technician may observe DTC P0101 set as current or in history. Cause This condition may be caused by snow being ingested into the air cleaner housing and accumulating in the air cleaner element, resulting in restricted airflow into the engine. Correction 1. Verify the condition by questioning the customer as to when the condition occurs (such as during or right after a snow storm). ‹› If the condition occurs as described above, proceed to Step 2. ‹› If the condition does not occur as described above, refer to Diagnostic Trouble Code (DTC) List Vehicle in SI. 2. Remove the air cleaner element. Refer to Air Cleaner Element Replacement in SI. 3. Inspect the air cleaner element for the following conditions: 1. Packed snow 2. Frozen ice 3. A soaking wet condition that would indicate previous snow ingestion 4. Excessive debris and contamination as a result of the ingestion ‹› If any of the above conditions are observed, replace the air cleaner element. Remove any snow or ice that may have accumulated in the air intake duct. Note Winter covers for trucks that are equipped with the Duramax(TM) Diesel Engine are included with vehicle orders that ship to the following areas: All of Canada, and the following states: Alaska, Colorado, Idaho, Maine, Michigan, Minnesota, Montana, New Hampshire, New York, North Dakota, South Dakota, Vermont, Wisconsin, Wyoming. These vehicles should not need a new cover. 4. Install the grille opening section ONLY (if using the 2 piece cover) of the winter front cover following the usage guidelines provided in the Owners Manual for the appropriate type winter cover. ‹› If the customer does not have a cover, obtain and install the grille opening section ONLY, GM P/N 25822811 (GMC) or GM P/N 25822812 (Chevrolet). 5. The grille opening cover MUST BE installed to ensure a complete repair, BEFORE ENCOUNTERING SNOW. This repair allows warm air to be circulated into the air cleaner. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Cleaner Fresh Air Duct/Hose: > 08-06-04-054A > Jan > 10 > Engine - Reduced Power/MIL ON/DTC P0101 > Page 1872 Additional Information to Advise Customer Important If the vehicle is driven in a snow storm before installing the winter cover and the customer chooses to resolve the issue, they must follow this procedure using the following steps: 1. Remove ANY ice or snow that may have accumulated in the air intake duct, BEFORE REPLACING the air cleaner element. 2. INSTALL the winter cover BEFORE continuing to drive the truck. 3. Turn OFF the ignition, and all electrical accessories and components. 4. Remove the key from the vehicle, THEN open and close the door. 5. WAIT for 2 minutes to allow the engine control module (ECM) to power down. This can be verified by watching for the instrument panel cluster (IPC) gage needles to drop slightly. 1. Allowing the ECM to power down will let DTC P0101 revert to a History DTC and the vehicle should return to full power if the issue has been eliminated. 2. Advise the customer to take the vehicle to the dealer as soon as possible to verify the condition has been eliminated. Parts Information Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Air Cleaner Outlet Duct Replacement Air Cleaner Fresh Air Duct/Hose: Service and Repair Air Cleaner Outlet Duct Replacement Air Cleaner Outlet Duct Replacement Removal Procedure 1. Loosen the outlet duct clamps at the air cleaner assembly and the turbocharger. 2. Remove the air cleaner outlet duct. Installation Procedure Note: The air cleaner outlet duct must be fully seated against the positive stop feature on the turbocharger inlet and also must be fully seated against the positive stop features on both sides of the air cleaner assembly. 1. Install the air cleaner outlet duct. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Air Cleaner Outlet Duct Replacement > Page 1875 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Tighten the outlet duct clamps at the turbocharger and the air cleaner assembly. Tighten the clamps to 4 Nm (35 lb in). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Air Cleaner Outlet Duct Replacement > Page 1876 Air Cleaner Fresh Air Duct/Hose: Service and Repair Air Intake Pipe Replacement Air Intake Pipe Replacement Removal Procedure 1. Remove the water outlet tube. Refer to Water Outlet Tube Replacement (LU3) (See: Engine, Cooling and Exhaust/Cooling System/Coolant Outlet/Service and Repair)Water Outlet Tube Replacement (LMM) (See: Engine, Cooling and Exhaust/Cooling System/Coolant Outlet/Service and Repair). 2. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (See: Air Cleaner Outlet Duct Replacement). Note: It is not necessary to completely remove the PCV hose/pipe from the engine when removing the air intake pipe. 3. Remove the positive crankcase ventilation (PCV) hose/pipe from the air intake pipe. Refer to Positive Crankcase Ventilation Hose/Pipe/Tube Replacement (See: Powertrain Management/Emission Control Systems/Positive Crankcase Ventilation/PCV Valve Hose/Service and Repair). 4. Disconnect the engine wiring harness electrical connector from the turbocharger control solenoid valve. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Air Cleaner Outlet Duct Replacement > Page 1877 5. Remove the engine wiring harness clip (1) from the bracket on the turbocharger. 6. Reposition the turbocharger control solenoid valve wiring harness extension out of the way. Note: The clamp for the air intake pipe uses reverse threads. 7. Loosen the air intake pipe to turbocharger clamp (1). 8. Remove the air intake pipe (2) from the turbocharger. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Air Cleaner Outlet Duct Replacement > Page 1878 1. Clean the mating surfaces on the air intake pipe and the turbocharger. 2. Align the arrow (2) on the air intake pipe to the arrow (1) on the turbocharger. 3. Install the air intake pipe (2) into the turbocharger. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Note: The clamp for the air intake pipe uses reverse threads. 4. Tighten the air intake pipe to turbocharger clamp (1). Tighten the clamp to 4.6 Nm (41 lb in). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Air Cleaner Outlet Duct Replacement > Page 1879 5. Route the turbocharger control solenoid valve wiring harness extension into position. 6. Install the engine wiring harness clip (1) to the bracket on the turbocharger. 7. Connect the engine wiring harness electrical connector to the turbocharger control solenoid valve. 8. Install the PCV hose/pipe to the air intake pipe. Refer to Positive Crankcase Ventilation Hose/Pipe/Tube Replacement (See: Powertrain Management/Emission Control Systems/Positive Crankcase Ventilation/PCV Valve Hose/Service and Repair). 9. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (See: Air Cleaner Outlet Duct Replacement). 10. Install the water outlet tube. Refer to Water Outlet Tube Replacement (LU3) (See: Engine, Cooling and Exhaust/Cooling System/Coolant Outlet/Service and Repair)Water Outlet Tube Replacement (LMM) (See: Engine, Cooling and Exhaust/Cooling System/Coolant Outlet/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 08-06-04-054B > Jan > 11 > Diesel Engine - Low Power/MIL ON/DTC P0101 Air Filter Element: Customer Interest Diesel Engine - Low Power/MIL ON/DTC P0101 TECHNICAL Bulletin No.: 08-06-04-054B Date: January 24, 2011 Subject: Snow or Ice Ingestion into Air Cleaner Element, Malfunction Indicator Lamp (MIL) Illuminated, Engine Power is Reduced Message Displayed, DTC P0101 Set (Perform Repair as Outlined) Models: 2007-2010 Chevrolet Silverado 2500/3500 Series 2007-2010 GMC Sierra 2500/3500 Series Equipped with Duramax(TM) Diesel Engine (RPO LMM) Supercede: This bulletin is being revised to provide a procedure to relocate the OAT sensor, if equipped with RPO CJ2. Please discard Corporate Bulletin 08-06-04-054A (Section 06 - Engine / Propulsion System). Condition Some customers may comment on the malfunction indicator lamp (MIL) being illuminated and an Engine Power is Reduced message being displayed. The technician may observe DTC P0101 set as current or in history. Cause This condition may be caused by snow being ingested into the air cleaner housing and accumulating in the air cleaner element, resulting in restricted airflow into the engine. Correction 1. Verify the condition by questioning the customer as to when the condition occurs (such as during or right after a snow storm). ‹› If the condition occurs as described above, proceed to Step 2. ‹› If the condition does not occur as described above, refer to Diagnostic Trouble Code (DTC) List Vehicle in SI. 2. Remove the air cleaner element. Refer to Air Cleaner Element Replacement in SI. 3. Inspect the air cleaner element for the following conditions: 1. Packed snow 2. Frozen ice 3. A soaking wet condition that would indicate previous snow ingestion 4. Excessive debris and contamination as a result of the ingestion ‹› If any of the above conditions are observed, replace the air cleaner element. Remove any snow or ice that may have accumulated in the air intake duct. Note Winter covers for trucks that are equipped with the Duramax(TM) Diesel Engine are included with vehicle orders that ship to the following areas: All of Canada, and the following states: Alaska, Colorado, Idaho, Maine, Michigan, Minnesota, Montana, New Hampshire, New York, North Dakota, South Dakota, Vermont, Wisconsin, Wyoming. These vehicles should not need a new cover. 4. Install the grille opening section ONLY (if using the 2 piece cover) of the winter front cover following the usage guidelines provided in the Owners Manual for the appropriate type winter cover. ‹› If the customer does not have a cover, obtain and install the grille opening section ONLY , GM P/N 25822811 (GMC) or GM P/N 25822812 (Chevrolet). 5. The grille opening cover MUST BE installed to ensure a complete repair, BEFORE ENCOUNTERING SNOW. This repair allows warm air to be circulated into the air cleaner. Additional Information to Advise Customer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 08-06-04-054B > Jan > 11 > Diesel Engine - Low Power/MIL ON/DTC P0101 > Page 1888 Important If the vehicle is driven in a snow storm before installing the winter cover and the customer chooses to resolve the issue, they must follow this procedure using the following steps: 1. Remove ANY ice or snow that may have accumulated in the air intake duct, BEFORE REPLACING the air cleaner element. 2. INSTALL the winter cover BEFORE continuing to drive the truck. 3. Turn OFF the ignition, and all electrical accessories and components. 4. Remove the key from the vehicle, THEN open and close the door. 5. WAIT for 2 minutes to allow the engine control module (ECM) to power down. This can be verified by watching for the instrument panel cluster (IPC) gage needles to drop slightly. 1. Allowing the ECM to power down will let DTC P0101 revert to a History DTC and the vehicle should return to full power if the issue has been eliminated. 2. Advise the customer to take the vehicle to the dealer as soon as possible to verify the condition has been eliminated. Ambient (Outside) Air Temperature Sensor Relocation For vehicles equipped with Automatic Temperature Control HVAC (RPO CJ2), the ambient (outside) air temperature sensor needs to be relocated using the following procedure: 1. Remove the radiator grille. Refer to the Radiator Grille Replacement procedure in SI. 2. Remove the ambient air sensor from its current location by carefully lifting the sensor from the radiator support cross bar. 3. Remove the harness clip nearest to the sensor. 4. Reinstall the ambient air sensor to the new location using the existing hole (1) in the lower section of the radiator support. 5. Reinstall the harness clip to the existing hole (2) in the radiator support. 6. Reinstall the radiator grille. Parts Information Warranty Information Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 08-06-04-054B > Jan > 11 > Diesel Engine - Low Power/MIL ON/DTC P0101 > Page 1889 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 08-06-04-054A > Jan > 10 > Engine - Reduced Power/MIL ON/DTC P0101 Air Filter Element: Customer Interest Engine - Reduced Power/MIL ON/DTC P0101 TECHNICAL Bulletin No.: 08-06-04-054A Date: January 07, 2010 Subject: Snow or Ice Ingestion into Air Cleaner Element, Malfunction Indicator Lamp (MIL) Illuminated, Engine Power is Reduced Message Displayed, DTC P0101 Set (Perform Repair as Outlined) Models: 2007-2010 Chevrolet Silverado 2500/3500 Series 2007-2010 GMC Sierra 2500/3500 Series Equipped with Duramax(TM) Diesel Engine (RPO LMM) Please Refer to GMVIS Supercede: This bulletin is being revised to remove the graphic, update the Parts and Correction information and add information to advise a customer. Please discard Corporate Bulletin 08-06-04-054 (Section 06 - Engine / Propulsion System). Condition Some customers may comment on the malfunction indicator lamp (MIL) being illuminated and an Engine Power is Reduced message being displayed. The technician may observe DTC P0101 set as current or in history. Cause This condition may be caused by snow being ingested into the air cleaner housing and accumulating in the air cleaner element, resulting in restricted airflow into the engine. Correction 1. Verify the condition by questioning the customer as to when the condition occurs (such as during or right after a snow storm). ‹› If the condition occurs as described above, proceed to Step 2. ‹› If the condition does not occur as described above, refer to Diagnostic Trouble Code (DTC) List Vehicle in SI. 2. Remove the air cleaner element. Refer to Air Cleaner Element Replacement in SI. 3. Inspect the air cleaner element for the following conditions: 1. Packed snow 2. Frozen ice 3. A soaking wet condition that would indicate previous snow ingestion 4. Excessive debris and contamination as a result of the ingestion ‹› If any of the above conditions are observed, replace the air cleaner element. Remove any snow or ice that may have accumulated in the air intake duct. Note Winter covers for trucks that are equipped with the Duramax(TM) Diesel Engine are included with vehicle orders that ship to the following areas: All of Canada, and the following states: Alaska, Colorado, Idaho, Maine, Michigan, Minnesota, Montana, New Hampshire, New York, North Dakota, South Dakota, Vermont, Wisconsin, Wyoming. These vehicles should not need a new cover. 4. Install the grille opening section ONLY (if using the 2 piece cover) of the winter front cover following the usage guidelines provided in the Owners Manual for the appropriate type winter cover. ‹› If the customer does not have a cover, obtain and install the grille opening section ONLY, GM P/N 25822811 (GMC) or GM P/N 25822812 (Chevrolet). 5. The grille opening cover MUST BE installed to ensure a complete repair, BEFORE ENCOUNTERING SNOW. This repair allows warm air to be circulated into the air cleaner. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 08-06-04-054A > Jan > 10 > Engine - Reduced Power/MIL ON/DTC P0101 > Page 1894 Additional Information to Advise Customer Important If the vehicle is driven in a snow storm before installing the winter cover and the customer chooses to resolve the issue, they must follow this procedure using the following steps: 1. Remove ANY ice or snow that may have accumulated in the air intake duct, BEFORE REPLACING the air cleaner element. 2. INSTALL the winter cover BEFORE continuing to drive the truck. 3. Turn OFF the ignition, and all electrical accessories and components. 4. Remove the key from the vehicle, THEN open and close the door. 5. WAIT for 2 minutes to allow the engine control module (ECM) to power down. This can be verified by watching for the instrument panel cluster (IPC) gage needles to drop slightly. 1. Allowing the ECM to power down will let DTC P0101 revert to a History DTC and the vehicle should return to full power if the issue has been eliminated. 2. Advise the customer to take the vehicle to the dealer as soon as possible to verify the condition has been eliminated. Parts Information Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 08-06-04-054B > Jan > 11 > Diesel Engine - Low Power/MIL ON/DTC P0101 Air Filter Element: All Technical Service Bulletins Diesel Engine - Low Power/MIL ON/DTC P0101 TECHNICAL Bulletin No.: 08-06-04-054B Date: January 24, 2011 Subject: Snow or Ice Ingestion into Air Cleaner Element, Malfunction Indicator Lamp (MIL) Illuminated, Engine Power is Reduced Message Displayed, DTC P0101 Set (Perform Repair as Outlined) Models: 2007-2010 Chevrolet Silverado 2500/3500 Series 2007-2010 GMC Sierra 2500/3500 Series Equipped with Duramax(TM) Diesel Engine (RPO LMM) Supercede: This bulletin is being revised to provide a procedure to relocate the OAT sensor, if equipped with RPO CJ2. Please discard Corporate Bulletin 08-06-04-054A (Section 06 - Engine / Propulsion System). Condition Some customers may comment on the malfunction indicator lamp (MIL) being illuminated and an Engine Power is Reduced message being displayed. The technician may observe DTC P0101 set as current or in history. Cause This condition may be caused by snow being ingested into the air cleaner housing and accumulating in the air cleaner element, resulting in restricted airflow into the engine. Correction 1. Verify the condition by questioning the customer as to when the condition occurs (such as during or right after a snow storm). ‹› If the condition occurs as described above, proceed to Step 2. ‹› If the condition does not occur as described above, refer to Diagnostic Trouble Code (DTC) List Vehicle in SI. 2. Remove the air cleaner element. Refer to Air Cleaner Element Replacement in SI. 3. Inspect the air cleaner element for the following conditions: 1. Packed snow 2. Frozen ice 3. A soaking wet condition that would indicate previous snow ingestion 4. Excessive debris and contamination as a result of the ingestion ‹› If any of the above conditions are observed, replace the air cleaner element. Remove any snow or ice that may have accumulated in the air intake duct. Note Winter covers for trucks that are equipped with the Duramax(TM) Diesel Engine are included with vehicle orders that ship to the following areas: All of Canada, and the following states: Alaska, Colorado, Idaho, Maine, Michigan, Minnesota, Montana, New Hampshire, New York, North Dakota, South Dakota, Vermont, Wisconsin, Wyoming. These vehicles should not need a new cover. 4. Install the grille opening section ONLY (if using the 2 piece cover) of the winter front cover following the usage guidelines provided in the Owners Manual for the appropriate type winter cover. ‹› If the customer does not have a cover, obtain and install the grille opening section ONLY , GM P/N 25822811 (GMC) or GM P/N 25822812 (Chevrolet). 5. The grille opening cover MUST BE installed to ensure a complete repair, BEFORE ENCOUNTERING SNOW. This repair allows warm air to be circulated into the air cleaner. Additional Information to Advise Customer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 08-06-04-054B > Jan > 11 > Diesel Engine - Low Power/MIL ON/DTC P0101 > Page 1900 Important If the vehicle is driven in a snow storm before installing the winter cover and the customer chooses to resolve the issue, they must follow this procedure using the following steps: 1. Remove ANY ice or snow that may have accumulated in the air intake duct, BEFORE REPLACING the air cleaner element. 2. INSTALL the winter cover BEFORE continuing to drive the truck. 3. Turn OFF the ignition, and all electrical accessories and components. 4. Remove the key from the vehicle, THEN open and close the door. 5. WAIT for 2 minutes to allow the engine control module (ECM) to power down. This can be verified by watching for the instrument panel cluster (IPC) gage needles to drop slightly. 1. Allowing the ECM to power down will let DTC P0101 revert to a History DTC and the vehicle should return to full power if the issue has been eliminated. 2. Advise the customer to take the vehicle to the dealer as soon as possible to verify the condition has been eliminated. Ambient (Outside) Air Temperature Sensor Relocation For vehicles equipped with Automatic Temperature Control HVAC (RPO CJ2), the ambient (outside) air temperature sensor needs to be relocated using the following procedure: 1. Remove the radiator grille. Refer to the Radiator Grille Replacement procedure in SI. 2. Remove the ambient air sensor from its current location by carefully lifting the sensor from the radiator support cross bar. 3. Remove the harness clip nearest to the sensor. 4. Reinstall the ambient air sensor to the new location using the existing hole (1) in the lower section of the radiator support. 5. Reinstall the harness clip to the existing hole (2) in the radiator support. 6. Reinstall the radiator grille. Parts Information Warranty Information Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 08-06-04-054B > Jan > 11 > Diesel Engine - Low Power/MIL ON/DTC P0101 > Page 1901 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 08-06-04-054A > Jan > 10 > Engine Reduced Power/MIL ON/DTC P0101 Air Filter Element: All Technical Service Bulletins Engine - Reduced Power/MIL ON/DTC P0101 TECHNICAL Bulletin No.: 08-06-04-054A Date: January 07, 2010 Subject: Snow or Ice Ingestion into Air Cleaner Element, Malfunction Indicator Lamp (MIL) Illuminated, Engine Power is Reduced Message Displayed, DTC P0101 Set (Perform Repair as Outlined) Models: 2007-2010 Chevrolet Silverado 2500/3500 Series 2007-2010 GMC Sierra 2500/3500 Series Equipped with Duramax(TM) Diesel Engine (RPO LMM) Please Refer to GMVIS Supercede: This bulletin is being revised to remove the graphic, update the Parts and Correction information and add information to advise a customer. Please discard Corporate Bulletin 08-06-04-054 (Section 06 - Engine / Propulsion System). Condition Some customers may comment on the malfunction indicator lamp (MIL) being illuminated and an Engine Power is Reduced message being displayed. The technician may observe DTC P0101 set as current or in history. Cause This condition may be caused by snow being ingested into the air cleaner housing and accumulating in the air cleaner element, resulting in restricted airflow into the engine. Correction 1. Verify the condition by questioning the customer as to when the condition occurs (such as during or right after a snow storm). ‹› If the condition occurs as described above, proceed to Step 2. ‹› If the condition does not occur as described above, refer to Diagnostic Trouble Code (DTC) List Vehicle in SI. 2. Remove the air cleaner element. Refer to Air Cleaner Element Replacement in SI. 3. Inspect the air cleaner element for the following conditions: 1. Packed snow 2. Frozen ice 3. A soaking wet condition that would indicate previous snow ingestion 4. Excessive debris and contamination as a result of the ingestion ‹› If any of the above conditions are observed, replace the air cleaner element. Remove any snow or ice that may have accumulated in the air intake duct. Note Winter covers for trucks that are equipped with the Duramax(TM) Diesel Engine are included with vehicle orders that ship to the following areas: All of Canada, and the following states: Alaska, Colorado, Idaho, Maine, Michigan, Minnesota, Montana, New Hampshire, New York, North Dakota, South Dakota, Vermont, Wisconsin, Wyoming. These vehicles should not need a new cover. 4. Install the grille opening section ONLY (if using the 2 piece cover) of the winter front cover following the usage guidelines provided in the Owners Manual for the appropriate type winter cover. ‹› If the customer does not have a cover, obtain and install the grille opening section ONLY, GM P/N 25822811 (GMC) or GM P/N 25822812 (Chevrolet). 5. The grille opening cover MUST BE installed to ensure a complete repair, BEFORE ENCOUNTERING SNOW. This repair allows warm air to be circulated into the air cleaner. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 08-06-04-054A > Jan > 10 > Engine Reduced Power/MIL ON/DTC P0101 > Page 1906 Additional Information to Advise Customer Important If the vehicle is driven in a snow storm before installing the winter cover and the customer chooses to resolve the issue, they must follow this procedure using the following steps: 1. Remove ANY ice or snow that may have accumulated in the air intake duct, BEFORE REPLACING the air cleaner element. 2. INSTALL the winter cover BEFORE continuing to drive the truck. 3. Turn OFF the ignition, and all electrical accessories and components. 4. Remove the key from the vehicle, THEN open and close the door. 5. WAIT for 2 minutes to allow the engine control module (ECM) to power down. This can be verified by watching for the instrument panel cluster (IPC) gage needles to drop slightly. 1. Allowing the ECM to power down will let DTC P0101 revert to a History DTC and the vehicle should return to full power if the issue has been eliminated. 2. Advise the customer to take the vehicle to the dealer as soon as possible to verify the condition has been eliminated. Parts Information Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 1907 Air Filter Element: Service and Repair Air Cleaner Element Replacement Removal Procedure 1. Loosen the screw holding the air cleaner housing door in place. 2. Remove the air cleaner housing door. 3. Remove the air filter element. Installation Procedure 1. Stand facing the front fender on the passenger side of the vehicle. Insert the element into the housing. Place the palm of your hand on the inboard end of the element, and press the element into position. 2. Press both downward and inboard until the outboard end of the element clicks into place inboard of the locating tab. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 1908 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the air cleaner housing door and tighten the screw. Tighten the screw to 4 Nm (35 lb in). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Transmission Fluid Filter Adapter Replacement Fluid Filter - A/T: Service and Repair Transmission Fluid Filter Adapter Replacement Transmission Fluid Filter Adapter Replacement Removal Procedure Note: * DO NOT drain the fluid if only the transmission external oil filter adapter is being replaced. * Use a standard strap-type filter wrench to remove or install the transmission external oil filter. 1. Remove the transmission external oil filter (4) by rotating in the counterclockwise direction. 2. Remove the magnet (2) from the transmission external oil filter adapter (1) in the converter housing or from the filter element. 3. Clean any metal debris from the magnet. Presence of any metal pieces larger than dust may indicate that transmission replacement or overhaul is required. 4. Remove the filter adapter (1) from the converter housing. Installation Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the transmission external oil filter adapter (1). Tighten the adapter to 30 Nm (22 lb ft). 2. Reinstall the magnet (2) onto the filter adapter (1). 3. Lubricate the gasket (3) on the transmission external oil filter with transmission fluid. 4. Install, by hand, the transmission external oil filter (4) until the gasket on the filter touches the converter housing. Caution: Turning the transmission external oil filter more than ONE FULL TURN after gasket contact will damage the filter and may cause fluid leakage. 5. Turn the filter ONE FULL TURN ONLY after gasket contact. Caution: Use only clean and approved transmission fluid. 6. Check the transmission fluid level. Refer to Transmission Fluid Level and Condition Check (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Testing and Inspection/Component Tests and General Diagnostics/Transmission Fluid Level and Condition Check). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Transmission Fluid Filter Adapter Replacement > Page 1913 Fluid Filter - A/T: Service and Repair Automatic Transmission Fluid and Filter Replacement Automatic Transmission Fluid and Filter Replacement Removal Procedure Note: DO NOT drain the fluid if only the transmission external oil filter is being replaced. 1. Remove the drain plug (6) and drain plug seal (5). Drain the transmission fluid into a suitable container. 2. Inspect the drained fluid. Refer to Transmission Fluid Level and Condition Check (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Testing and Inspection/Component Tests and General Diagnostics/Transmission Fluid Level and Condition Check). Note: Use a standard strap-type filter wrench to remove the transmission external oil filter. 3. Remove the filter (4) by rotating in the counterclockwise direction. 4. Remove the magnet (2) from the filter adapter (1) in the converter housing or from the top of the transmission external oil filter (3). 5. Clean any metal debris from the magnet. Presence of any metal pieces larger than dust may indicate that transmission replacement or overhaul is required. Installation Procedure 1. Install the magnet (2) onto the filter adapter (1) which is in the converter housing. 2. Lubricate the gasket (3) on the transmission external oil filter with transmission fluid. 3. Install, by hand, the transmission external oil filter (4) until the gasket on the filter touches the converter housing. Caution: Turning the transmission external oil filter more than ONE FULL TURN after gasket contact will damage the filter and may cause fluid leakage. 4. Turn the filter ONE FULL TURN ONLY after gasket contact. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Install the drain plug (6) and drain plug seal (5). Tighten the drain plug to 35 Nm (26 lb ft). 6. Refill Transmission with DEXRON(R)VI Automatic Transmission Fluid. Refer to Fluid Capacity Specifications (See: Fluids/Fluid A/T/Specifications). Note: DTC P0701 may often set following fluid service. Cycling the ignition clears the code and allows Drive or Reverse range to be attained. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Transmission Fluid Filter Adapter Replacement > Page 1914 7. Cycle the ignition until Drive or Reverse range is attained. Note: Fluid remains in the external circuits and transmission cavities after draining the transmission. 8. Check the transmission fluid level. Refer to Transmission Fluid Level and Condition Check (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Testing and Inspection/Component Tests and General Diagnostics/Transmission Fluid Level and Condition Check). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair Fuel Pressure Relief Valve Replacement Removal Procedure 1. Remove the glow plug module and bracket. Refer to Glow Plug Control Module Replacement (See: Powertrain Management/Glow Plug System/Glow Plug Control Module/Service and Repair). 2. Remove the fuel pressure relief valve from the left fuel rail. Installation Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the fuel pressure relief valve to the left fuel rail. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Page 1919 Tighten the valve to 100 Nm (74 lb ft). 2. Install the glow plug module and bracket. Refer to Glow Plug Control Module Replacement (See: Powertrain Management/Glow Plug System/Glow Plug Control Module/Service and Repair). 3. Prime the fuel system. Refer to Fuel System Priming (See: Powertrain Management/Fuel Delivery and Air Induction/Service and Repair/Fuel System Priming). 4. Start the engine. If the engine stalls, repeat the above step. 5. Once the engine starts, inspect for fuel leaks. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service Bulletins > Engine - Noise/Damage Oil Filter Application Importance Oil Filter: Technical Service Bulletins Engine - Noise/Damage Oil Filter Application Importance INFORMATION Bulletin No.: 07-06-01-016B Date: July 27, 2009 Subject: Information on Internal Engine Noise or Damage After Oil Filter Replacement Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being updated to add model years. Please discard Corporate Bulletin Number 07-06-01-016A (Section 06 - Engine/Propulsion System). Important Engine damage that is the result of an incorrect or improperly installed engine oil filter is not a warrantable claim. The best way to avoid oil filter quality concerns is to purchase ACDelco(R) oil filters directly from GMSPO. Oil filter misapplication may cause abnormal engine noise or internal damage. Always utilize the most recent parts information to ensure the correct part number filter is installed when replacing oil filters. Do not rely on physical dimensions alone. Counterfeit copies of name brand parts have been discovered in some aftermarket parts systems. Always ensure the parts you install are from a trusted source. Improper oil filter installation may result in catastrophic engine damage. Refer to the appropriate Service Information (SI) installation instructions when replacing any oil filter and pay particular attention to procedures for proper cartridge filter element alignment. If the diagnostics in SI (Engine Mechanical) lead to the oil filter as the cause of the internal engine noise or damage, dealers should submit a field product report. Refer to Corporate Bulletin Number 02-00-89-002I (Information for Dealers on How to Submit a Field Product Report). Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service Bulletins > Page 1924 Oil Filter: Service and Repair Engine Oil and Oil Filter Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Position a suitable drain pan under the oil pan drain plug. 3. Remove the oil drain plug. 4. Allow the oil to drain completely. 5. Clean and inspect the oil pan drain plug, replace if necessary. 6. Clean and inspect the oil pan drain plug sealing surface, replace the oil pan if necessary. 7. Wipe any remaining oil from the drain plug hole and reinstall the oil pan drain plug until snug. 8. Position a suitable drain pan under the oil filter 9. Remove the oil filter. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service Bulletins > Page 1925 10. Ensure that the oil filter gasket is still on the old oil filter, if not remove the oil filter gasket from the adapter. Installation Procedure 1. Apply clean engine oil to the NEW oil filter gasket. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the NEW oil filter and tighten after contact plus 1 to 11/4 turn. 3. Tighten the oil pan drain plug to 84 Nm (62 lb ft). 4. Remove the oil drain pan from under the vehicle. 5. Lower the vehicle. 6. Fill the engine with new engine oil. Refer to Approximate Fluid Capacities (See: Specifications) and Fluid and Lubricant Recommendations (USA and Canada) (See: ). 7. Start the engine. 8. Inspect for oil leaks after engine start up. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service Bulletins > Page 1926 9. Turn off the engine and allow the oil a few minutes to drain back into the oil pan. 10. Remove the oil level indicator from the oil level indicator tube. 11. Clean off the indicator end of the oil level indicator with a clean paper towel or cloth. 12. Install the oil level indicator into the oil level indicator tube until the oil level indicator handle contacts the top of the oil level indicator tube. 13. Again, remove the oil level indicator from the oil level indicator tube keeping the tip of the oil level indicator down. 14. Check the level of the engine oil on the oil level indicator. 15. If necessary, adjust the oil level be adding or draining oil. 16. Check for oil leaks. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair > Thermostat Housing Crossover Replacement Coolant Line/Hose: Service and Repair Thermostat Housing Crossover Replacement Thermostat Housing Crossover Replacement (LMM) Removal Procedure 1. Remove the air cleaner. Refer to Air Cleaner Assembly Replacement (See: Filters/Air Cleaner Housing/Service and Repair). 2. Drain the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair). 3. Disconnect the negative battery cables. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 4. Remove the drive belt. Refer to Drive Belt Replacement (See: Drive Belt/Service and Repair). 5. Disconnect the air conditioning (A/C) pressure switch electrical connector (1). 6. Disconnect the A/C compressor clutch electrical connector (2). 7. Remove the generator bracket. Refer to Generator Bracket Replacement (V6) (See: Starting and Charging/Charging System/Alternator/Service and Repair)Generator Bracket Replacement (6.6L) (See: Starting and Charging/Charging System/Alternator/Service and Repair)Generator Bracket Replacement (V8) (See: Starting and Charging/Charging System/Alternator/Service and Repair). 8. Remove the front oil fill tube. Refer to Oil Filler Tube Replacement (See: Engine, Cooling and Exhaust/Engine/Engine Lubrication/Engine Oil Dip Stick - Dip Stick Tube/Service and Repair/Oil Filler Tube Replacement). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair > Thermostat Housing Crossover Replacement > Page 1932 9. Disconnect the engine coolant temperature (ECT) sensor electrical connectors. 10. Remove the water outlet. Refer to Water Outlet Tube Replacement (LU3) (See: Engine, Cooling and Exhaust/Cooling System/Coolant Outlet/Service and Repair)Water Outlet Tube Replacement (LMM) (See: Engine, Cooling and Exhaust/Cooling System/Coolant Outlet/Service and Repair). 11. Without disconnecting the power steering hoses, remove the power steering pump bolts and the power steering pump. Reposition the power steering pump and secure to the side. Refer to Power Steering Pump Replacement (4.8L, 5.3L, 6.0L, and 6.2L) (See: Steering and Suspension/Steering/Power Steering/Power Steering Pump/Service and Repair)Power Steering Pump Replacement (4.3L) (See: Steering and Suspension/Steering/Power Steering/Power Steering Pump/Service and Repair)Power Steering Pump Replacement (6.6L) (See: Steering and Suspension/Steering/Power Steering/Power Steering Pump/Service and Repair). 12. Remove the power steering pump bracket. Refer to Air Conditioning (A/C) Compressor and Power Steering Pump Bracket Replacement (See: Engine, Cooling and Exhaust/Engine/Drive Belts, Mounts, Brackets and Accessories/Engine Accessory Bracket/Service and Repair). 13. Remove the bolts and wiring harness bracket at the thermostat housing. 14. Position the bracket and wiring harness aside. 15. Remove the cooling fan pulley. Refer to Fan Pulley Replacement (See: Engine, Cooling and Exhaust/Cooling System/Radiator Cooling Fan/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair > Thermostat Housing Crossover Replacement > Page 1933 16. Reposition the turbocharger coolant return pipe hose clamp. 17. Remove the turbocharger coolant return pipe hose. 18. Remove the fuel line bracket bolt at the thermostat housing crossover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair > Thermostat Housing Crossover Replacement > Page 1934 19. Remove the water pump inlet pipe bolts. 20. Remove the thermostat housing crossover bolts and nuts. 21. Remove the thermostat housing crossover, with the bypass pipe. 22. Remove and discard the thermostat bypass pipe to water pump O-ring seal. 23. Remove and discard the thermostat housing crossover gaskets. 24. If necessary, perform the following: 1. Remove the thermostat bypass pipe from the thermostat housing crossover. 2. Remove and discard the thermostat bypass pipe O-ring seal. 3. Remove the thermostat cover bolts and cover. 4. Remove the thermostats. 5. Remove and discard the thermostat seals. 25. If required, clean and inspect the thermostat housing. Refer to Engine Coolant Thermostat Housing Cleaning and Inspection (See: Engine, Cooling and Exhaust/Engine/Service and Repair/Overhaul/90. Engine Coolant Thermostat Housing Cleaning and Inspection). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair > Thermostat Housing Crossover Replacement > Page 1935 Installation Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. If necessary, perform the following: 1. Install NEW seals to the thermostats. 2. Install the thermostats. 3. Install the thermostat cover and bolts. Tighten the bolts to 21 Nm (15 lb ft). 4. Install a NEW O-ring seal to the thermostat bypass pipe. 5. Install the thermostat bypass pipe to the thermostat housing. 2. Install a NEW thermostat bypass pipe to water pump O-ring seal. 3. Install the thermostat housing crossover using NEW gaskets. 4. Install the thermostat housing crossover bolts and nuts. Tighten the bolts/nuts to 21 Nm (15 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair > Thermostat Housing Crossover Replacement > Page 1936 5. Install the water pump inlet pipe bolts. Tighten the bolts to 21 Nm (15 lb ft). 6. Install the fuel line bracket bolt at the thermostat housing crossover. Tighten the bolt to 21 Nm (15 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair > Thermostat Housing Crossover Replacement > Page 1937 7. Install the turbocharger coolant return pipe hose. 8. Position the turbocharger coolant return pipe hose clamp. 9. Install the wiring harness bracket and bolts to the thermostat housing. Tighten the bolts to 10 Nm (89 lb in). 10. Install the cooling fan pulley. Refer to Fan Pulley Replacement (See: Engine, Cooling and Exhaust/Cooling System/Radiator Cooling Fan/Service and Repair). 11. Install the power steering pump bracket. Refer to Air Conditioning (A/C) Compressor and Power Steering Pump Bracket Replacement (See: Engine, Cooling and Exhaust/Engine/Drive Belts, Mounts, Brackets and Accessories/Engine Accessory Bracket/Service and Repair). 12. Reposition the power steering pump and install the power steering pump bolts. Refer to Power Steering Pump Replacement (4.8L, 5.3L, 6.0L, and 6.2L) (See: Steering and Suspension/Steering/Power Steering/Power Steering Pump/Service and Repair)Power Steering Pump Replacement (4.3L) (See: Steering and Suspension/Steering/Power Steering/Power Steering Pump/Service and Repair)Power Steering Pump Replacement (6.6L) (See: Steering and Suspension/Steering/Power Steering/Power Steering Pump/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair > Thermostat Housing Crossover Replacement > Page 1938 13. Install the water outlet. Refer to Water Outlet Tube Replacement (LU3) (See: Engine, Cooling and Exhaust/Cooling System/Coolant Outlet/Service and Repair)Water Outlet Tube Replacement (LMM) (See: Engine, Cooling and Exhaust/Cooling System/Coolant Outlet/Service and Repair). 14. Connect the ECT sensor electrical connectors. 15. Install the front oil fill tube. Refer to Oil Filler Tube Replacement (See: Engine, Cooling and Exhaust/Engine/Engine Lubrication/Engine Oil Dip Stick - Dip Stick Tube/Service and Repair/Oil Filler Tube Replacement). 16. Install the generator bracket. Refer to Generator Bracket Replacement (V6) (See: Starting and Charging/Charging System/Alternator/Service and Repair)Generator Bracket Replacement (6.6L) (See: Starting and Charging/Charging System/Alternator/Service and Repair)Generator Bracket Replacement (V8) (See: Starting and Charging/Charging System/Alternator/Service and Repair). 17. Connect the A/C compressor clutch electrical connector (2). 18. Connect the A/C cut out switch electrical connector (1). 19. Install the drive belt. Refer to Drive Belt Replacement (See: Drive Belt/Service and Repair). 20. Connect the negative battery cables. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair > Thermostat Housing Crossover Replacement > Page 1939 Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 21. Fill the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair). 22. Install the air cleaner. Refer to Air Cleaner Assembly Replacement (See: Filters/Air Cleaner Housing/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair > Thermostat Housing Crossover Replacement > Page 1940 Coolant Line/Hose: Service and Repair Engine Coolant Air Bleed Pipe Replacement (without AFM) Engine Coolant Air Bleed Pipe Replacement (without AFM) Removal Procedure 1. If replacing the rear coolant air bleed covers, remove the intake manifold. Refer to Intake Manifold Replacement (Without AFM) (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair)Intake Manifold Replacement (With AFM) (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair). Otherwise proceed to the next step. 2. Remove the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (). 3. Drain the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair). 4. Reposition the radiator vent inlet hose clamp (1) at the coolant air bleed pipe fitting. 5. Remove the radiator vent inlet hose (2) from the coolant air bleed pipe fitting. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair > Thermostat Housing Crossover Replacement > Page 1941 6. Remove the coolant air bleed pipe bolts (309) (intake manifold shown removed for clarity). 7. Remove the coolant air bleed pipe (307) and seals (308). 8. Remove the coolant air bleed cover bolts (312), if required. 9. Remove the coolant air bleed covers (313) and seals (308), if required. 10. Remove the seals (308) from the coolant air bleed pipe and/or covers. 11. Discard the seals. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair > Thermostat Housing Crossover Replacement > Page 1942 Note: Position the O-ring seal (308) onto the nipple portion of the pipe. 1. Install the seals onto the coolant air bleed pipe and/or covers. 2. Install the coolant air bleed pipe (307) and seals (308) onto the cylinder heads. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the coolant air bleed pipe bolts (309). Tighten the bolts to 12 Nm (106 lb in). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair > Thermostat Housing Crossover Replacement > Page 1943 4. Install the coolant air bleed covers (313) and seals (308), if required. 5. Install the coolant air bleed cover bolts (312), if required. Tighten the bolts to 12 Nm (106 lb in). 6. Install the radiator vent inlet hose (2) to the coolant air bleed pipe fitting. 7. Position the radiator vent inlet hose clamp (1) at the coolant air bleed pipe fitting. 8. Install the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (). 9. Fill the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair). 10. If the rear coolant air bleed covers were replaced, install the intake manifold. Refer to Intake Manifold Replacement (Without AFM) (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair)Intake Manifold Replacement (With AFM) (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair > Thermostat Housing Crossover Replacement > Page 1944 Coolant Line/Hose: Service and Repair Engine Coolant Air Bleed Pipe Replacement (with AFM) Engine Coolant Air Bleed Pipe Replacement (with AFM) Removal Procedure 1. Remove the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (). 2. Drain the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair). 3. Reposition the radiator vent inlet hose clamp (1) at the coolant air bleed pipe fitting. 4. Remove the radiator vent inlet hose (2) from the coolant air bleed pipe fitting. 5. Remove the coolant air bleed pipe bolts (309) (intake manifold shown removed for clarity). 6. Remove the coolant air bleed pipe (307) and seals (308). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair > Thermostat Housing Crossover Replacement > Page 1945 7. Remove the coolant air bleed cover bolts (312), if required. 8. Discard the seals. Installation Procedure Note: Position the O-ring seal (308) onto the nipple portion of the pipe. 1. Install the seals onto the coolant air bleed pipe and/or covers. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair > Thermostat Housing Crossover Replacement > Page 1946 2. Install the coolant air bleed pipe (307) and seals (308) onto the cylinder heads. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the coolant air bleed pipe bolts (309). Tighten the bolts to 12 Nm (106 lb in). 4. Install the coolant air bleed covers (313) and seals (308), if required. 5. Install the coolant air bleed cover bolts (312), if required. Tighten the bolts to 12 Nm (106 lb in). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair > Thermostat Housing Crossover Replacement > Page 1947 6. Install the radiator vent inlet hose (2) to the coolant air bleed pipe fitting. 7. Position the radiator vent inlet hose clamp (1) at the coolant air bleed pipe fitting. 8. Install the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (). 9. Fill the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair). 10. If the rear coolant air bleed covers were replaced, install the intake manifold. Refer to Intake Manifold Replacement (Without AFM) (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair)Intake Manifold Replacement (With AFM) (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater Inlet Hose Replacement (Non-HP2) Heater Hose: Service and Repair Heater Inlet Hose Replacement (Non-HP2) Heater Inlet Hose Replacement (Non-HP2) Removal Procedure 1. Drain the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair). 2. Remove the air intake tube. 3. Remove the heater and surge tank hoses from the mounting clip. 4. Squeeze the plastic retainer release tabs. Quick Connect Fittings 5. Pull the connection apart. 6. Remove the inlet heater hose from the water pump. 7. Remove the inlet heater hose. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater Inlet Hose Replacement (Non-HP2) > Page 1952 Installation Procedure 1. Install the inlet heater hose. 2. Install the inlet heater hose to the water pump. 3. Connect the heater hose to the heater core. Important: Firmly push the quick connect onto the heater core pipe until you hear an audible click. 4. Install the heater and surge tank hoses to the mounting clip. 5. Install the air intake tube. 6. Fill the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater Inlet Hose Replacement (Non-HP2) > Page 1953 Heater Hose: Service and Repair Heater Outlet Hose Replacement (Non-HP2) Heater Outlet Hose Replacement (Non-HP2) Removal Procedure 1. Drain the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair). 2. Remove the air intake tube. 3. Remove the heater and surge tank hoses from the mounting clip. 4. Squeeze the plastic retainer release tabs. Quick Connect Fittings 5. Pull the connection apart. 6. Remove the outlet heater hose from the water pump. 7. Reposition the outlet heater hose clamp at the surge tank. 8. Remove the outlet heater hose from the surge tank. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater Inlet Hose Replacement (Non-HP2) > Page 1954 9. Remove the outlet heater hose. Installation Procedure 1. Install the outlet heater hose. 2. Install the outlet heater hose to the water pump. 3. Install the outlet heater hose to the surge tank. 4. Install the outlet heater hose clamp to the surge tank. 5. Connect the heater and surge tank hoses to the heater core. Important: Firmly push the quick connect onto the heater core hose until you hear an audible click. 6. Pull the heater outlet hose to ensure the connection. 7. Install the heater and surge tank hoses to the mounting clip. 8. Install the air intake tube. 9. Fill the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Discharge Hose Replacement Hose/Line HVAC: Service and Repair Discharge Hose Replacement Discharge Hose Replacement (LMM) Special Tools J 39400-A Halogen Leak Detector Removal Procedure 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging (Non-HP2) (See: Fluids/Refrigerant/Service and Repair)Refrigerant Recovery and Recharging (HP2) (See: Heating and Air Conditioning/Service and Repair). 2. Remove the discharge hose mounting bolt (2) from the A/C compressor. Discard the bolt. 3. Remove the discharge hose (5) from the A/C compressor. 4. Remove the upper radiator air baffle. Refer to Radiator Air Upper Baffle and Deflector Replacement (See: Engine, Cooling and Exhaust/Cooling System/Radiator/Service and Repair/Removal and Replacement/Radiator Air Upper Baffle and Deflector Replacement). 5. Remove the discharge hose nut from the condenser. Discard the nut. 6. Remove the discharge hose from the condenser. 7. Disconnect the A/C recirculation switch from the discharge hose. 8. Remove the discharge hose from the vehicle. 9. Discard all of the used sealing washers. Cap the system openings. Installation Procedure 1. Install the discharge hose to the vehicle. 2. Connect the A/C recirculation switch to the discharge hose. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Discharge Hose Replacement > Page 1959 3. Install the discharge hose to the condenser using new sealing washers. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the NEW discharge hose nut to the condenser. Tighten the nut to 16 Nm (12 lb ft). 5. Install the upper radiator air baffle. Refer to Radiator Air Upper Baffle and Deflector Replacement (See: Engine, Cooling and Exhaust/Cooling System/Radiator/Service and Repair/Removal and Replacement/Radiator Air Upper Baffle and Deflector Replacement). 6. Install the discharge hose (5) to the compressor using new sealing washers. 7. Install the NEW discharge hose mounting bolt (2) to the A/C compressor. Tighten the bolt to 16 Nm (12 lb ft). 8. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging (Non-HP2) (See: Fluids/Refrigerant/Service and Repair )Refrigerant Recovery and Recharging (HP2) (See: Heating and Air Conditioning/Service and Repair). 9. Leak test the fittings of the component using the J 39400-A . Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Discharge Hose Replacement > Page 1960 Hose/Line HVAC: Service and Repair Suction Hose Replacement Suction Hose Replacement (LMM) Special Tools J 39400-A Halogen Leak Detector Removal Procedure 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging (Non-HP2) (See: Fluids/Refrigerant/Service and Repair)Refrigerant Recovery and Recharging (HP2) (See: Heating and Air Conditioning/Service and Repair). 2. Remove the suction hose mounting bolt (3) from the A/C compressor. Discard the bolt. 3. Remove the suction hose (1) from the compressor. 4. Remove the suction hose nut from the accumulator. Discard the nut. 5. Remove the suction hose from the accumulator. 6. Remove the suction hose from the vehicle. 7. Discard all of the used sealing washers. Cap the system openings. Installation Procedure 1. Install the suction hose to the vehicle using new sealing washers. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Discharge Hose Replacement > Page 1961 2. Install the suction hose to the accumulator. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the NEW suction hose nut to the accumulator. Tighten the nut to 16 Nm (12 lb ft). 4. Install the suction hose to the compressor (1). 5. Install the NEW suction hose mounting bolt (3). Tighten the bolt to 16 Nm (12 lb ft). 6. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging (Non-HP2) (See: Fluids/Refrigerant/Service and Repair )Refrigerant Recovery and Recharging (HP2) (See: Heating and Air Conditioning/Service and Repair). 7. Leak test the fittings of the component using the J 39400-A . Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Discharge Hose Replacement > Page 1962 Hose/Line HVAC: Service and Repair Air Conditioning Evaporator Tube Replacement (Non-HP2) Air Conditioning Evaporator Tube Replacement (Non-HP2) Special Tools J 39400-A Halogen Leak Detector Removal Procedure 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging (Non-HP2) (See: Fluids/Refrigerant/Service and Repair)Refrigerant Recovery and Recharging (HP2) (See: Heating and Air Conditioning/Service and Repair). 2. Remove the upper radiator air baffle and deflector. Refer to Radiator Air Upper Baffle and Deflector Replacement (See: Engine, Cooling and Exhaust/Cooling System/Radiator/Service and Repair/Removal and Replacement/Radiator Air Upper Baffle and Deflector Replacement). 3. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (See: Filters/Air Cleaner Housing/Service and Repair). 4. Remove the surge tank hold down nut and bolt and position aside. Note: Do not open cooling system. 5. Remove the evaporator tube nut from the evaporator. 6. Disconnect the evaporator tube from the evaporator. 7. Remove the evaporator tube nut from the auxiliary A/C tube, if equipped. 8. Disconnect the evaporator tube from the auxiliary A/C tube, if equipped. 9. Remove the evaporator tube nut from the condenser. 10. Disconnect the evaporator tube from the condenser. 11. Remove the evaporator tube from the vehicle. 12. Discard all of the used sealing washers. Cap all of the open connections. Installation Procedure 1. Connect the evaporator tube to the condenser using new sealing washers. Refer to Air Conditioning System Seal Replacement (See: Heating and Air Conditioning/Coupler HVAC/A/C Coupler O-ring/Service and Repair/Air Conditioning System Seal Replacement). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Discharge Hose Replacement > Page 1963 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the evaporator tube nut to the condenser and tighten to 16 Nm (12 lb ft). 3. Connect the evaporator tube to the auxiliary A/C tube using new sealing washers, if equipped. Refer to Air Conditioning System Seal Replacement (See: Heating and Air Conditioning/Coupler HVAC/A/C Coupler O-ring/Service and Repair/Air Conditioning System Seal Replacement). 4. Install the evaporator tube nut to the auxiliary A/C tube, if equipped, and tighten to 16 Nm (12 lb ft). 5. Install the evaporator tube to the evaporator. 6. Install the evaporator tube nut to the evaporator and tighten to 16 Nm (12 lb ft). 7. Install the surge tank hold down nut and bolt and position aside. 8. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (See: Filters/Air Cleaner Housing/Service and Repair). 9. Install the upper radiator air baffle and deflector. Refer to Radiator Air Upper Baffle and Deflector Replacement (See: Engine, Cooling and Exhaust/Cooling System/Radiator/Service and Repair/Removal and Replacement/Radiator Air Upper Baffle and Deflector Replacement). 10. Evacuate and recharge the system. Refer to Refrigerant Recovery and Recharging (Non-HP2) (See: Fluids/Refrigerant/Service and Repair )Refrigerant Recovery and Recharging (HP2) (See: Heating and Air Conditioning/Service and Repair). 11. Leak test the fittings of the components using the J 39400-A . Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service Precautions Power Steering Line/Hose: Service Precautions Power Steering Hose Disconnected Caution Caution: Do not start the vehicle with any power steering gear inlet or outlet hoses disconnected. When disconnected, plug or cap all openings of components. Failure to do so could result in contamination or loss of power steering fluid and damage to the system. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service Precautions > Page 1967 Power Steering Line/Hose: Service and Repair Power Steering Gear Inlet Pipe/Hose Replacement (Diesel) Removal Procedure 1. Place drain pans under the vehicle as needed. 2. Disconnect the power steering gear inlet hose (1) from the power brake booster. 3. Remove the power steering gear inlet hose clip bolt (3). 4. Disconnect the power steering gear inlet hose (4) from the steering gear. 5. Remove the power steering gear inlet hose (2) from the vehicle. Installation Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service Precautions > Page 1968 1. Install the power steering gear inlet hose (2) to the vehicle. 2. Connect the power steering gear inlet hose (4) to the steering gear. Tighten the fitting to 32 Nm (24 lb ft). 3. Install the power steering gear inlet hose clip bolt (3). Tighten the bolt to 12 Nm (106 lb in). 4. Connect the power steering gear inlet hose (1) to the power brake booster. Tighten the fitting to 32 Nm (24 lb ft). 5. Clean any excess power steering fluid from the vehicle and remove the drain pans. 6. Fill and bleed the power steering system. Refer to Power Steering System Bleeding (See: Steering and Suspension/Steering/Power Steering/Power Steering Bleeding/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Service and Repair > Radiator Inlet Hose Replacement Radiator Hose: Service and Repair Radiator Inlet Hose Replacement Radiator Inlet Hose Replacement (Diesel) Removal Procedure 1. Drain the engine coolant. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair). 2. Move the hose clamps back on the radiator inlet hose. 3. Remove the radiator inlet hose from the radiator. 4. Remove the radiator inlet hose from the water outlet tube. Installation Procedure 1. Install the radiator inlet hose to the water outlet tube. 2. Install the radiator inlet hose to the radiator. 3. Install the hose clamps on the radiator outlet hose. 4. Fill the engine coolant. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Service and Repair > Radiator Inlet Hose Replacement > Page 1973 Radiator Hose: Service and Repair Radiator Outlet Hose Replacement Radiator Outlet Hose Replacement (Diesel) Removal Procedure 1. Drain the engine coolant. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair). 2. Remove the upper and lower fan shroud. Refer to Engine Coolant Fan Upper Shroud Replacement (LMM Diesel) (See: Engine, Cooling and Exhaust/Cooling System/Fan Shroud/Service and Repair)Engine Coolant Fan Upper Shroud Replacement (Mechanical) (See: Engine, Cooling and Exhaust/Cooling System/Fan Shroud/Service and Repair) and Engine Coolant Fan Lower Shroud Replacement (Mechanical) (See: Engine, Cooling and Exhaust/Cooling System/Fan Shroud/Service and Repair). 3. Remove the surge tank outlet hose (1) from the surge tank. 4. Remove the radiator outlet hose from the water pump. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Service and Repair > Radiator Inlet Hose Replacement > Page 1974 5. Remove the heater outlet hose from the radiator outlet hose. 6. Remove the radiator outlet hose from the radiator. 7. Remove the radiator outlet hose clip retainers from the brackets. 8. Remove the radiator outlet hose from the vehicle. Installation Procedure 1. Install the radiator outlet hose to the vehicle. 2. Install the radiator outlet hose and clamp to the radiator. Ensure the hose is positioned properly in order to prevent interference with the fan shroud. 3. Install the radiator outlet hose clip retainers to the brackets. 4. Install the surge tank outlet hose (1) to the surge tank. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Service and Repair > Radiator Inlet Hose Replacement > Page 1975 5. Install the radiator outlet hose and clamp to the water pump. 6. Install the heater outlet hose to the radiator outlet hose. 7. Install the upper and lower fan shroud. Refer to Engine Coolant Fan Upper Shroud Replacement (LMM Diesel) (See: Engine, Cooling and Exhaust/Cooling System/Fan Shroud/Service and Repair)Engine Coolant Fan Upper Shroud Replacement (Mechanical) (See: Engine, Cooling and Exhaust/Cooling System/Fan Shroud/Service and Repair) and Engine Coolant Fan Lower Shroud Replacement (Mechanical) (See: Engine, Cooling and Exhaust/Cooling System/Fan Shroud/Service and Repair). 8. Fill the engine coolant. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Service and Repair > Radiator Inlet Hose Replacement > Page 1976 Radiator Hose: Service and Repair Radiator Hose Quick Connect Fitting Radiator Hose Quick Connect Fitting Removal Procedure 1. Using a bent-tip screwdriver or equivalent, pull on one of the open ends of the retaining ring in order to rotate the retaining ring. 2. Rotate the retaining ring (3) around the quick connector until the retaining ring is out of position and can be completely removed. 3. Remove the radiator outlet hose (2) from the quick connector fitting at the radiator (1). Installation Procedure Note: Do not install the retaining ring (3) onto the fitting by pushing the retaining ring down over the fitting. 1. Hook one of the open ends of the retaining ring (3) in one of the slots in the quick connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Service and Repair > Radiator Inlet Hose Replacement > Page 1977 2. Rotate the retaining ring (3) around the connector until the retaining ring is positioned with all 3 ears through the 3 slots. 3. Ensure the 3 retaining ring ears can be seen from the inside of the connector and the retaining ring can move freely in the slots. 4. Install the radiator outlet hose (2) onto the radiator quick connector fitting until a click is heard or felt. Pull back on the radiator outlet hose (2) to ensure a proper connection. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications Brake Fluid: Specifications Hydraulic Brake System: DOT 3 Hydraulic Brake Fluid (GM Part No. U.S. 12377967, in Canada 89021320). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Clutch Fluid > Component Information > Specifications Clutch Fluid: Specifications HYDRAULIC CLUTCH FLUID GM Part No. U.S. 12345347, in Canada 10953517) or equivalent DOT-3 brake fluid. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications COOLING SYSTEM Front Heat or A/C Only ........................................................................................................................ ........................................... 20.0 liters (21.2 quarts) Front Heat or A/C Plus Fuel Operated Heater (FOH) ...................................................................................................................... 20.9 liters (22.1 quarts) Front and Rear Heat or A/C Only .................................................................................................................................................... 21.5 liters (22.7 quarts) Front and Rear Heat or A/C Plus Fuel Operated Heater (FOH) ....................................................................................................... 22.4 liters (23.7 quarts) NOTE: All capacities are approximate. When adding, be sure to fill to the approximate level. Recheck fluid level after filling. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications > Page 1989 Coolant: Fluid Type Specifications ENGINE COOLANT The cooling system in the vehicle is filled with DEX-COOL engine coolant. This coolant is designed to remain in the vehicle for five years or 240 000 km (150,000 miles), whichever occurs first. The following explains the cooling system and how to check and add coolant when it is low. CAUTION: Adding only plain water to your cooling system can be dangerous. Plain water, or some other liquid such as alcohol, can boil before the proper coolant mixture will. Your vehicle's coolant warning system is set for the proper coolant mixture. With plain water or the wrong mixture, your engine could get too hot but you would not get the overheat warning. Your engine could catch fire and you or others could be burned. Use a 50/50 mixture of clean, drinkable water and DEX-COOL coolant. Use a 50/50 mixture of clean, drinkable water and DEX-COOL coolant. If using this mixture, nothing else needs to be added. This mixture: Gives freezing protection down to -34°F (-37°C). Gives boiling protection up to 265°F (129°C). Protects against rust and corrosion. Will not damage aluminum parts. Helps keep the proper engine temperature. NOTICE: If you use an improper coolant mixture, your engine could overheat and be badly damaged. The repair cost would not be covered by your warranty. Too much water in the mixture can freeze and crack the engine, radiator, heater core and other parts. NOTICE: If extra inhibitors and/or additives are used in the vehicle's cooling system, the vehicle could be damaged. Use only the proper mixture of the engine coolant listed for the cooling system. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Diesel Emissions Fluid > Component Information > Specifications > Capacity Specifications Diesel Emissions Fluid: Capacity Specifications Diesel Exhaust Fluid (DEF) .............................................................................................................................................................. 22.0 liters (5.8 gallons) NOTE: All capacities are approximate. When adding, be sure to fill to the approximate level. Recheck fluid level after filling. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Diesel Emissions Fluid > Component Information > Specifications > Capacity Specifications > Page 1994 Diesel Emissions Fluid: Fluid Type Specifications DIESEL EXHAUST AFTERTREATMENT SYSTEM Diesel Exhaust Fluid (GM Part No. U.S. 88862659, in Canada 88862660) or diesel exhaust fluid that meets ISO 22241-1 and displays the API Diesel Exhaust Fluid Certification Mark. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - Water Or Coolant Contamination Information Fluid - A/T: Technical Service Bulletins A/T - Water Or Coolant Contamination Information INFORMATION Bulletin No.: 08-07-30-035B Date: November 01, 2010 Subject: Information on Water or Ethylene Glycol in Transmission Fluid Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks with Automatic Transmission Supercede: This bulletin is being revised to update model years. Please discard Corporate Bulletin Number 08-07-30-035A (Section 07 - Transmission/Transaxle). Water or ethylene glycol in automatic transmission fluid (ATF) is harmful to internal transmission components and will have a negative effect on reliability and durability of these parts. Water or ethylene glycol in ATF will also change the friction of the clutches, frequently resulting in shudder during engagement or gear changes, especially during torque converter clutch engagement. Indications of water in the ATF may include: - ATF blowing out of the transmission vent tube. - ATF may appear cloudy or, in cases of extreme contamination, have the appearance of a strawberry milkshake. - Visible water in the oil pan. - A milky white substance inside the pan area. - Spacer plate gaskets that appear to be glued to the valve body face or case. - Spacer plate gaskets that appear to be swollen or wrinkled in areas where they are not compressed. - Rust on internal transmission iron/steel components. If water in the ATF has been found and the source of the water entry has not been identified, or if a leaking in-radiator transmission oil cooler is suspected (with no evidence of cross-contamination in the coolant recovery reservoir), a simple and quick test kit is available that detects the presence of ethylene glycol in ATF. The "Gly-Tek" test kit, available from the Nelco Company, should be obtained and the ATF tested to make an accurate decision on the need for radiator replacement. This can help to prevent customer comebacks if the in-radiator transmission oil cooler is leaking and reduce repair expenses by avoiding radiator replacement if the cooler is not leaking. These test kits can be obtained from: Nelco Company Test kits can be ordered by phone or through the website listed above. Orders are shipped standard delivery time but can be shipped on a next day delivery basis for an extra charge. One test kit will complete 10 individual fluid sample tests. For vehicles repaired under warranty, the cost of the complete test kit plus shipping charges should be divided by 10 and submitted on the warranty claim as a net item. The transmission should be repaired or replaced based on the normal cost comparison procedure. Important If water or coolant is found in the transmission, the following components MUST be replaced. - Replace all of the rubber-type seals. - Replace all of the composition-faced clutch plates and/or bands. - Replace all of the nylon parts. - Replace the torque converter. - Thoroughly clean and rebuild the transmission, using new gaskets and oil filter. Important The following steps must be completed when repairing or replacing. Flush and flow check the transmission oil cooler using J 45096. Refer to Corporate Bulletin Number 02-07-30-052F- Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow. - Thoroughly inspect the engine cooling system and hoses and clean/repair as necessary. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - Water Or Coolant Contamination Information > Page 1999 Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications AUTOMATIC TRANSMISSION FLUID CAPACITY Allison 1000 Automatic Transmission Initial Fill .. .............................................................................................................................................................. .......................... 12.0 liters (12.7 quarts) Refill .................................................................................... ................................................................................................................. 7.0 liters (7.4 quarts) NOTE: All capacities are approximate. When adding, be sure to fill to the approximate level. Recheck fluid level after filling. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 2002 Fluid - A/T: Fluid Type Specifications AUTOMATIC TRANSAXLE FLUID DEXRON-VI Automatic Transmission Fluid. For areas where ambient temperatures are below -40°F (-40°C) use Synthetic Transmission Fluid approved to Allison Transmission specification TES-295 (GM Part No. U.S. 12378515, in Canada 88900701). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 2003 Fluid - A/T: Service and Repair Automatic Transmission Fluid and Filter Replacement Removal Procedure Note: DO NOT drain the fluid if only the transmission external oil filter is being replaced. 1. Remove the drain plug (6) and drain plug seal (5). Drain the transmission fluid into a suitable container. 2. Inspect the drained fluid. Refer to Transmission Fluid Level and Condition Check (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Testing and Inspection/Component Tests and General Diagnostics/Transmission Fluid Level and Condition Check). Note: Use a standard strap-type filter wrench to remove the transmission external oil filter. 3. Remove the filter (4) by rotating in the counterclockwise direction. 4. Remove the magnet (2) from the filter adapter (1) in the converter housing or from the top of the transmission external oil filter (3). 5. Clean any metal debris from the magnet. Presence of any metal pieces larger than dust may indicate that transmission replacement or overhaul is required. Installation Procedure 1. Install the magnet (2) onto the filter adapter (1) which is in the converter housing. 2. Lubricate the gasket (3) on the transmission external oil filter with transmission fluid. 3. Install, by hand, the transmission external oil filter (4) until the gasket on the filter touches the converter housing. Caution: Turning the transmission external oil filter more than ONE FULL TURN after gasket contact will damage the filter and may cause fluid leakage. 4. Turn the filter ONE FULL TURN ONLY after gasket contact. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Install the drain plug (6) and drain plug seal (5). Tighten the drain plug to 35 Nm (26 lb ft). 6. Refill Transmission with DEXRON(R)VI Automatic Transmission Fluid. Refer to Fluid Capacity Specifications (See: Specifications). Note: DTC P0701 may often set following fluid service. Cycling the ignition clears the code and allows Drive or Reverse range to be attained. 7. Cycle the ignition until Drive or Reverse range is attained. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 2004 Note: Fluid remains in the external circuits and transmission cavities after draining the transmission. 8. Check the transmission fluid level. Refer to Transmission Fluid Level and Condition Check (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Testing and Inspection/Component Tests and General Diagnostics/Transmission Fluid Level and Condition Check). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Capacity Specifications Fluid - M/T: Capacity Specifications MANUAL TRANSMISSION FLUID CAPACITY TREMEC 5-SPEED (RPO M96) .......................................................................................................................................................... 3.5 liters (3.7 quarts) TREMEC 5-SPEED (RPO TZ0) .......................................................................................................................................................... 4.4 liters (4.6 quarts) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Capacity Specifications > Page 2009 Fluid - M/T: Fluid Type Specifications MANUAL TRANSMISSION FLUID TYPE TREMEC 5-SPEED (M96) ............................................................................................................................................. 5W-30 Synthetic Oil P/N ET-M99 TREMEC 5-SPEED (TZ0) .............................................................................................................................................. 1874 MTX Fluid 12550 ET-M81 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Service and Repair > Tremec 5-Speed (M96) - Manual Transmission Fluid - M/T: Service and Repair Tremec 5-Speed (M96) - Manual Transmission Transmission Fluid Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Place a suitable drain pan under the transmission in order to catch the drained transmission fluid. 3. Remove the oil fill plug (1). 4. Remove the oil drain plug (2). 5. Remove any old sealant from the transmission housing. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Service and Repair > Tremec 5-Speed (M96) - Manual Transmission > Page 2012 1. Apply a thin bead of sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the oil drain plug threads. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the oil drain plug (2). Tighten the plug to 37 Nm (27 lb ft). 3. Fill the transmission with the proper fluid to just below the bottom of the fill plug hole. 4. Apply a thin bead of sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the oil fill plug threads. 5. Install the oil fill plug (1). Tighten the plug to 37 Nm (27 lb ft). 6. Lower the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Service and Repair > Tremec 5-Speed (M96) - Manual Transmission > Page 2013 Fluid - M/T: Service and Repair Tremec 5-Speed (TZ0) - Manual Transmission Transmission Fluid Replacement Special Tools J 36511 Oil Fill/Drain Plug Hex Bit (17 mm) Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Using J 36511 remove the oil fill plug. 3. Place a suitable drain pan under the transmission in order to catch the drained transmission fluid. 4. Using J 36511 remove the oil drain plug. 5. Remove any old sealant from the transmission housing. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Service and Repair > Tremec 5-Speed (M96) - Manual Transmission > Page 2014 Installation Procedure 1. Apply sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the oil drain and fill plug threads. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Using J 36511 install the oil drain plug. Tighten the plug to 30 Nm (22 lb ft). 3. Remove and drain the drain pan used to catch the used transmission fluid. 4. Fill the transmission to just below the bottom of the fill plug hole. Refer to Lubrication Specifications (See: Specifications/Mechanical Specifications/Manual Transmission/Transaxle/Tremec 5-Speed (TZ0) - Manual Transmission/Lubrication Specifications). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Service and Repair > Tremec 5-Speed (M96) - Manual Transmission > Page 2015 5. Using J 36511 install the oil fill plug. Tighten the plug to 30 Nm (22 lb ft). 6. Lower the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications DRIVE AXLE FLUID CAPACITIES FRONT AXLE 1000 Series (8.25") ...................................................................................................... ..................................................................... 1.43 liters (1.51 quarts) 2000 Series (9.25") .................. ......................................................................................................................................................... 1.73 liters (1.83 quarts) REAR AXLE 1000 Series without RPO AXN (8.6") .............................................................................................................................................. 2.03 liters (2.15 quarts) 1000 Series with RPO AXN (9.5"LD) ................................................................................................................................................ 2.6 liters (2.75 quarts) 2000 Series (9.5"HD) ............................................................................................ ............................................................................. 2.6 liters (2.75 quarts) 2000 Series with RPO LY6 (10.5") .................................................................................................................................................... 2.6 liters (2.75 quarts) 2000 Series with RPO LMM (11.5") .................................................................................................................................................. 3.0 liters (3.17 quarts) 3000 Series (11.5") ................................................................................................ ............................................................................. 3.0 liters (3.17 quarts) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 2020 Fluid - Differential: Fluid Type Specifications FRONT AND REAR AXLE SAE 75W-90 Synthetic Axle Lubricant (GM Part No. U.S. 89021677, in Canada 89021678) meeting GM Specification 9986115. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Service and Repair > Procedures Fluid - Differential: Procedures Front Drive Axle Front Axle Lubricant Level Inspection (9.25 Inch Axle) 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Make sure the vehicle is level. 3. Inspect the front axle for leaks. Repair as necessary. 4. Clean the area around the front axle fill plug. 5. Remove the front axle fill plug (1). 6. Inspect the oil level. The 9.25 inch axle the oil level should be between 0-6 mm (0-0.25 in) below the fill plug opening. 7. If the level is low, add oil until the level is between 0-6 mm (0-0.25 in) for the 9.25 inch axle. Use the correct fluid. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Specifications/Fluid Type Specifications). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 8. Install the fill plug and tighten to 33 Nm (24 lb ft). 9. Lower the vehicle. Rear Axle Lubricant Level Inspection (8.6, 9.5 LD Axle) Rear Axle Lubricant Level Inspection (8.6, 9.5 LD Axle) Note: All axle assemblies are filled by volume of fluid during production. They are not filled to reach a certain level. When checking the fluid level on any axle, variations in the readings can be caused by factory fill differences between the minimum and the maximum fluid volume. Also, if a vehicle has just been driven before checking the fluid level, it may appear lower than normal because the fluid has traveled out along the axle tubes and has not drained back to the sump area. Therefore, a reading taken five minutes after the vehicle has been driven will appear to have a lower fluid level than a vehicle that has been stationary for an hour or two. Remember that the rear axle assembly must be supported to get a true reading. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Ensure the vehicle is level. 3. Inspect the rear axle for leaks. Repair as necessary. 4. Clean the area around the rear axle fill plug. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Service and Repair > Procedures > Page 2023 5. Remove the rear axle fill plug. 6. Inspect the lubricant level: The lubricant level should be between 1-19 mm (0.04-0.75 in) below the fill plug opening for the 8.6 inch axle. The lubricant level should be between 15-40 mm (0.59-1.57 in) below the fill plug opening for the 9.5 inch LD axle. 7. If the level is low, add lubricant until the level is even with the bottom edge of the fill plug opening. Use the proper fluid. Refer to Fluid and Lubricant Recommendations (USA and Canada) (See: ). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 8. Install the rear axle fill plug and tighten to 33 Nm (24 lb ft). 9. Lower the vehicle. Rear Axle Lubricant Level Inspection (11.5 Inch Axle) Rear Axle Lubricant Level Inspection (11.5 Inch Axle) 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Make sure the vehicle is level. 3. Inspect the rear axle for leaks. Repair as necessary. 4. Clean the area around the rear axle fill plug. 5. Remove the rear axle fill plug and the seal. 6. Inspect the lubricant level. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Service and Repair > Procedures > Page 2024 The lubricant level should be between 17-21 mm (0.6-0.8 in) below the fill plug opening. 7. If the level is low, add lubricant until the level is between 17-21 mm (0.6-0.8 in) below the fill plug opening. Use the proper fluid. Refer to Fluid and Lubricant Recommendations (USA and Canada) (See: ). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 8. Install the rear axle fill plug and gasket. Tighten the rear axle fill plug to 33 Nm (24 lb ft). 9. Lower the vehicle. Rear Axle Lubricant Level Inspection (10.5 Inch Axle) Rear Axle Lubricant Level Inspection (10.5 Inch Axle) 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Make sure the vehicle is level. 3. Inspect the rear axle for leaks. Repair as necessary. 4. Clean the area around the rear axle fill plug. 5. Remove the rear axle fill plug. 6. Inspect the lubricant level. The lubricant level should be between 0-10 mm (0-0.4 in) below the fill plug opening. 7. If the level is low, add lubricant until the level is even with the bottom edge of the fill plug opening. Use the proper fluid. Refer to Fluid and Lubricant Recommendations (USA and Canada) (See: ). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 8. Install the rear axle fill plug. Tighten the rear axle fill plug to 33 Nm (24 lb ft). 9. Lower the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Service and Repair > Procedures > Page 2025 Fluid - Differential: Removal and Replacement Front Drive Axle Front Axle Lubricant Replacement Removal Procedure 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Remove the engine shield, if equipped. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement). 3. Clean the area around the front axle fill plug and the drain plug. 4. Remove the fill plug. 5. Remove the drain plug. 6. Drain the fluid from the front differential carrier assembly. Installation Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the drain plug. Tighten the drain plug to 33 Nm (24 lb ft). 2. Fill the differential carrier assembly with axle lubricant. Use the correct fluid. Refer to Approximate Fluid Capacities (See: Specifications) and Adhesives, Fluids, Lubricants, and Sealers (See: Specifications/Fluid Type Specifications). 3. Install the fill plug. Tighten the fill plug to 33 Nm (24 lb ft). 4. Install the engine shield, if equipped. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement). 5. Lower the vehicle. Differential Oil Replacement (8.6 Inch Axle) Differential Oil Replacement (8.6 Inch Axle) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Service and Repair > Procedures > Page 2026 Removal Procedure 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Clean the area around the rear axle fill plug. 3. Remove the rear axle fill plug. 4. Remove the rear axle cover. Refer to Rear Axle Housing Cover and Gasket Replacement (8.6, 9.5 Inch Axles) ()Rear Axle Housing Cover and Gasket Replacement (10.5/11.5 Inch Axle) (). 5. Drain the lubricant into a suitable container. Installation Procedure 1. Install the rear axle cover. Refer to Rear Axle Housing Cover and Gasket Replacement (8.6, 9.5 Inch Axles) ()Rear Axle Housing Cover and Gasket Replacement (10.5/11.5 Inch Axle) (). 2. Fill the rear axle with axle lubricant. Use the proper fluid. Refer to Approximate Fluid Capacities (See: Specifications) and Adhesives, Fluids, Lubricants, and Sealers (See: Specifications/Fluid Type Specifications). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the rear axle fill plug and tighten to 33 Nm (24 lb ft). 4. Lower the vehicle. Differential Oil Replacement (9.5LD Inch Axle) Differential Oil Replacement (9.5LD Inch Axle) Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Service and Repair > Procedures > Page 2027 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Remove the drain plug. 3. Remove the fill plug. Installation Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the drain plug and tighten to 33 Nm (24 lb ft). 2. Fill the rear drive axle. * Use the proper fluid, refer to Approximate Fluid Capacities (See: Specifications). * For the proper capacity, refer to Fluid and Lubricant Recommendations (USA and Canada) (See: ). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Service and Repair > Procedures > Page 2028 3. Install the fill plug and tighten to 33 Nm (24 lb ft). 4. Remove the support and lower the vehicle. Differential Oil Replacement (10.5 Inch Axle) Differential Oil Replacement (10.5 Inch Axle) Removal Procedure 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Remove the fill plug (1). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Service and Repair > Procedures > Page 2029 3. Remove the rear axle drain plug (1). 4. Drain the lubricant into a suitable container. Installation Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the rear axle drain plug (1) and tighten to 33 Nm (24 lb ft). 2. Fill the rear axle with the proper fluid. Refer to Approximate Fluid Capacities (See: Specifications) and Fluid and Lubricant Recommendations (USA and Canada) (See: ). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Service and Repair > Procedures > Page 2030 3. Install the fill plug (1) and tighten to 33 Nm (24 lb ft). 4. Remove the support and lower the vehicle. Differential Oil Replacement (11.5 Inch Axle) Differential Oil Replacement (11.5 Inch Axle) Removal Procedure 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair) in General Information. 2. Remove the fill plug. 3. Remove the rear axle drain plug. 4. Drain the lubricant into a suitable container. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Service and Repair > Procedures > Page 2031 5. Inspect the drain plug for excessive metal particle accumulation. This accumulation is symptomatic of extreme wear. 6. Clean the drain plug. Installation Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the rear axle drain plug and tighten to 33 Nm (24 lb ft). 2. Fill the rear axle. Use the proper fluid. Refer to Approximate Fluid Capacities (See: Specifications) and Fluid and Lubricant Recommendations (USA and Canada) (See: ) in Maintenance and Lubrication. 3. Install the fill plug and washer and tighten to 33 Nm (24 lb ft). 4. Lower the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications Fluid - Transfer Case: Capacity Specifications TRANSFER CASE FLUID BW 4485-NR3 ..................................................................................................................................... ...................................... Fill to bottom of drain hole. MP 1222/1225/1226-NQG ................................................................................................................... ............................................... 1.6 quarts (1.5 liters) MP 1625/1626-NQF ............................................................................................................................ ................................................ 1.6 quarts (1.5 liters) MP 3023/3024-NQH ............................................................................................................................ ............................................... 1.6 quarts (1.5 liters) NOTE: All capacities are approximate. When adding, be sure to fill to the approximate level. Recheck fluid level after filling. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications > Page 2036 Fluid - Transfer Case: Fluid Type Specifications TRANSFER CASE FLUID DEXRON-VI Automatic Transmission Fluid. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Service and Repair > BW 4485-NR3 - Transfer Case Fluid - Transfer Case: Service and Repair BW 4485-NR3 - Transfer Case Transfer Case Fluid Replacement Removal Procedure Note: When performing the following procedure, use only hand tools to remove and install the drain and fill plugs. 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Remove the transfer case shield, if equipped. Refer to Transfer Case Shield Replacement (See: Transmission and Drivetrain/Transfer Case/Service and Repair/Removal and Replacement/BW 4485-NR3 - Transfer Case/Transfer Case Shield Replacement). 3. Remove the fill plug. 4. Remove the drain plug. Note: Ensure that an approved drain pan is used when draining the transfer case. 5. Allow the transfer case to drain completely. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Service and Repair > BW 4485-NR3 - Transfer Case > Page 2039 Note: Use only drain and fill plugs that are made from aluminum. Steel or brass plugs are not compatible with the magnesium case. 1. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent, to the threads of the drain and fill plugs. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the drain plug. Tighten the plug to 25 Nm (18 lb ft). 3. Fill the transfer case to the bottom of the fill plug hole with the recommended fluid. 4. Install the fill plug. Tighten the plug to 25 Nm (18 lb ft). 5. Install the transfer case shield, if equipped. Refer to Transfer Case Shield Replacement (See: Transmission and Drivetrain/Transfer Case/Service and Repair/Removal and Replacement/BW 4485-NR3 - Transfer Case/Transfer Case Shield Replacement). 6. Lower the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Service and Repair > BW 4485-NR3 - Transfer Case > Page 2040 Fluid - Transfer Case: Service and Repair MP 1222/1225/1226-NQG - Transfer Case Transfer Case Fluid Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Service and Repair > BW 4485-NR3 - Transfer Case > Page 2041 Fluid - Transfer Case: Service and Repair MP 1625/1626-NQF - Transfer Case Transfer Case Fluid Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Service and Repair > BW 4485-NR3 - Transfer Case > Page 2042 Fluid - Transfer Case: Service and Repair MP 3023/3024-NQH - Transfer Case Transfer Case Fluid Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil With Filter ........................................................................................................................... ............................................. 10.0 quarts (9.5 liters) NOTE: All capacities are approximate. When adding, be sure to fill to the approximate level. Recheck fluid level after filling. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 2047 Engine Oil: Fluid Type Specifications WHAT KIND OF ENGINE OIL TO USE LOOK FOR THESE THINGS: Oils designated as API CJ-4 are required for your vehicle. The CJ-4 designation can appear either alone or in combination with other American Petroleum Institute (API) designations, such as API CJ-4/SL. These letters show API levels of quality. SAE 15W-40 is best for your vehicle. When it is very cold, below 0°F (-18°C), you should use SAE 5W-40 to improve cold starting. These numbers on the oil container show its viscosity, or thickness. Do not use other viscosity oils such as SAE 10W-30, SAE 10W-40, or SAE 20W-50. NOTICE: Use only engine oils that have the designation CJ-4 for the diesel engine. Failure to use the recommended oil can result in engine damage not covered by your warranty. ENGINE OIL ADDITIVES ENGINE OIL FLUSHES Do not add anything to the oil. The recommended oils with the API service symbol are all you need for good performance and engine protection. Engine oil flushes are not recommended and could cause engine damage not covered by the vehicle warranty. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 2048 Engine Oil: Service and Repair Engine Oil and Oil Filter Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Position a suitable drain pan under the oil pan drain plug. 3. Remove the oil drain plug. 4. Allow the oil to drain completely. 5. Clean and inspect the oil pan drain plug, replace if necessary. 6. Clean and inspect the oil pan drain plug sealing surface, replace the oil pan if necessary. 7. Wipe any remaining oil from the drain plug hole and reinstall the oil pan drain plug until snug. 8. Position a suitable drain pan under the oil filter 9. Remove the oil filter. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 2049 10. Ensure that the oil filter gasket is still on the old oil filter, if not remove the oil filter gasket from the adapter. Installation Procedure 1. Apply clean engine oil to the NEW oil filter gasket. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the NEW oil filter and tighten after contact plus 1 to 11/4 turn. 3. Tighten the oil pan drain plug to 84 Nm (62 lb ft). 4. Remove the oil drain pan from under the vehicle. 5. Lower the vehicle. 6. Fill the engine with new engine oil. Refer to Approximate Fluid Capacities (See: Specifications) and Fluid and Lubricant Recommendations (USA and Canada) (See: ). 7. Start the engine. 8. Inspect for oil leaks after engine start up. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 2050 9. Turn off the engine and allow the oil a few minutes to drain back into the oil pan. 10. Remove the oil level indicator from the oil level indicator tube. 11. Clean off the indicator end of the oil level indicator with a clean paper towel or cloth. 12. Install the oil level indicator into the oil level indicator tube until the oil level indicator handle contacts the top of the oil level indicator tube. 13. Again, remove the oil level indicator from the oil level indicator tube keeping the tip of the oil level indicator down. 14. Check the level of the engine oil on the oil level indicator. 15. If necessary, adjust the oil level be adding or draining oil. 16. Check for oil leaks. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications Power Steering Fluid: Specifications POWER STEERING SYSTEM GM Power Steering Fluid GM P/N 89021184 (Canadian P/N 89021186) or equivalent. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications Refrigerant System Specifications (Non-HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 2058 Refrigerant: Fluid Type Specifications Refrigerant System Specifications (Non-HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Page 2059 Refrigerant: Service and Repair Refrigerant Recovery and Recharging (Non-HP2) Special Tools * J 43600 - ACR 2000 Air Conditioning Service Center * J 45037 - A/C Oil Injector For equivalent regional tools, refer to Special Tools (See: Heating and Air Conditioning/Tools and Equipment/Heating, Ventilation, and Air Conditioning). Warning To prevent personal injury, avoid breathing A/C Refrigerant and lubricant vapor or mist. Work in a well ventilated area. To remove refrigerant from the A/C System, use service equipment designed for recovery that is certified to meet the requirements of the appropriate SAE Standards. If an accidental system discharge occurs, ventilate the work area before continuing service. Additional health and safety information may be obtained from the refrigerant, refrigerant recovery, and lubricant manufacturers. Warning For personal protection, goggles and lint-free gloves should be worn and a clean cloth wrapped around fittings, valves, and connections when doing work that includes opening the refrigerant system. If refrigerant comes in contact with any part of the body severe frostbite and personal injury can result. The exposed area should be flushed immediately with cold water and prompt medical help should be obtained. Caution: You must replace the desiccant if the A/C refrigerant system has been open to atmosphere for more than four hours, or if the A/C refrigerant oil has been contaminated. Failure to replace the desiccant will result in damage to the A/C refrigerant system. Caution: R-134a is the only approved refrigerant for use in this vehicle. The use of any other refrigerant may result in poor system performance or component failure. Caution: To avoid system damage use only R-134a dedicated tools when servicing the A/C system. Caution: Use only Polyalkylene Glycol Synthetic Refrigerant Oil (PAG) for internal circulation through the R-134a A/C system and only 525 viscosity mineral oil on fitting threads and O-rings. If lubricants other than those specified are used, compressor failure and/or fitting seizure may result. Caution: R-12 refrigerant and R-134a refrigerant must never be mixed, even in the smallest of amounts, as they are incompatible with each other. If the refrigerants are mixed, compressor failure is likely to occur. Refer to the manufacturer instructions included with the service equipment before servicing. The J 43600 - service center is a complete air conditioning service center for R-134a. The ACR 2000 recovers, recycles, evacuates and recharges A/C refrigerant quickly, accurately and automatically. The unit has a display screen that contains the function controls and displays prompts that will lead the technician through the recover, recycle, evacuate and recharge operations. R-134a is recovered into and charged out of an internal storage vessel. The ACR 2000 automatically replenishes this vessel from an external source tank in order to maintain a constant 5.45-6.82 kg (12-15 lbs) of A/C refrigerant. The ACR 2000 has a built in A/C refrigerant identifier that will test for contamination, prior to recovery and will notify the technician if there are foreign gases present in the A/C system. If foreign gases are present, the ACR 2000 will not recover the refrigerant from the A/C system. The ACR 2000 also features automatic air purge, single pass recycling and an automatic oil drain. Refer to the J 43600 - service center ACR 2000 manual for operation and setup instruction. Always recharge the A/C System with the proper amount of R-134a. Refer to Refrigerant System Specifications (Non-HP2) (See: Refrigerant Oil/Specifications) for the correct amount. A/C Refrigerant System Oil Charge Replenishing If oil was removed from the A/C system during the recovery process or due to component replacement, the oil must be replenished. Oil can be injected into a charged system using J 45037 - injector. For the proper quantities of oil to add to the A/C refrigerant system, refer to Refrigerant System Specifications (Non-HP2) (See: Refrigerant Oil/Specifications). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications Refrigerant System Specifications (Non-HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 2064 Refrigerant Oil: Fluid Type Specifications Refrigerant System Specifications (Non-HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Antilock Brake Automated Bleed Procedure Brake Bleeding: Service and Repair Antilock Brake Automated Bleed Procedure Less Than 3900 KG (8600 Lb) GVW Antilock Brake System Automated Bleed Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Brakes and Traction Control/Service Precautions/Vehicle Damage Warnings). Note: The base hydraulic brake system must be bled before performing this automated bleeding procedure. If you have not yet performed the base hydraulic brake system bleeding procedure, refer to Hydraulic Brake System Bleeding (Manual) (See: )Hydraulic Brake System Bleeding (Pressure) ( See: )Hydraulic Brake System Bleeding (Two-mode Hybrid) (See: ) before proceeding. 1. Install a scan tool to the vehicle. 2. Start the engine and allow the engine to idle. 3. Using the scan tool, begin the automated bleed procedure. 4. Follow the instructions on the scan tool to complete the automated bleed procedure. Apply the brake pedal when instructed by the scan tool. 5. Turn the ignition OFF. 6. Remove the scan tool from the vehicle. 7. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 8. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) (See: )Hydraulic Brake System Bleeding (Pressure) ( See: )Hydraulic Brake System Bleeding (Two-mode Hybrid) (See: ). 9. With the ignition OFF, apply the brakes 3-5 times, or until the brake pedal becomes firm, in order to deplete the brake booster power reserve. 10. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 11. If the brake pedal feels spongy, repeat the automated bleeding procedure. If the brake pedal still feels spongy after repeating the automated bleeding procedure inspect the brake system for external leaks. Refer to Brake System External Leak Inspection (See: Brakes and Traction Control/Hydraulic System/Testing and Inspection/Component Tests and General Diagnostics/Brake System External Leak Inspection). 12. Turn the ignition key ON, with the engine OFF; check to see if the brake system warning lamp remains illuminated. 13. If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. Refer to Symptoms - Hydraulic Brakes (See: Brakes and Traction Control/Hydraulic System/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Hydraulic Brakes). 14. Drive the vehicle to exceed 13 km/h (8 mph) to allow ABS initialization to occur. Observe brake pedal feel. 15. If the brake pedal feels spongy, repeat the automated bleeding procedure until a firm brake pedal is obtained. Greater Than/Equal to 3900 KG (8600 Lb) GVW Antilock Brake System Automated Bleed Warning: Refer to Brake Fluid Irritant Warning (See: Brakes and Traction Control/Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Brakes and Traction Control/Service Precautions/Vehicle Damage Warnings). Note: * Before performing the ABS Automated Bleed Procedure, first perform a manual or pressure bleed of the base hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) (See: )Hydraulic Brake System Bleeding (Pressure) (See: )Hydraulic Brake System Bleeding (Two-mode Hybrid) (See: ). * The automated bleed procedure must be performed when a new brake pressure modulator valve (BPMV) is installed, because the secondary circuits of the new BPMV are not prefilled with brake fluid. * The automated bleed procedure is recommended when one of the following conditions exist: * Base brake system bleeding does not achieve the desired pedal height or feel * Extreme loss of brake fluid has occurred * Air ingestion is suspected in the secondary circuits of the brake modulator assembly The ABS Automated Bleed Procedure uses a scan tool to cycle the system solenoid valves and run the pump in order to purge any air from the secondary circuits. These circuits are normally closed off, and are only opened during system initialization at vehicle start up and during ABS operation. The automated bleed procedure opens these secondary circuits and allows any air trapped in these circuits to flow out away from the brake modulator assembly, which is then forced out at the brake corners by the pressure bleeder. Automated Bleed Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Antilock Brake Automated Bleed Procedure > Page 2069 Caution: The Auto Bleed Procedure may be terminated at any time during the process by pressing the EXIT button. No further Scan Tool prompts pertaining to the Auto Bleed procedure will be given. After exiting the bleed procedure, relieve bleed pressure and disconnect bleed equipment per manufacturers instructions. Failure to properly relieve pressure may result in spilled brake fluid causing damage to components and painted surfaces. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair). 3. Inspect the brake system for leaks and visual damage. Refer to Symptoms - Hydraulic Brakes (See: Brakes and Traction Control/Hydraulic System/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Hydraulic Brakes). Repair or replace components as needed. 4. Lower the vehicle. 5. Prepare the brake bleeding equipment and the vehicle for a pressure bleed of the base hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) (See: )Hydraulic Brake System Bleeding (Pressure) (See: )Hydraulic Brake System Bleeding (Two-mode Hybrid) (See: ). 6. Inspect the battery state of charge. Refer to Battery Inspection/Test (See: Starting and Charging/Testing and Inspection/Component Tests and General Diagnostics). 7. Install a scan tool. 8. Turn the ignition ON, with the engine OFF. 9. With the scan tool, perform the following steps: 1. Select Diagnostics 2. Select the appropriate vehicle information 3. Select Chassis 4. Select Electronic Brake Control Module (EBCM) 5. Select Special Functions 6. Select Automated Bleed 10. With an assistant ready, raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). Note: * Apply the brake pedal when instructed, using moderate effort. * Ensure the pedal remains applied until instructed to release by the scan tool. * Do not exceed the time period allowed by the scan tool for having the bleeder valves open. * The bleed sequence for each corner is as follows: - Left front - Right front - Right rear - Left rear 11. Perform the automated bleed procedure as instructed by the scan tool. 12. If the automated bleed procedure is aborted, a malfunction exists. If a DTC is detected, refer to Diagnostic Trouble Code (DTC) List - Vehicle ( See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle) to diagnose the DTC. 13. After completion of the automated bleed procedure, press and hold the brake pedal to inspect for pedal firmness. 14. If the brake pedal feels spongy, repeat the bleed procedure completely. 15. Remove the scan tool. 16. Install the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair). 17. Lower the vehicle. 18. Adjust the brake fluid level. Refer to Master Cylinder Reservoir Filling (Non-Hybrid) (See: Brakes and Traction Control/Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Reservoir Filling)Master Cylinder Reservoir Filling (Two-mode Hybrid) (See: Brakes and Traction Control/Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Reservoir Filling). 19. Road test the vehicle while confirming the brake pedal remains high and firm. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Antilock Brake Automated Bleed Procedure > Page 2070 Brake Bleeding: Service and Repair Hydraulic Brake Bleeding (Manual) Hydraulic Brake System Bleeding (Manual) Warning: Refer to Brake Fluid Irritant Warning (See: Brakes and Traction Control/Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Brakes and Traction Control/Service Precautions/Vehicle Damage Warnings). 1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort increases significantly, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add GM approved brake fluid from a clean, sealed brake fluid container. Refer to Fluid and Lubricant Recommendations (USA and Canada) (See: ). If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. 2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 4. Reconnect the brake pipe to the master cylinder port and tighten securely. 5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the master cylinder. 9. With the front brake pipe installed securely to the master cylinder, after all air has been purged from the front port of the master cylinder, loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8. 10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 4. Fill the brake master cylinder reservoir with GM approved brake fluid from a clean, sealed brake fluid container. Refer to Master Cylinder Reservoir Filling (Non-Hybrid) (See: Brakes and Traction Control/Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Reservoir Filling)Master Cylinder Reservoir Filling (Two-mode Hybrid) (See: Brakes and Traction Control/Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Reservoir Filling). Ensure that the brake master cylinder reservoir remains at least half-full during this bleeding procedure. Add fluid as needed to maintain the proper level. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 6. Install a transparent hose over the end of the bleeder valve. 7. Submerge the open end of the transparent hose into a transparent container partially filled with GM approved brake fluid from a clean, sealed brake fluid container. Refer to Fluid and Lubricant Recommendations (USA and Canada) (See: ). 8. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 9. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. 10. Tighten the bleeder valve, then have the assistant slowly release the brake pedal. 11. Wait 15 seconds, then repeat steps 8-10 until all air is purged from the same wheel hydraulic circuit. 12. With the right rear wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the right rear hydraulic circuit install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 13. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 14. With the left rear wheel hydraulic circuit bleeder valve tightened securely, after all air purged from the left rear hydraulic circuit, install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve. 15. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 16. With the right front wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the right front hydraulic circuit, install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 17. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 18. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. 19. Fill the brake master cylinder reservoir to the maximum-fill level with GM approved brake fluid from a clean, sealed brake fluid container. Refer to Master Cylinder Reservoir Filling (Non-Hybrid) (See: Brakes and Traction Control/Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Reservoir Filling)Master Cylinder Reservoir Filling (Two-mode Hybrid) (See: Brakes and Traction Control/Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Reservoir Filling). 20. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 21. If the brake pedal feels spongy, repeat the bleeding procedure again. If the brake pedal still feels spongy after repeating the bleeding procedure, perform the following steps: Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Antilock Brake Automated Bleed Procedure > Page 2071 1. Inspect the brake system for external leaks. Refer to Brake System External Leak Inspection (See: Brakes and Traction Control/Hydraulic System/Testing and Inspection/Component Tests and General Diagnostics/Brake System External Leak Inspection). 2. Pressure bleed the hydraulic brake system in order to purge any air that may still be trapped in the system. 22. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. Note: If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. 23. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic Brakes (See: Brakes and Traction Control/Hydraulic System/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Hydraulic Brakes). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Antilock Brake Automated Bleed Procedure > Page 2072 Brake Bleeding: Service and Repair Hydraulic Brake Bleeding (Pressure) Hydraulic Brake System Bleeding (Pressure) Special Tools * J-29532 - Diaphragm Pressure Bleeder, or equivalent * J-35589-A - Brake Pressure Bleeder Adapter Warning: Refer to Brake Fluid Irritant Warning (See: Brakes and Traction Control/Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Brakes and Traction Control/Service Precautions/Vehicle Damage Warnings). Caution: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort increases significantly, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. 2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 4. Reconnect the brake pipe to the master cylinder port and tighten securely. 5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the master cylinder. 9. With the front brake pipe installed securely to the master cylinder, after all air has been purged from the front port of the master cylinder, loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8. 10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 4. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Install the J-35589-A - Brake Pressure Bleeder Adapter to the brake master cylinder reservoir. 6. Check the brake fluid level in the J-29532 - Diaphragm Pressure Bleeder, or equivalent. Add Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container as necessary to bring the level to approximately the half-full point. 7. Connect the J-29532 - Diaphragm Pressure Bleeder, or equivalent , to the J-35589-A - Brake Pressure Bleeder Adapter. 8. Charge the J-29532 - Diaphragm Pressure Bleeder, or equivalent , air tank to 175-205 kPa (25-30 psi). 9. Open the J-29532 - Diaphragm Pressure Bleeder, or equivalent , fluid tank valve to allow pressurized brake fluid to enter the brake system. 10. Wait approximately 30 seconds, then inspect the entire hydraulic brake system in order to ensure that there are no existing external brake fluid leaks. Any brake fluid leaks identified require repair prior to completing this procedure. 11. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 12. Install a transparent hose over the end of the bleeder valve. 13. Submerge the open end of the transparent hose into a transparent container partially filled with Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 14. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. Allow fluid to flow until air bubbles stop flowing from the bleeder, then tighten the bleeder valve. 15. With the right rear wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the right rear hydraulic circuit, install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 16. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 17. With the left rear wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the left rear hydraulic circuit, install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Antilock Brake Automated Bleed Procedure > Page 2073 18. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 19. With the right front wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the right front hydraulic circuit, install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 20. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 21. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. 22. Close the J-29532 - Diaphragm Pressure Bleeder, or equivalent , fluid tank valve, then disconnect the J-29532 - Diaphragm Pressure Bleeder, or equivalent , from the J-35589-A - Brake Pressure Bleeder Adapter. 23. Remove the J-35589-A - Brake Pressure Bleeder Adapter from the brake master cylinder reservoir. 24. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 25. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 26. If the brake pedal feels spongy perform the following steps: 1. Inspect the brake system for external leaks. Refer to Brake System External Leak Inspection (See: Brakes and Traction Control/Hydraulic System/Testing and Inspection/Component Tests and General Diagnostics/Brake System External Leak Inspection). 2. Using a scan tool, perform the antilock brake system automated bleeding procedure to remove any air that may have been trapped in the brake pressure modulator valve (BPMV). Refer to the following procedures, as appropriate: * Antilock Brake System Automated Bleed (See: )for Two-mode Hybrid vehicles * Antilock Brake System Automated Bleed (See: )for non-hybrid vehicles less than 3900 kg (8600 lb) GVW * Antilock Brake System Automated Bleed (See: )for non-hybrid vehicles greater than/equal to 3900 kg (8600 lb) GVW 27. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. Note: If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. 28. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic Brakes (See: Brakes and Traction Control/Hydraulic System/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Hydraulic Brakes). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Antilock Brake Automated Bleed Procedure > Page 2074 Brake Bleeding: Service and Repair Hydraulic Brake Flushing Hydraulic Brake System Flushing Warning: Refer to Brake Fluid Irritant Warning (See: Brakes and Traction Control/Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Brakes and Traction Control/Service Precautions/Vehicle Damage Warnings). Caution: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Inspect the brake fluid for the following conditions, indicating brake fluid contamination: * Fluid separation, indicating two types of fluid are present; a substance other than the recommended brake fluid has been introduced into the brake hydraulic system - Swirled appearance - oil-based substance - Layered appearance - silicone-based substance * Fluid discoloration, indicating the presence of moisture or particles that have been introduced into the brake hydraulic system - Cloudy appearance - moisture - Dark appearance/suspended particles in fluid - dirt, rust, corrosion, brake dust 2. Inspect the master cylinder reservoir cap diaphragm and the reservoir-to-master cylinder grommets for swelling, indicating brake fluid contamination. 3. If the brake fluid WAS contaminated with an oil-based or a silicone-based substance, indicated by fluid separation and/or a swollen master cylinder reservoir cap diaphragm and/or swollen reservoir-to-master cylinder grommets, perform the following: 1. Remove ALL of the following components listed from the vehicle. Each component contains internal rubber seals/linings which have been contaminated by the contaminated brake fluid in the brake hydraulic system. Refer to the procedures indicated: * Master Cylinder Replacement (Vacuum Assist) (See: Brakes and Traction Control/Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Replacement)Master Cylinder Replacement (Two-Mode Hybrid) (See: Brakes and Traction Control/Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Replacement )Master Cylinder Replacement (Hydraulic Assist) (See: Brakes and Traction Control/Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Replacement) * Front Brake Hose Replacement (JH6, JH7) (See: Brakes and Traction Control/Hydraulic System/Brake Hose/Line/Service and Repair/Front Brake Hose Replacement (JH6, JH7))Front Brake Hose Replacement (JD9, JF3, JF7, JG4) (See: Brakes and Traction Control/Hydraulic System/Brake Hose/Line/Service and Repair/Front Brake Hose Replacement (JD9, JF3, JF7, JG4)) * Rear Brake Hose Replacement (To Axle - JF3 without JL4, JF7, JG4) (See: Brakes and Traction Control/Hydraulic System/Brake Hose/Line/Service and Repair/Rear Brake Hose Replacement (To Axle - JF3 without JL4, JF7, JG4))Rear Brake Hose Replacement (To Axle - JD9, JF3 with JL4) (See: Brakes and Traction Control/Hydraulic System/Brake Hose/Line/Service and Repair/Rear Brake Hose Replacement (To Axle - JD9, JF3 with JL4))Rear Brake Hose Replacement (Frame to Axle - JH6, JH7) (See: Brakes and Traction Control/Hydraulic System/Brake Hose/Line/Service and Repair/Rear Brake Hose Replacement (Frame to Axle - JH6, JH7))Rear Brake Hose Replacement (To Caliper - JD9) (See: Brakes and Traction Control/Hydraulic System/Brake Hose/Line/Service and Repair/Rear Brake Hose Replacement (To Caliper - JD9))Rear Brake Hose Replacement (Caliper - JH6, JH7) (See: Brakes and Traction Control/Hydraulic System/Brake Hose/Line/Service and Repair/Rear Brake Hose Replacement (Caliper - JH6, JH7)) * Front Brake Caliper Replacement (JD9, JF3, JF7, JG4) (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Front Brake Caliper Replacement (JD9, JF3, JF7, JG4))Front Brake Caliper Replacement (JH6, JH7) ( See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Front Brake Caliper Replacement (JH6, JH7)) * Rear Brake Caliper Replacement (JD9) (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Rear Brake Caliper Replacement (JD9))Rear Brake Caliper Replacement (JH6, JH7) (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Rear Brake Caliper Replacement (JH6, JH7)) * Brake Pressure Modulator Valve Replacement (See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Hydraulic Control Assembly - Antilock Brakes/Service and Repair) * Brake Pressure Modulator Valve Replacement (See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Hydraulic Control Assembly - Antilock Brakes/Service and Repair/Non-Hybrid Less than 3900 kg (8600 lb) GVW) * Brake Pressure Modulator Valve Replacement (See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Hydraulic Control Assembly - Antilock Brakes/Service and Repair/Non-Hybrid Greater than/Equal to 3900 kg (8600 lb) GVW) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Antilock Brake Automated Bleed Procedure > Page 2075 2. Clean out all the hydraulic brake pipes using denatured alcohol, or equivalent. 3. Dry the brake pipes using non-lubricated, filtered air. 4. Repair or replace ALL of the following components listed and install them to the vehicle. Each component contains internal rubber seals/linings which have been contaminated by the contaminated brake fluid in the brake hydraulic system. Refer to the procedures indicated: * Master Cylinder Replacement (Vacuum Assist) (See: Brakes and Traction Control/Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Replacement)Master Cylinder Replacement (Two-Mode Hybrid) (See: Brakes and Traction Control/Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Replacement )Master Cylinder Replacement (Hydraulic Assist) (See: Brakes and Traction Control/Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Replacement) ; also perform the following: Clean the brake master cylinder reservoir using denatured alcohol, or equivalent, then dry the reservoir using non-lubricated, filtered air. Inspect the reservoir for cracks and/or damage and replace if necessary. Refer to Master Cylinder Reservoir Replacement (Vacuum Assist) (See: Brakes and Traction Control/Hydraulic System/Brake Fluid Reservoir/Service and Repair/Master Cylinder Reservoir Replacement (Vacuum Assist))Master Cylinder Reservoir Replacement (Hydraulic Assist) (See: Brakes and Traction Control/Hydraulic System/Brake Fluid Reservoir/Service and Repair/Master Cylinder Reservoir Replacement (Hydraulic Assist))Master Cylinder Reservoir Replacement (Two-mode Hybrid) (). Replace the brake master cylinder reservoir cap diaphragm. * Front Brake Hose Replacement (JH6, JH7) (See: Brakes and Traction Control/Hydraulic System/Brake Hose/Line/Service and Repair/Front Brake Hose Replacement (JH6, JH7))Front Brake Hose Replacement (JD9, JF3, JF7, JG4) (See: Brakes and Traction Control/Hydraulic System/Brake Hose/Line/Service and Repair/Front Brake Hose Replacement (JD9, JF3, JF7, JG4)) * Rear Brake Hose Replacement (To Axle - JF3 without JL4, JF7, JG4) (See: Brakes and Traction Control/Hydraulic System/Brake Hose/Line/Service and Repair/Rear Brake Hose Replacement (To Axle - JF3 without JL4, JF7, JG4))Rear Brake Hose Replacement (To Axle - JD9, JF3 with JL4) (See: Brakes and Traction Control/Hydraulic System/Brake Hose/Line/Service and Repair/Rear Brake Hose Replacement (To Axle - JD9, JF3 with JL4))Rear Brake Hose Replacement (Frame to Axle - JH6, JH7) (See: Brakes and Traction Control/Hydraulic System/Brake Hose/Line/Service and Repair/Rear Brake Hose Replacement (Frame to Axle - JH6, JH7))Rear Brake Hose Replacement (To Caliper - JD9) (See: Brakes and Traction Control/Hydraulic System/Brake Hose/Line/Service and Repair/Rear Brake Hose Replacement (To Caliper - JD9))Rear Brake Hose Replacement (Caliper - JH6, JH7) (See: Brakes and Traction Control/Hydraulic System/Brake Hose/Line/Service and Repair/Rear Brake Hose Replacement (Caliper - JH6, JH7)) * Front Brake Caliper Overhaul (JH6, JH7) (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Overhaul/Front Brake Caliper Overhaul (JH6, JH7)) or Front Brake Caliper Replacement (JD9, JF3, JF7, JG4) (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Front Brake Caliper Replacement (JD9, JF3, JF7, JG4))Front Brake Caliper Replacement (JH6, JH7) (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Front Brake Caliper Replacement (JH6, JH7)) * Rear Brake Caliper Overhaul (JH6, JH7) (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Overhaul/Rear Brake Caliper Overhaul (JH6, JH7)) or Rear Brake Caliper Replacement (JD9) (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Rear Brake Caliper Replacement (JD9))Rear Brake Caliper Replacement (JH6, JH7) (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Rear Brake Caliper Replacement (JH6, JH7)) * Brake Pressure Modulator Valve Replacement (See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Hydraulic Control Assembly - Antilock Brakes/Service and Repair) * Brake Pressure Modulator Valve Replacement (See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Hydraulic Control Assembly - Antilock Brakes/Service and Repair/Non-Hybrid Less than 3900 kg (8600 lb) GVW) * Brake Pressure Modulator Valve Replacement (See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Hydraulic Control Assembly - Antilock Brakes/Service and Repair/Non-Hybrid Greater than/Equal to 3900 kg (8600 lb) GVW) 4. If the brake fluid was NOT contaminated with an oil-based or a silicone-based substance, but WAS contaminated with water or dirt, rust, corrosion, and/or brake dust, replace the brake master cylinder reservoir cap diaphragm. The diaphragm may have allowed the moisture or particles to enter the hydraulic system. 5. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11(R), GM P/N 12377967 (Canada P/N 992667) or equivalent, DOT-3 brake fluid from a clean, sealed brake fluid container. 6. Pressure bleed the hydraulic brake system. Begin the procedure with the pressure bleeder reservoir filled to the maximum-fill level with the correct brake fluid as indicated. Refer to Hydraulic Brake System Bleeding (Manual) (See: )Hydraulic Brake System Bleeding (Pressure) (See: )Hydraulic Brake System Bleeding (Two-mode Hybrid) (See: ). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling SIR component location affects how a vehicle should be serviced. There are parts of the SIR system installed in various locations around a vehicle. To find the location of the SIR components refer to SIR Identification Views (See: Restraint Systems/Air Bag Systems/Locations). There are several reasons for disabling the SIR system, such as repairs to the SIR system or servicing a component near or attached to an SIR component. There are several ways to disable the SIR system depending on what type of service is being performed. The following information covers the proper procedures for disabling/enabling the SIR system. SIR Service Precautions Warning When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. The inflatable restraint sensing and diagnostic module (SDM) maintains a reserved energy supply. The reserved energy supply provides deployment power for the air bags if the SDM loses battery power during a collision. Deployment power is available for as much as 1 minute after disconnecting the vehicle power. Waiting 1 minute before working on the system after disabling the SIR system prevents deployment of the air bags from the reserved energy supply. General Service Instructions The following are general service instructions which must be followed in order to properly repair the vehicle and return it to its original integrity: * Do not expose air bags to temperatures above 65°C (149°F). * Verify the correct replacement part number. Do not substitute a component from a different vehicle. * Use only original GM replacement parts available from your authorized GM dealer. Do not use salvaged parts for repairs to the SIR system. Discard any of the following components if it has been dropped from a height of 92 cm (3 feet) or greater: * Inflatable restraint sensing and diagnostic module (SDM) * Any air bag * Driver steering wheel air bag coil * Any impact sensor * Seat belt anchor and/or retractor pretensioners * Passenger presence module and/or occupant sensor Disabling Procedure - Air Bag Fuse 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. Note: The SDM may have more than one fused power input. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove all fuses supplying power to the SDM. With all SDM fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate a SIR system malfunction. 3. Locate and remove the fuse(s) supplying power to the SDM. Refer to SIR Schematics (See: Diagrams/Electrical Diagrams/Air Bag Systems) or Electrical Center Identification Views (See: Fuses and Circuit Breakers/Fuse/Application and ID). 4. Wait 1 minute before working on the system. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Page 2079 Enabling Procedure - Air Bag Fuse 1. Place the ignition in the OFF position. 2. Install the fuse(s) supplying power to the SDM. Refer to SIR Schematics (See: Diagrams/Electrical Diagrams/Air Bag Systems) or Electrical Center Identification Views (See: Fuses and Circuit Breakers/Fuse/Application and ID). 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle). Disabling Procedure - Negative Battery Cable 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. 3. Disconnect the negative battery cable from the battery. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 4. Wait 1 minute before working on system. Enabling Procedure - Negative Battery Cable 1. Place the ignition in the OFF position. 2. Connect the negative battery cable to the battery. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Center Instrument Panel Fuse Block - Owners Manual Fuse: Locations Center Instrument Panel Fuse Block - Owners Manual CENTER INSTRUMENT PANEL FUSE BLOCK The center instrument panel fuse block is located underneath the instrument panel, to the left of the steering column. TOP VIEW HARNESS CONNECTOR - USAGE BODY 2 ............................................................................................................................................... ................................... Body Harness Connector 2 BODY 1 ............................................................... ................................................................................................................... Body Harness Connector 1 BODY 3 ............................................................................................................................................ ...................................... Body Harness Connector 3 HEADLINER 3 .................................................. .............................................................................................................. Headliner Harness Connector 3 HEADLINER 2 ................................................................................................................ ................................................ Headliner Harness Connector 2 HEADLINER 1 ................................. ............................................................................................................................... Headliner Harness Connector 1 SEO/UPFITTER .......................................................................................................................... Special Equipment Option Upfitter Harness Connector CIRCUIT BREAKER - USAGE CB1 ......................................................................................................................................................... Passenger Side Power Window Circuit Breaker CB2 ......................................................................... .......................................................................................................... Passenger Seat Circuit Breaker CB3 ...................................................................................................................................................... .................................. Driver Seat Circuit Breaker CB4 ....................................................................... .......................................................................................................................... Rear Sliding Window Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Center Instrument Panel Fuse Block - Owners Manual > Page 2085 Fuse: Locations Instrument Panel Fuse Block - Owners Manual INSTRUMENT PANEL FUSE BLOCK The instrument panel fuse block access door is located on the driver side edge of the instrument panel. Pull off the cover to access the fuse block. The vehicle may not use all of the fuses shown. FUSES ................................................................................................................................................. ..................................................................... USAGE Fuse 1 .................................................................................................................................................. .............................................................. Rear Seats Fuse 2 ................................................................ .................................................................................................................. Rear Accessory Power Outlet Fuse 3 ....................................................................................................................................... ................................... Steering Wheel Controls Backlight Fuse 4 ...................................................... .......................................................................................................................................... Driver Door Module Fuse 5 ..................................................................................................................................... ............................... Dome Lamps, Driver Side Turn Signal Fuse 6 .................................................... ...................................................................................................................... Driver Side Turn Signal, Stoplamp Fuse 7 ................................................................................................................................. .............................................. Instrument Panel Back Lighting Fuse 8 ................................................ .................................................................................................................... Passenger Side Turn Signal, Stoplamp Fuse 9 ..................................................................................................................... ............................................. Passenger Door Module, Driver Unlock Fuse 10 .................................. ................................................................................................................................. Power Door Lock 2 (Unlock Feature) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Center Instrument Panel Fuse Block - Owners Manual > Page 2086 Fuse 11 ................................................................................................................................................ ....................... Power Door Lock 2 (Lock Feature) Fuse 12 ......................................................................................................................................................... Stoplamps, Center-High Mounted Stoplamp Fuse 13 ......................................................................... .................................................................................................................. Rear Climate Controls Fuse 14 ................................................................................................................................................ ......................................................... Power Mirror Fuse 15 ................................................................ ............................................................................................................... Body Control Module (BCM) Fuse 16 ................................................................................................................................................ ....................................... Accessory Power Outlets Fuse 17 .............................................................. ......................................................................................................................................... Interior Lamps Fuse 18 .................................................................................................................................... ............................... Power Door Lock 1 (Unlock Feature) Fuse 19 .................................................... .................................................................................................................................... Rear Seat Entertainment Fuse 20 ..................................................................................................................................................... Ultrasonic Rear Parking Assist, Power Liftgate Fuse 21 ..................................................................... .................................................................................................. Power Door Lock 1 (Lock Feature) Fuse 22 ................................................................................................................................................ ........................... Driver Information Center (DIC) Fuse 23 ................................................................. ............................................................................................................................................ Rear Wiper Fuse 24 ..................................................................................................................................... ..................................................................... Cooled Seats Fuse 25 .............................................................................................................................................. Driver Seat Module, Remote Keyless Entry System Fuse 26 ........................................................................................................................................................... Driver Power Door Lock (Unlock Feature) CIRCUIT BREAKER ............................................................................................................................ ................................................................ USAGE LT DR .......................................................................................................................................................... Driver Side Power Window Circuit Breaker HARNESS CONNECTOR ................................................................................................................... ................................................................. USAGE LT DR .................................................................................................................................................. .......................... Driver Door Harness Connection BODY .................................................................. ................................................................................................................................ Harness Connector BODY ................................................................................................................................. ................................................................. Harness Connector Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood Fuse: Application and ID Fuse Block - Underhood Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2089 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2090 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2091 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2092 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2093 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2094 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2095 Fuse Block - Underhood Top View - Diesel Fuse Block - Underhood Top View - Gas Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2096 Fuse Block - Underhood Bottom View Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2097 Fuse Block - Underhood X1 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2098 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2099 Fuse Block - Underhood X2 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2100 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2101 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2102 Fuse Block - Underhood X3 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2103 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2104 Fuse Block - Underhood X4 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2105 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2106 Fuse Block - Underhood X5 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2107 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2108 Fuse Block - Underhood X6 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2109 Fuse Block - Underhood X7 (except TP2) Fuse Block - Underhood X7 (TP2) Fuse Block - Underhood X8 (except JL1) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2110 Fuse Block - Underhood X8 (JL1) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2111 Fuse: Application and ID Fuse Block - I/P Electrical Center Identification Views Fuse Block - I/P Label Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2112 Fuse Block - I/P Top View Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2113 Fuse Block - I/P Bottom View Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2114 Fuse Block - I/P X1 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2115 Fuse Block - I/P X2 (except MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2116 Fuse Block - I/P X3 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2117 Fuse Block - I/P X4 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2118 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2119 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2120 Fuse: Application and ID Fuse Block - Mobile Radio Electrical Center Identification Views Fuse Block - Mobile Radio, Top View (9L4) Fuse Block - Mobile Radio (9L4) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2121 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2122 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2123 Fuse: Application and ID Fuse Holder Electrical Center Identification Views Fuse Block - Auxiliary, Fuse Holder (HP2) Fuse Block - Auxiliary, Fuse Holder (HP2) Fuse Holder X1 (Gas except 9L4) Fuse Holder X1 (Diesel or Gas with 9L4) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2124 Fuse Holder X2 (Gas with TP2) Fuse Holder X2 (Diesel or Gas except LU3) Fuse Holder X2 (LU3) Fuse Holder X2 (Gas except LU3) Fuse Holder X2 (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2125 Fuse Holder X3 (9L4) Fuse Holder X3 (Diesel) Fuse Holder X4 (TP2) Fuse Holder X4 (Diesel) Fuse Holder X4 (Diesel with K76 or YF2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2126 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2127 Fuse: Application and ID Junction Block Electrical Center Identification Views Junction Block - Left I/P, Label Junction Block - Left I/P, Top View Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2128 Junction Block - Left I/P, Bottom View Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2129 Junction Block - Left I/P X1 (except MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2130 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2131 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2132 Junction Block - Left I/P X2 (except MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2133 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2134 Junction Block - Left I/P X3 (except MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2135 Junction Block - Left I/P X4 (except MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2136 Junction Block - Left I/P X5 (SPO Alarm or SPO Heated Seats) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2137 Junction Block - Left I/P X7 (JF4) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2138 Junction Block - Left I/P X8 (except MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2139 Junction Block - Left I/P X9 (except MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2140 Junction Block - Left I/P X10 (except MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2141 Junction Block - Left I/P X11 (except MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2142 Junction Block - Left I/P X12 (except MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2143 Junction Block - Left I/P X13 (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2144 Junction Block - Left I/P X14 (5X7, 5Y0, 9L4, SPO DVD or SPO Heated Seats) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2145 Junction Block - Right I/P, Top View Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2146 Junction Block - Right I/P (Wire Entry) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2147 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2148 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2149 Junction Block - Right I/P X2 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2150 Junction Block - Right I/P X3 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2151 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2152 Junction Block - Right I/P X4 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2153 Junction Block - Right I/P X5 Junction Block - Right I/P X6 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2154 Junction Block - Rear Lamps Junction Block - Rear Lamps X1 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2155 Junction Block - Rear Lamps X2 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2156 Junction Block - Rear Lamps X3 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 2157 Junction Block - Rear Lamps X4 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations Fuse Block: Component Locations Fuse Block - I/P Electrical Center Identification Views Fuse Block - I/P Label Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 2162 Fuse Block - I/P Top View Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 2163 Fuse Block - I/P Bottom View Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 2164 Fuse Block - I/P X1 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 2165 Fuse Block - I/P X2 (except MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 2166 Fuse Block - I/P X3 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 2167 Fuse Block - I/P X4 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 2168 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 2169 Fuse Block - Underhood Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 2170 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 2171 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 2172 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 2173 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 2174 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 2175 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 2176 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 2177 Fuse Block - Underhood Top View - Diesel Fuse Block - Underhood Top View - Gas Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 2178 Fuse Block - Underhood Bottom View Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 2179 Fuse Block - Underhood X1 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 2180 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 2181 Fuse Block - Underhood X2 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 2182 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 2183 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 2184 Fuse Block - Underhood X3 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 2185 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 2186 Fuse Block - Underhood X4 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 2187 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 2188 Fuse Block - Underhood X5 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 2189 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 2190 Fuse Block - Underhood X6 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 2191 Fuse Block - Underhood X7 (except TP2) Fuse Block - Underhood X7 (TP2) Fuse Block - Underhood X8 (except JL1) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 2192 Fuse Block - Underhood X8 (JL1) Fuse Block - Mobile Radio Electrical Center Identification Views Fuse Block - Mobile Radio, Top View (9L4) Fuse Block - Mobile Radio (9L4) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 2193 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 2194 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 2195 Fuse Block: Connector Locations Harness Routing Views Chassis Harness Routing (Except LY6/LMM/HP2) 1 - X300 2 - X408 (UD7) 3 - G401 4 - J423 (except LU3) 5 - J331 6 - Fuse Block - Underhood X3 7 - X115 8 - X102 (JL1) 9 - J338 (except LU3/LMG) 10 - J300 11 - G300 Chassis Harness Routing (LY6/LMM except 31 Series) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 2196 1 - X300 2 - X408 (UD7) 3 - Trailer Connector (UY7) 4 - J411 (JL1) 5 - G401 6 - J331 7 - Fuse Block - Underhood X3 8 - X115 9 - X102 (JL1) 10 - J300 11 - G300 Chassis Harness - Front Engine Compartment (31 Series) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 2197 1 - X102 (JL1) 2 - Fuel Pump Relay - Secondary (LY6 without NQZ) 3 - Fuse Block - Underhood 4 X126 Driver Door Harness Routing Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 2198 1 - Door Frame 2 - Fuse Block - I/P X4 3 - J502 (YE9 without AN3) 4 - X500 (YE9 without AN3/DL3) 5 - X502 (ASF without YE9 or with AN3) Engine Harness Routing - Left Side (4.3L) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 2199 1 - Throttle Body 2 - G107 3 - Transmission 4 - X300 5 - X109 6 - X110 (NQG/NQH) 7 - Fuse Block - Underhood X2 Engine Harness Routing - Left Front Side (4.8L/5.3L/6.0L/6.2L except LFA/HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 2200 1 - Air Intake Duct 2 - X111 3 - Fuse Block - Underhood X2 4 - X109 5 - X110 (NQF/NQG/NQH) 6 Engine Control Module (ECM) X2 7 - Engine Control Module (ECM) X1 8 - G102 9 - J105 Engine Chassis Harness Routing - Top Front (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 2201 1 - Battery - Right 2 - Fuse Holder 3 - X127 4 - X108 5 - X107 6 - X123 (PTO) 7 - Fuse Block Underhood 8 - X109 9 - Battery - Left 10 - Engine Control Module (ECM) 11 - Transmission Control Module (TCM) I/P Harness Routing - Engine Compartment (Except HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 2202 1 - G110 (XA7) 2 - J113 (NQH) 3 - Fuse Block - Underhood X5 4 - Fuse Block - Underhood X4 5 Left Front Fender 6 - X103 7 - X109 8 - X115 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Schematic Symbols Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2205 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2206 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2207 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2208 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2209 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2210 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2211 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2212 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2213 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2214 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2215 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2216 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2217 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2218 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2219 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2220 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2221 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2222 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2223 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2224 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2225 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2226 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2227 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2228 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2229 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2230 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2231 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2232 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2233 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2234 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2235 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2236 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2237 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2238 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2239 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2240 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2241 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2242 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2243 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2244 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2245 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2246 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2247 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2248 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2249 Fuse Block: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed with Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2250 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2251 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Connector Test Adapters) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2252 Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Test Lamp) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Fused Jumper Wires) * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage Drop) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Frequency) * Testing Ground and Low Reference Circuits (See: Testing and Inspection/Component Tests and General Diagnostics/Testing Ground and Low Reference Circuits) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fuses) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Circuit Breakers) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fusible Links) Troubleshooting with a Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Testing for a Short to Voltage Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2253 Testing for a Short to Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure tests for a short to voltage in a circuit. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the Digital Multimeter (DMM) to the V (DC) position. 4. Connect the positive lead of the DMM to one end of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. Turn ON the ignition and operate all accessories. 7. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Special Tools J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure). Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents). Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2254 The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the frequency of a signal. Note: Connecting the Digital Multimeter (DMM) to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Set to Hz on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2255 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the Digital Multimeter (DMM). 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the difference in voltage potential between 2 points. 1. Set the Digital Multimeter (DMM) to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2256 Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Backprobe Note: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2257 (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for Continuity Testing for Continuity Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures verify good continuity in a circuit. With a Digital Multimeter (DMM) 1. Set the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Select the MIN MAX function on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2258 Testing for Electrical Intermittents Testing for Electrical Intermittents Special Tools J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. Note: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions). 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2259 visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing for Terminal Fretting Some intermittent conditions can be caused by wire terminal fretting corrosion. Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can pile up enough at the electrical contact spots that the electrical resistance across the connection increases. Movement between the contacting surfaces as small as 10 to 100 microns can cause fretting. To put this in perspective, a sheet of paper is about 100 microns thick, so fretting motion is small and hard to see. Vibration and thermal expansion/contraction are the main sources that create fretting motion. Since vehicles vibrate and can experience large temperature swings, they are a good source for fretting motion. Tin, copper, nickel, and iron surfaces are all susceptible to fretting corrosion. Fretting corrosion can be difficult to see but it looks like small, dark smudges on the terminals contact surface. To correct a fretting condition disconnect the suspect connector and add Nyogel lubricant 760G (dielectric grease) to both sides of the connector terminals. Then reconnect the connector and wipe away any excess lubricant. This will correct the additional terminal contact resistance due to the terminal fretting corrosion. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2260 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics). * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Ground Distribution Schematics). Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Checking Aftermarket Accessories). * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2261 Note: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures test for a short to ground in a circuit. With a Digital Multimeter (DMM) 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohms position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Danger: High voltage circuits should only be tested using a digital multimeter (DMM) and test leads with at least a CAT III rating, such as the J 39200-A Digital Multimeter. Failure to follow the procedures exactly as written may result in serious injury or death. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Digital Multimeter (DMM) Basic Requirements Service information is validated using digital multimeters that meet or exceed the following requirements. Using a multimeter that does not meet these basic requirements may give inaccurate readings which could lead to an incorrect diagnosis. Display and Settings 1. Four digits displayed 2. Voltage, amperage, resistance, frequency, diode test settings, and min-max function 3. Display positive and negative values Voltage 1. Have at least 10 M ohm input impedance Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2262 2. Test a DC voltage range of 0.1-1000 V. 3. Test an AC voltage range of 0.1-1000 V. Amperage 1. Test a DC amperage range of 0.1µA-10 A. 2. Test an AC amperage range of 0.1µA-10 A. Resistance Test a resistance range of 0.1 ohm-40 Mohm and displays infinite for a value greater than 40 M ohm (O.L. (Over-load)) Frequency Test for a frequency range of 0.5 HZ-199 K HZ Diode Test 1. Apply at least 1 mA when performing the diode bias test 2. Display the break over voltage drop (0-3 V) of a forward biased diode 3. Display infinite (O.L. (Over-load)) when a diode is reverse biased Min-Max Readings 1. Can update at a 1 ms sample rate 2. Saves and displays minimum and maximum values Note: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Probe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors). * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the EL-38125-580 GM Approved Terminal Release Tool Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the EL-38125-580 GM Approved Terminal Release Tool Kit , ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the EL-38125-580 GM Approved Terminal Release Tool Kit label on the inside of the EL-38125-580 GM Approved Terminal Release Tool Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2263 Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/EPC Connectors AFL/EPC Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2264 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 3. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2265 View showing depressing of the lever lock release tab. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2266 6. Release the rear lower half of the wiredress cover. 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2267 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2268 Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Bosch Connectors (ECM) Bosch Connectors (ECM) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2269 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. 2. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2270 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-bladed tool to release the locking tabs and remove the dress cover. 4. The terminal positive assurance (TPA) is located in the front of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2271 5. Use a small flat-blade tool to remove TPA from the connector. 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2272 Note: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2273 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2274 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Terminal Replacement Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2275 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2276 5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Position Assurance Locks) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Terminal Position Assurance Locks) * AFL/EPC Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/AFL/EPC Connectors) * Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (BSK))Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (0.64))Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (2.8 JPT))Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (ECM)) * Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Weather Pack))Delphi Connectors (Push To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Push to Seat))Delphi Connectors Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2277 (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Pull to Seat))Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro-Pack 100W))Delphi Connectors (Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro .64))Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (12-Way)) * FCI Connectors (Lever Lock) (See: General Electrical Diagnostic Procedures/Connector Repairs/FCI Connectors (Lever Lock)) * JST Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/JST Connectors) * Kostal Connectors (Glow Plug Control Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Glow Plug Control Module))Kostal Connectors (Transmission) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Transmission)) * Molex Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Molex Connectors) * Sumitomo Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Sumitomo Connectors) * Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (CM 42-Way))Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Sensor))Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (0.25 Cap))Tyco/AMP Connectors (43-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (43-Way))Tyco/AMP Connectors (Door Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Door Module))Tyco/AMP Connectors (102-Way Inline) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (102-Way Inline))Tyco/AMP Connectors (Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Seat))Tyco/AMP Connectors (SIR) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (SIR)) * Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (2-Way))Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (16-Way)) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2278 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2279 * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2280 * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2281 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2282 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2283 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Push to Seat) Delphi Connectors (Push To Seat) Special Tools J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2284 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs). 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Terminated Lead Repair 1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice sleeves depending on the gauge size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Delphi Connectors (Pull to Seat) Delphi Connectors (Pull To Seat) Special Tools Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2285 J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Note: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2286 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. View of a typical Micro 64 connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2287 Depress the lock and pull the lever over and past the lock. View of the connector when released from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2288 View of another type of Micro 64 connector. Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2289 View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2290 Note: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2291 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2292 Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Note: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2293 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2294 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2295 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2296 1. Cut the wire as close to the terminal as possible. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2297 Terminal Replacement Procedure After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Special Tools J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Note: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals). 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12-Way) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2298 Delphi Connectors (12-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2299 4. Release the lower wire dress cover locking tab. 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2300 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2301 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors (Lever Lock) FCI Connectors (Lever Lock) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2302 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. The release tab is located on the top of the wiredress cover. 3. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2303 6. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2304 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2305 1. While depressing the lock, remove the connector from the component. 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2306 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. 4. View of the TPA when removed from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2307 5. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Glow Plug Control Module) Kostal Connectors (Glow Plug Control Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2308 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2309 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2310 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. Note: The front TPA cannot be removed from the connector. Only move it to the preset position. 6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm). 7. Use a small flat-blade tool to completely remove the rear TPA from the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2311 8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Transmission) Kostal Connectors (Transmission) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2312 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2313 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Terminal Replacement Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2314 After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2315 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2316 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2317 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2318 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2319 3. To assemble the connector, reverse the connector disassembly procedure. Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2320 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2321 7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2322 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2323 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2324 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2325 Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2326 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2327 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2328 6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (102-Way Inline) Tyco/AMP Connectors (102-Way Inline) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2329 View of a typical connector in the assembled position. 1. Pull the locking lever to the 90 degree position from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2330 2. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal. 3. Slide the male connector body out away from the guide plates. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2331 Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 4. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. 5. Using terminal release tool J 38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2332 6. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 7. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2333 8. The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool J-38125-11A or equivalent to release the locking tab and slide the connector off the female body. 9. Move the locking lever 180 degrees from the connected position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2334 10. With the locking lever in the 180 degree position the guide plates can be removed from the connector body. Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 11. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2335 12. Using terminal release tool J 38125-216, lift the terminal plate past the terminals and out of the connector body cavity. 13. Terminal plate will bind slightly on each corner. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2336 14. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 15. Using terminal release tool J 38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2337 16. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 17. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2338 18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever. 19. Slide the male connector body back inward toward the guide plates. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2339 20. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly. 21. Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Seat) Tyco/AMP Connectors (Seat) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2340 Removal Procedure 1. Grasp the locking slide lever and pull outward from the end of the connector. 2. As the slide lever is pulled out the mating connector is lifted from the seated position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2341 Note: TPA is keyed and can only be inserted in one direction. 3. Using terminal release tool J 38125-11A or equivalent, push the TPA tabs into the connector body. 4. Pull the TPA from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2342 5. Using terminal release tool J 38125-11A or equivalent, release the connector wire dress cover locking tab. 6. With the lock tab released, lift the connector wire dress cover from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2343 7. Using terminal release tool J 38125-212, press the prongs into the holes each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 8. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2344 9. Using terminal release tool J 38125-556, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (SIR) Tyco/AMP Connectors (SIR) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2345 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2346 3. Using terminal tool J-38125-11A or equivalent, release the wire dress cover locking tabs. 4. Pivot connector wire dress cover while removing from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2347 5. Using terminal tool J-38125-11A or equivalent, remove the TPA by lifting straight off the connector body. 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals Repairing Connector Terminals Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2348 Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gauge size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2349 2. Disconnect the connector from the component. 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2350 4. Relieve the tension on the nose piece retainers by inserting J 38125-12A into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. 5. Once the nose piece retainers are relaxed, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2351 6. On the opposite side of the nose piece, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2352 8. Insert the J 38125-553 tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2353 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. If the TPA is removed, be sure to reinstall it before reconnecting the connector. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2354 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Special Tools Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2355 J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Note: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2356 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2357 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2358 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2359 1. While depressing the lock, pull the two connector halves apart. Note: The TPA is fragile and may break if not done carefully. 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. 3. View of the male half of the connector with female terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2360 4. View of the female half of the connector with male terminals. 5. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. View of the female half of the connector with male terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2361 7. View of the male half of the connector with female terminals. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2362 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are a one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine if the element in the fuse is broken (2). If not broken (1), also check for continuity using a Digital Multimeter (DMM) or a continuity tester. If the element is broken or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a Digital Multimeter (DMM) at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gauge size. Repairing a Fusible Link Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2363 Flat Wire Repairs The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Special Tools J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool * J 38125-5 Ultra Torch Special Tool The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Note: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation). GMLAN Connector Terminal Repair Note: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) for the appropriate connector repair procedure. GMLAN Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2364 Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2365 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Special Tools J-38125 Terminal Repair Kit Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2366 repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs High Temperature Wiring Repairs Special Tools J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gauge size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2367 splice. Note: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2368 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2369 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the wire insulation has been chafed, or broken, enough to show the conductive portion of the wire, and the wire is not damaged, determine the length of insulation that needs to be repaired. If the repair is less than 280 mm (11 in), cut the wire within the damaged area. Then slide the appropriate heat shrink tubing (listed below) over the wire, and repair the wire by splicing the wires together. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Once the wire is spliced together slide heat shrink tubing over the damaged area and apply heat to seal the repaired wire. If the wire is damaged, or the damaged area is larger than 280 mm (11 in), then replace the damaged wire by splicing in a new section of wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2370 SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Special Tools J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2371 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2372 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2373 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Special Tools J-38125 Terminal Repair Kit Note: Use only DuraSeal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use DuraSeal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use DuraSeal splice sleeves where there are special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2374 * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2375 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2376 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the instructions for Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Staggering the splices by 65 mm (2.5 in) is recommended. Note: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product AL-36FR to replace the damaged mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Flat Wire Repairs) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/GMLAN Wiring Repairs) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Heated Oxygen Sensor Wiring Repairs) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves) * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Twisted or Shielded Cable) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Inline Harness Diodes) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/SIR/SRS Wiring Repairs) US English/Metric Conversion US English/Metric Conversion Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2377 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2378 Testing Ground and Low Reference Circuits Testing Ground and Low Reference Circuits Because a test lamp can light with up to 200 ohm in a ground or low reference circuit they are not recommended to be used for this type of test. A low impedance test lamp can light and indicate the circuit is good when there is as much as 20-30 ohm present, while a high impedance test lamp can light with up to 200 ohm present in the circuit. This is why the Digital Multi-Meter (DMM) is used when validating a ground or low reference circuit continuity. When using the DMM there are many vehicle conditions that can affect the ground and low reference continuity testing. If these conditions are not met, a ground or low reference circuit test can fail on a good circuit. This may cause longer diagnosis time and incorrect component replacement. Any current flow through a ground or low reference circuit, while being tested, will skew the DMM continuity reading, or display a reading higher than when there is no current flowing. Performing a ground or low reference circuit continuity test, in reference to the vehicles battery negative terminal, will have the highest risk of failing a good ground or low reference circuit test than any other ground reference point. The best ground test points would be a control module housing (if the control modules housing is metal and grounded), door jamb striker (if attached to metal), under dash metal frame work, engine block, or body ground studs (other than where the negative battery cable is attached). A typical DMM ground or low reference circuit continuity reading can be as high as 100 ohm with the ignition ON, and drop to 15-25 ohm after the ignition is turned OFF. The reading will drop below 10 ohm after 30-40 seconds, then below 5 ohm after 60 seconds. Once the vehicle completely goes to sleep (generally 3-10 minutes) the reading will drop below 0.3 ohm. The following list of conditions may need to be met to ensure a valid continuity reading on a ground or low reference circuit: * Ignition OFF * Key out of the ignition switch (when not equipped with keyless entry and remote start) * Retained Accessory Power (RAP) OFF (open and close the driver door after ignition OFF) * Battery charger set at a 2 A or less charge rate * Scan tool not communicating with any vehicle control module (in some cases it may need to be disconnected from the DLC) * All entry doors closed * Headlamps OFF (auto headlamps disabled) * Any delay lighting OFF * HVAC after blow OFF * Any accessory that can work when the ignition is OFF * Wait up to 60 seconds (after all other listed conditions are met) Activating the DOOR LOCK function with a key fob can greatly reduce the time to achieve a valid ground or low reference continuity test result. Terminal Removal Terminal Removal Special Tools * EL-38125-580 - Terminal Release Tool Kit * EL-35616 - Connector Test Adapter Kit For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repair procedures. 1. Find the appropriate connector end view within the connector end view section. The connector end view has the following information: Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2379 * Diagnostic probe tool * Terminal release tool * Terminal/terminated lead part numbers Note: Not using the proper test kit probe may cause damage to the terminal(s) that are probed. 2. Determine if a terminal is damaged. * Locate the diagnostic probe tool from the connector end view. The connector end view describes the color and part number to help the technician find and use the correct tool. * Connect the probe tool to the Digital Multimeter. * Insert the probe tool into the cavity and follow the procedures from the Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter). 3. Disconnect the connector body to perform the repair. 4. Use the following procedure to remove the terminal from the connector body. Note: Several procedures for specific connector bodies are called out in the Wiring Repairs section. * The terminal position assurance (TPA) and connector position assurance (CPA) should be removed before releasing the terminal for the connector body. * Look at the connector end view to locate the cavity of the damaged terminal and find the proper terminal release tool from the terminal release tool kit. Note: Using the incorrect terminal release tool can damage the connector body. * Insert the terminal release tool into the cavity. Note: Some terminals have a lever that must be disengaged before the terminal can be released. 5. Gently pull the wire out of the back of the connector. 6. Repair the terminal by following the Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) procedure. 7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminated Lead Repair Terminated Lead Repair Special Tools * J-38125-8 - Splice Sleeve Crimp Tool Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2380 * J-38125-5 - Ultra Torch For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) procedures. Terminated leads are terminals that are crimped onto wires. The terminated lead can be used throughout the vehicle since it is designed for temperatures up to 150°C. The length of the wire is 450 mm. The DuraSeal splice sleeve has the following 2 critical features: * A special heat shrink tubing that environmentally seals the splice. The shrink tubing contains a sealing adhesive inside the shrink tubing. * A cross hatched (knurled) core crimp that provides the necessary contact integrity for sensitive low energy circuits. 1. Use the connector end view to identify the correct terminated lead. 2. The terminated lead package should include a DuraSeal splice sleeve. If not, use the chart to identify the correct part. 3. Open the harness by removing any tape: Use a sewing seam ripper, or a comparable tool, to cut open the harness, to avoid wire insulation damage. 4. Depending on how many terminals need repairs, cut the terminal and wire back at least 40 mm. Try to keep the harness wire length the same. If more than one terminated lead is required, stagger the lengths by 40 mm. This helps reduce the bundle size of the wire harness. 5. Use the EL-38125-10 - tool in order to position the DuraSeal splice sleeve in the proper color nest of the splice sleeve crimp tool. The crimp tool has four nests, one for each color. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2381 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the J-38125-5 - ultra torch , apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2382 Fuse Block: Connector Views Electrical Center Identification Views Junction Block - Left I/P, Label Junction Block - Left I/P, Top View Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2383 Junction Block - Left I/P, Bottom View Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2384 Junction Block - Left I/P X1 (except MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2385 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2386 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2387 Junction Block - Left I/P X2 (except MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2388 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2389 Junction Block - Left I/P X3 (except MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2390 Junction Block - Left I/P X4 (except MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2391 Junction Block - Left I/P X5 (SPO Alarm or SPO Heated Seats) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2392 Junction Block - Left I/P X7 (JF4) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2393 Junction Block - Left I/P X8 (except MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2394 Junction Block - Left I/P X9 (except MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2395 Junction Block - Left I/P X10 (except MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2396 Junction Block - Left I/P X11 (except MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2397 Junction Block - Left I/P X12 (except MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2398 Junction Block - Left I/P X13 (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2399 Junction Block - Left I/P X14 (5X7, 5Y0, 9L4, SPO DVD or SPO Heated Seats) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2400 Junction Block - Right I/P, Top View Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2401 Junction Block - Right I/P (Wire Entry) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2402 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2403 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2404 Junction Block - Right I/P X2 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2405 Junction Block - Right I/P X3 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2406 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2407 Junction Block - Right I/P X4 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2408 Junction Block - Right I/P X5 Junction Block - Right I/P X6 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2409 Junction Block - Rear Lamps Junction Block - Rear Lamps X1 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2410 Junction Block - Rear Lamps X2 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2411 Junction Block - Rear Lamps X3 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 2412 Junction Block - Rear Lamps X4 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Procedures Fuse Block: Procedures Ground Repair Electrical Grounds Proper electrical system function relies on secure, positive, corrosion-free ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacements. In general, electrical ground connections are accomplished using one, or a combination of, three attachment methods: * Welded M6 stud and nut * Welded M6 nut and bolt * Welded M8 nut and bolt Caution: Use GM approved replacement fasteners with conductive finish for electrical ground repair. Determine which attachment method is used, and carry out the appropriate repair. M6 Weld Stud Replacement 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note: Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Carefully remove paint and primer from the area surrounding the rivet stud flange until bare metal is visible. Caution: Use GM approved replacement fasteners with conductive finish for electrical ground repair. 5. Select a replacement conductive M6 rivet stud. Refer to GM parts catalog for the correct part number and application. 6. Using a rivet stud installer, install the replacement conductive M6 rivet stud. 7. Ensure the new rivet stud is securely fastened, with no detectable movement. Note: The rivet stud and surrounding panel area must be properly refinished prior to the installation of the ground terminal and nut to maintain positive electrical grounding. 8. Completely wrap the threads of the rivet stud with painters tape or equivalent. 9. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair (). 10. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 11. Remove the painters tape or equivalent from the rivet stud threads. 12. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 13. Carefully remove any corrosion from the electrical ground wire terminal. Refer to Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections). 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the new conductive M6 rivet stud threads. 15. Install the ground terminal to the new rivet stud. 16. Select a new, conductive M6 nut. Refer to GM parts catalog for the correct part number and application. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 17. Install the M6 nut and tighten to 8 Nm (71 lb in). 18. Check for proper system operation. M6 Weld Nut Caution: Use GM approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a new, conductive self-threading M7 bolt may be used to secure the ground terminal. Refer to GM parts catalog for the correct part number and application. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the new, conductive, self-threading M7 bolt Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Procedures > Page 2415 threads. 5. Carefully remove any corrosion from the electrical ground terminal. Refer to Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections). 6. Install the electrical ground terminal to the new, conductive M7 bolt. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 7. Install the M7 bolt and tighten to 9 Nm (80 lb in). 8. Check for proper system operation. M6 Weld Nut (Alternative Repair) Caution: Use GM approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a conductive M6 bolt and a conductive M6 nut may be used to secure the electrical ground terminal. Refer to GM parts catalog for the correct part number and application. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 ) clearance behind the panel surface and 20 mm (0.79 ) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note: Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Carefully remove paint and primer from the area surrounding the new ground site until bare metal is visible. 6. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the new, conductive M6 bolt threads. 7. Carefully remove any corrosion from the electrical ground terminal. Refer to Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections). 8. Install the electrical ground terminal and new, conductive M6 bolt to the ground location. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 9. Install the conductive M6 nut and tighten to 8 Nm (71 lb in). Note: The repair area must be properly refinished to maintain positive electrical grounding. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair (). 11. Check for proper system operation. M8 Weld Nut Caution: Use GM approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a conductive M8 bolt and a conductive M8 nut may be used to secure the ground terminal. Refer to GM parts catalog for the correct part numbers and application. 2. Select a location adjacent to M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note: Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Carefully remove paint and primer from the area surrounding the new ground site until bare metal is visible. 6. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the new, conductive M8 bolt threads. 7. Carefully remove any corrosion from the electrical ground terminal. Refer to Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections). 8. Install the electrical ground terminal and new, conductive M8 bolt to the ground location. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 9. Install the conductive M8 nut and tighten to 22 Nm (16 lb ft). Note: The repair area must be properly refinished to maintain positive electrical grounding. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Procedures > Page 2416 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair (). 11. Check for proper system operation. M8 Weld Nut (Alternative Repair) Caution: Use GM approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a conductive M6 rivet stud and a conductive M6 nut may be used to secure the ground terminal. Refer to GM parts catalog for the correct part numbers and application. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new, conductive M6 rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note: Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Carefully remove paint and primer from the area surrounding the rivet stud flange until bare metal is visible. 6. Using a rivet stud installer, install the replacement conductive M6 rivet stud. 7. Ensure the new rivet stud is securely fastened, with no detectable movement. Note: The rivet stud and surrounding panel area must be properly refinished prior to the installation of the ground terminal and nut to maintain positive electrical grounding. 8. Completely wrap the threads of the rivet stud with painters tape or equivalent. 9. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair (). 10. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 11. Remove the painters tape or equivalent from the rivet stud threads. 12. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 13. Carefully remove any corrosion from the electrical ground wire terminal. Refer to Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections). 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the new conductive M6 rivet stud threads. 15. Install the ground terminal to the new, conductive M6 rivet stud. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 16. Install the conductive M6 nut and tighten to 8 Nm (71 lb in). 17. Check for proper system operation. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Procedures > Page 2417 Fuse Block: Removal and Replacement 175 Amp Mega Fuse Replacement (Diesel) 175 Amp Mega Fuse Replacement (Diesel) Removal Procedure 1. Disconnect the auxiliary battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 2. Remove the mega fuse cover (3). 3. Remove the starter solenoid cable nut (1) from the fuse stud. 4. Remove the starter solenoid cable terminal (2) from the fuse stud. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Procedures > Page 2418 5. Remove the auxiliary battery positive cable nut (1) from the mega fuse holder. 6. Remove the generator battery jumper cable to fuse nut (3). 7. Remove the generator battery jumper cable terminal (2) from the fuse stud. 8. Remove the auxiliary battery positive cable from the fuse studs. 9. Remove the upper mega fuse nut (1), if necessary. 10. Remove the appropriate mega fuse (2). Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Procedures > Page 2419 1. Install the appropriate mega fuse (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the upper mega fuse nut (1), if necessary. Tighten the nut to 15 Nm (11 lb ft). 3. Install the auxiliary battery positive cable to the fuse studs. 4. Install the generator battery jumper cable terminal (2) to the fuse stud. 5. Install the generator battery jumper cable to fuse nut (3). Tighten the nut to 9 Nm (80 lb in). 6. Install the auxiliary battery positive cable nut (1) to the mega fuse holder. Tighten the nut to 15 Nm (11 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Procedures > Page 2420 7. Install the starter solenoid cable terminal (2) to the fuse stud. 8. Install the starter solenoid cable nut (1) to the fuse stud. Tighten the nut to 15 Nm (11 lb ft). 9. Install the mega fuse cover (3). 10. Connect the auxiliary battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 175 Amp Mega Fuse Replacement (Single Battery) 175 Amp Mega Fuse Replacement (Single Battery) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Procedures > Page 2421 175 Amp Mega Fuse Replacement (Auxiliary Battery) 175 Amp Mega Fuse Replacement (Auxiliary Battery) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Procedures > Page 2422 200 Amp Mega Fuse and Auxiliary Electrical Center 12VDC Junction Block Replacement 200 Amp Mega Fuse and Auxiliary Electrical Center 12VDC Junction Block Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Procedures > Page 2423 Instrument Panel Electrical Center or Junction Block Replacement - Left Side Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Procedures > Page 2424 Instrument Panel Electrical Center or Junction Block Replacement - Left Side Body Wiring Harness Junction Block Replacement Body Wiring Harness Junction Block Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Procedures > Page 2425 Underhood Electrical Center or Junction Block Replacement Underhood Electrical Center or Junction Block Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Procedures > Page 2426 Underhood Electrical Center or Junction Block Bracket Replacement Underhood Electrical Center or Junction Block Bracket Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Procedures > Page 2427 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood Relay Box: Application and ID Fuse Block - Underhood Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 2432 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 2433 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 2434 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 2435 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 2436 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 2437 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 2438 Fuse Block - Underhood Top View - Diesel Fuse Block - Underhood Top View - Gas Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 2439 Fuse Block - Underhood Bottom View Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 2440 Fuse Block - Underhood X1 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 2441 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 2442 Fuse Block - Underhood X2 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 2443 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 2444 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 2445 Fuse Block - Underhood X3 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 2446 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 2447 Fuse Block - Underhood X4 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 2448 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 2449 Fuse Block - Underhood X5 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 2450 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 2451 Fuse Block - Underhood X6 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 2452 Fuse Block - Underhood X7 (except TP2) Fuse Block - Underhood X7 (TP2) Fuse Block - Underhood X8 (except JL1) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 2453 Fuse Block - Underhood X8 (JL1) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 2454 Relay Box: Application and ID Fuse Block - I/P Electrical Center Identification Views Fuse Block - I/P Label Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 2455 Fuse Block - I/P Top View Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 2456 Fuse Block - I/P Bottom View Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 2457 Fuse Block - I/P X1 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 2458 Fuse Block - I/P X2 (except MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 2459 Fuse Block - I/P X3 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 2460 Fuse Block - I/P X4 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 2461 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 2462 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 2463 Relay Box: Application and ID Fuse Block - Mobile Radio Electrical Center Identification Views Fuse Block - Mobile Radio, Top View (9L4) Fuse Block - Mobile Radio (9L4) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 2464 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 2465 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips Low Tire Pressure Indicator: Technical Service Bulletins Tire Pressure Monitor - TPM System Message/Service Tips # 09-03-16-002A: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire Pressure Monitor (TPM) System Message, Light and Customer Information - (Apr 27, 2010) Subject: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire Pressure Monitor (TPM) System Message, Light and Customer Information Models: 2006-2011 Cars and Light Duty Trucks (Including Saturn and Saab) 2006-2010 HUMMER H2, H3 ATTENTION The information found in this bulletin is to be used as a dealership service consultant procedures for customers coming into the service lane with an illuminated "low tire light" or comments on a check tire pressure/low tire pressure/add air to tire or service tire monitor system message. Maintaining proper tire pressures is an Owner's Maintenance item and is not covered under warranty. This bulletin is being revised to add model years and update additional bulletin reference information. Please discard Corporate Bulletin Number 09-03-16-002 (Section 03 -- Suspension). Customer Concerns and Confusion with the Tire Pressure Monitoring (TPM) System The following procedure should be used by dealership service consultants when a customer comes into the service drive with a "low tire light" on or comments on a check tire pressure/low tire pressure/add air to tire or service tire monitor system message. The service consultant should perform the following steps: Procedure Turn the key to ON, without starting the engine. ^ If the low tire light comes on and stays on solid with a check tire pressure/low tire pressure/add air to tire message (on vehicles equipped with DIC), advise the customer: - The system is working properly. - Properly adjusting all tire air pressures to the recommended levels and driving the vehicle will turn the light off (refer to the Tire and Loading Information label on the driver side door). - More detailed information can be found in the Owner Manual. - Service is not covered under warranty - this maintenance is the responsibility of the owner. - Give the customer a copy of the "GM Customer TPMS Information". ^ If the Tire Pressure Monitor (TPM) light blinks for one minute then stays on solid with a service tire monitor system message (on vehicles equipped with DIC): - A TPM system problem exists. The vehicle should be written up accordingly and sent to your service department for further DTC diagnosis and service. - If dashes (--) are displayed in only one or two of the tire pressure readouts, it is likely caused by a previous TPM system relearn that was performed incorrectly due to interference from another vehicle's TPM system during the relearn process (refer to the Important statement later in this bulletin regarding TPM relearn with a Tech 2(R)). - If dashes (--) are displayed in all four of the tire pressure readouts, there is a system problem. Follow the appropriate SI service procedures. ^ If a customer indicates the low tire light comes on for a few minutes when the vehicle is started, then goes off after driving a while, advise the customer: - The system is working properly. - Most likely, air pressure in one or more of the tires is low enough to turn the light on when tires are cold. After driving for a while, tires will heat Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 2471 up, allowing tire air pressure to increase above the threshold causing the light to go off. Properly adjusting all tire air pressures to the recommended levels will correct this (Refer to the Tire and Loading Information Label on the driver side door). - More detailed information can be found in the Owner Manual. - Service is not covered under warranty - this maintenance is the responsibility of the owner. - Give the customer a copy of the "GM Customer TPMS Information". For more detailed information, refer to Corporate Bulletin Number 07-03-16-004C and TPMS Training Course 13044.12T2. Tire Pressure Light At key on, without starting the vehicle: Steady Solid Glowing TPM Indicator If the TPM indicator appears as a steady glowing yellow lamp (as above), the system is functioning properly and you should add air to the tires to correct this condition. Blinking TPM Indicator If the TPM indicator appears as a BLINKING yellow lamp for one minute and then stays on solid, diagnostic service is needed. The Effect of Outside Temperature on Tire Pressures Important: As a rule of thumb, tire pressure will change about 7kPa (1 psi) for every 6°C (10°F) decrease in temperature - Tire pressure will drop when it gets colder outside, and rise when it gets warmer. Under certain situations such as extreme outside temperature changes, the system may bring on a solid light with a check tire pressure message. This should be considered normal and the system is working properly. The light will turn off upon adding the proper amount of air to the tires (refer to the Tire & Loading Information label in the driver's door opening). When properly adjusting tire air pressure, the following steps are important to help optimize the system and prolong bringing a tire pressure light on: ^ Use an accurate, high quality tire pressure gauge. ^ Never set the tire pressure below the specified placard value regardless of tire temperature or ambient temperature. ^ Tire pressure should be set to the specified placard pressure at the lowest seasonal temperature the vehicle will encounter during operation. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 2472 ^ When adding proper tire air pressure, it is important to remember fluctuations in outside air temperatures and tire temperatures effect tire air pressures. ^ After you have added the proper tire pressure, if the vehicle has a DIC (after the system has updated), check to see if DIC displays are the same readings as the tire pressure gauge used (adjust as necessary). ^ Only perform a TPM sensor re-learn after a tire rotation or system part replacements and use the Tech 2(R) to initiate the relearn whenever possible to avoid invalid sensor I.D. learns. Important: Always take outside temperature and tire temperature into consideration to properly set tire pressures. Foe example, on colder days (20°F/-7°C), if setting tire pressure when the vehicle has been indoors (60°F/16°C) or the tires are warm from being driven, it will be necessary to compensate for the low outside temperature by adding 21-27 kPa (3-4 psi) more then the placecard pressure. At some later time, when the vehicle has been parked outside for a while, the tires will cool off and the pressures will drop back into the placecard range. Important: Recently, nitrogen gas (for use in inflating tires) has become available to the general customer through some retailers. The use of nitrogen gas to inflate tires is a technology used in automobile racing. Tires inflated with nitrogen gas may exhibit less of a pressure change in response to outside temperature changes. Nitrogen gas inflation is compatible with GM TPM sensors. For additional information, refer to Corporate Service Bulletin 05-03-10-020C. Important: All Models (Except the Pontiac Vibe): Do not perform a TPM relearn at PDI, the system has already been set at the Assembly Plant. Do not perform a TPM relearn after adding air to the tires. The low tire light is similar to the low fuel indicator and adding something (fuel, air) to the vehicle makes that light turn back off again. Note that because of system behavior, some vehicles must be driven a short distance before the sensors recognize the increase in pressure and turns the light off again. Pontiac Vibe Only: Do not use the TPMS reset button to turn off the light. The system will update and light will turn off when all tire pressures have been adjusted followed by short distance drive. Important: All models (except the Pontiac Vibe): Each tire monitor sensor is learned to a specific vehicle corner. When performing a TPM relearn (only after a tire rotation or replacement of a TPM sensor or Module), always use the Tech2(R) to initiate the J 46079 relearned process. Tech 2(R) - initiated relearns lock out other vehicle TPM signals that may be broadcasting in the area. Only signals initiated by the J 46079 tool will be accepted. This method avoids storing false TPM I.D.s and will prevent customers from returning with dashes (--) displayed in tire pressure readouts and/or a flashing tire pressure monitor (TPM) light. Checking the four TPM I.D.s with the Tech 2(R) prior to and following relearn to verify they are the same can prevent invalid I.D. learns. Pontiac Vibe Only: Tire Monitor Sensors are not learned to a specific vehicle corner. Do not perform a TPM Reset after tire rotation. The TPMS Reset button must only be used during pre-delivery inspection by the dealer to initialize the system (after all tire pressures have been adjusted properly) or when a Tire Pressure Monitor System component is replaced. The J 46079 tool does not work on Vibe TPM sensors. A TPMS relearn on Vibe must be preformed with a Tech 2(R) to set the TPMS Module in learn mode. The TPMS sensor IDs are entered through the Tech 2(R). Refer to SI for further Vibe TPMS information. Labor Operation and Repair Order/Warranty System Claim Required Documentation Important: The ONLY time labor operation E0726 or E0722 should be used is to diagnose for a system issue. That should ONLY occur if, at key ON, without starting the engine, the Tire Pressure Monitor (TPM) blinks for one minute and then stays on solid with a Service Tire Monitor System message (on vehicles equipped with a DIC) If that occurs, a TPM system problem exists and the system will have set a DTC. If one of these operastions is used, the following Repair Order and Warranty System documentation are required: ^ Document the customer complaint on the Repair Order. ^ Document the TPMS DTC that has set on the Repair Order. ^ Enter the TPMS DTC in the Warranty System (WINS) in the Failure Code/DTC field on the claim submission (refer to the Claims Processing Manual, Section IV, Warranty claim Data, Page 6, Item G). If the above information is not documented on the Repair Order and Warranty System, the claim may be rejected. If the Warranty Parts Center (WPC) generates a request, this repair order documentation must be sent back. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 2473 Customer TPMS Information Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 2474 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 2475 Frequently Asked Questions Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Maintenance Required Lamp/Indicator > Component Information > Service and Repair Maintenance Required Lamp/Indicator: Service and Repair SERVICE VEHICLE SOON or SERVICE ENGINE SOON INDICATOR If your vehicle is equipped with a "SERVICE VEHICLE SOON"or a "SERVICE ENGINE SOON" indicator. This indicator is not a maintenance indicator and does not mean a maintenance service is required. For additional "SERVICE VEHICLE SOON"or a "SERVICE ENGINE SOON" indicator information refer to Malfunction Indicator Lamp. For Maintenance Required Lamp/Indicator, refer to Oil Change Reminder Lamp. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Testing and Inspection Malfunction Indicator Lamp: Testing and Inspection Malfunction Indicator Lamp (MIL) Diagnosis Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Circuit/System Description The malfunction indicator lamp (MIL) is located on the instrument panel cluster (IPC). The MIL informs the driver that an emission system fault has occurred and that the engine control system requires service. The engine control module (ECM) monitors the MIL control circuit for conditions that are incorrect for the commanded states of the MIL. For example, a failure condition exists if the ECM detects low voltage when the MIL is commanded OFF, or high voltage when the MIL is commanded ON. Diagnostic Aids An intermittent or poor connection at the MIL control circuit at the inline harness connector may cause this DTC to set. Inspect the connector terminals for any condition that may result in excessive resistance. Refer to Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections). Reference Information Schematic Reference * Engine Controls Schematics (See: Powertrain Management/Diagrams/Electrical Diagrams) * Instrument Cluster Schematics (See: Diagrams/Electrical Diagrams/Instrument Panel, Gauges and Warning Indicators/System Diagram/Instrument Cluster Schematics) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) DTC Type Reference Powertrain Diagnostic Trouble Code (DTC) Type Definitions (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Powertrain Diagnostic Trouble Code (DTC) Type Definitions) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning) for scan tool information Circuit/System Verification Ignition ON, command the MIL ON and OFF with a scan tool. The MIL should turn ON and OFF with each command. Circuit/System Testing 1. Ignition ON, verify that the IPC warning indicators are illuminated. ‹› If the IPC warning indicators are not illuminated, test the IPC ignition circuit for a short to ground or an open/high resistance. If the circuit Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Testing and Inspection > Page 2482 tests normal and the ignition circuit fuse is open, replace the IPC. 2. Ignition OFF, disconnect the ECM X2 harness connector. Ignition ON, the MIL should not illuminate. ‹› If the MIL is illuminated, test the MIL control circuit terminal X2-30 for a short to ground. If the circuit tests normal, replace the IPC. 3. Ignition ON, connect a 3A fused jumper wire between the MIL control circuit terminal X2-30 and ground. The MIL should illuminate. ‹› If the MIL does not illuminate, test the MIL control circuit for a short to voltage, or an open/high resistance. If the circuit tests normal, replace the IPC/bulb. 4. If all circuits/connectors test normal, replace the ECM. Repair Instructions Perform the Diagnostic Repair Verification (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. * Instrument Cluster Replacement (Without RPO SLT) (See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair/Instrument Cluster Replacement (Without RPO SLT))Instrument Cluster Replacement (With RPO SLT) (See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair/Instrument Cluster Replacement (With RPO SLT)) * Control Module References (See: Testing and Inspection/Programming and Relearning) for ECM and ICM replacement, setup, and programming Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component Information > Service and Repair Oil Change Reminder Lamp: Service and Repair GM Oil Life System Resetting When the system has calculated that oil life has been diminished, it will indicate that an oil change is necessary. A CHANGE ENGINE OIL SOON message will come on. Change the engine oil as soon as possible within the next 1 000 km (600 miles). It is possible that, if driving under the best conditions, the oil life system may not indicate that an oil change is necessary for over a year. However, the engine oil and filter must be changed at least once a year and at this time the system must be reset. If the system is ever reset accidentally, change the engine oil at 5 000 km (3,000 miles) since last oil change. How to Reset the Engine Oil Life System The Engine Oil Life System calculates when to change the engine oil and filter based on vehicle use. Anytime the oil is changed, reset the system so it can calculate when the next oil change is required. If a situation occurs where the oil is changed prior to a CHANGE ENGINE OIL SOON message being turned on, reset the system. If the vehicle does not have a Driver Information Center (DIC), do the following: 1. Turn the ignition to ON, with the engine OFF. 2. Fully press and release the accelerator pedal slowly three times within five seconds. 3. Turn the key to OFF. If the CHANGE ENGINE OIL SOON message comes back on when you start the vehicle, the engine oil life system has not reset. Repeat the procedure. If the vehicle has a DIC, do the following: 1. Turn the ignition to ON, with the engine OFF. 2. Press the MODE button until the DIC reads OIL LIFE LEFT/HOLD SET TO RESET. 3. Press and hold the SET button until 100 percent is displayed. You will hear three chimes and the CHANGE ENGINE OIL SOON message will go off. 4. Turn the key to OFF. If the CHANGE ENGINE OIL SOON message comes back on when you start the vehicle, the engine oil life system has not reset. Repeat the procedure. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Service and Repair Vehicle Lifting: Service and Repair Lifting and Jacking the Vehicle Danger: To avoid any vehicle damage, serious personal injury or death, always use the jackstands to support the vehicle when lifting the vehicle with a jack. Danger: To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed and strap the vehicle to the hoist. Caution: Perform the following steps before beginning any vehicle lifting or jacking procedure: * Remove or secure all of the vehicle contents in order to avoid any shifting or any movement that may occur during the vehicle lifting or jacking procedure. * The lifting equipment or the jacking equipment weight rating must meet or exceed the weight of the vehicle and any vehicle contents. * The lifting equipment or the jacking equipment must meet the operational standards of the lifting equipment or jacking equipment manufacturer. * Perform the vehicle lifting or jacking procedure on a clean, hard, dry, level surface. * Perform the vehicle lifting or jacking procedure only at the identified lift points. DO NOT allow the lifting equipment or jacking equipment to contact any other vehicle components. Failure to perform the previous steps could result in damage to the lifting equipment or the jacking equipment, the vehicle, and/or the vehicle contents. For lifting the vehicle, various lift points are recommended. Before you begin any lifting procedure, place the vehicle on a clean, hard, level surface. Verify that all the lifting equipment meets weight standards and is in good working order. Verify that all of the vehicle loads are equally distributed and secure. If you are only supporting the vehicle at the frame side rails, verify that the lifting equipment does not put too much stress on, or weaken, the frame side rails. During hoisting, do NOT damage the fuel tanks, the exhaust system, or the underbody. 1 - Lower Control Arm Contact Points 2 - Front Frame Contact Points 3 - Rear Frame Contact Points 4 - Rear Axle Contact Points Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Service and Repair > Page 2490 5 - Differential Contact Points Frame Contact Hoist Front Hoist Pads Note: The front hoist pads must not contact the rocker panels, the front fenders, or the floor pan. Position the front hoist pads under the front frame between the lower control arm and the frame pad. Rear Hoist Pads Note: The rear hoist pads must not contact the body rocker panels or the floor pan. Position the rear hoist pads under the rear spring, just behind the hanger Suspension Contact Hoist Front Lift Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Service and Repair > Page 2491 Position the front lift under the outer edge of the front suspension lower control arms. Rear Lift Position the rear lift under the axle housing tubes on each side of the differential. Do not damage the stabilizer bar. Jacking When you are lifting a vehicle with a vehicle jack or a floor jack, block the wheels at the opposite end from which you are lifting. Use jack stands to provide additional support. Under the Frame Rails Note: The floor jack pad must not contact rocker panel or the floor pan. Position the floor jack pad under the frame rail pad. Under the Rear Differential Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Service and Repair > Page 2492 Position the floor jack pad under the center of the rear axle differential. Do not damage the establisher bar. Under the Rear Spring Hanger Position the jack under the rear spring hanger. Jack Stands When you support the vehicle with jack stands, place the jack stands under the frame, the front suspension crossmember, or the rear axle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Module > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > Page 2503 Tire Pressure Sensor: Testing and Inspection Tire Pressure Indicator Sensor Learn Special Tools J-46079 Tire Pressure Monitor Diagnostic Tool Learn Mode Description The tire pressure monitor (TPM) system uses the instrument panel cluster (IPC), body control module (BCM), remote control door lock receiver (RCDLR), keyless entry transmitter, 4 radio frequency transmitting pressure sensors, and the serial data circuit to perform the TPM learn mode functions. The sensor learn procedure must be performed after every tire rotation, RCDLR replacement, or sensor replacement. Once the learn mode has been enabled, each of the sensors unique identification codes can be learned into the RCDLR memory. When a sensor ID has been learned, the RCDLR sends a serial data message to the BCM to sound a horn chirp. This verifies the sensor has transmitted its ID and the RCDLR has received and learned it. The RCDLR must learn the sensor IDs in the proper sequence to determine correct sensor location. The first learned ID is assigned to the left front location, the second to right front, the third to right rear and the fourth to left rear. The turn signals will individually illuminate indicating which location is to be learned in the proper sequence. Sensor Functions Using J-46079 Each sensor has an internal low frequency coil. When the J-46079 is used in activate mode, it produces a low frequency transmission that activates the sensor. The sensor responds to a low frequency activation by transmitting in learn mode. When the RCDLR receives a learn mode transmission while in TPM learn mode, it will assign that sensors ID to the location on the vehicle relative to the order in which it was learned. Sensor Functions Using Pressure Increase/Decrease Method Each sensor takes a pressure measurement sample once every 30 seconds while in stationary mode. If the tire pressure increases, or decreases by more than 8.3 kPa (1.2 psi) from the last pressure measurement, another measurement will occur immediately to verify the change in pressure. If a pressure change has indeed occurred, the sensor transmits in Learn mode. When the RCDLR receives a Learn mode transmission while in TPM learn mode, it will assign that sensor's ID to the location on the vehicle relative to the order in which it was learned. Learn Mode Cancellation The learn mode will cancel if the ignition is cycled to OFF or if more than 2 minutes has elapsed for any sensor that has not been learned. If the learn mode is cancelled before the first sensor is learned, the original sensor IDs will be maintained. If the learn mode is canceled after the first sensor is learned, the following will occur: * All stored sensor IDs will be invalidated in the RCDLR memory. * If equipped, the DIC will display dashes instead of tire pressures. * DTC C0775 will be set. These conditions will now require the learn procedure to be repeated for the system to function properly. TPM Learn Procedure Note: If using the scan tool to enable the learn mode, the J-46079 must be used to activate the sensors. When this preferred method is used, any stray sensor signals will not affect the learn procedure. In the event a particular sensor's information is displayed on the special tool upon activation but the horn does not chirp, it may be necessary to rotate the wheel valve stem to a different position due to the sensor signal is being blocked by another component. If using the keyless entry transmitter or DIC buttons to enable the learn mode, the J-46079 or Pressure Increase/Decrease Method may be used. Before proceeding with this method, ensure that no other learn procedure is being performed simultaneously or that tire pressures are not being adjusted on another TPM equipped vehicle within close proximity. Stray signals from other TPM equipped vehicles just driving by can be inadvertently learned. If any random horn chirps are heard from the vehicle while performing the learn procedure, most likely a stray sensor has been learned and the procedure will need to be cancelled and repeated. Under these circumstances, performing the TPM Learn Procedure away from other vehicles would be highly recommended. In the event a particular sensor activation does not cause the horn to chirp, it may be necessary to rotate the wheel valve stem to a different position due to the sensor signal is being blocked by another component. Preferred Scan Tool Learn Enable Method 1. Using a scan tool, initiate the TPM Learn Mode. A double horn chirp will sound indicating the Learn Mode has been enabled. The left front turn signal will also be illuminated. 2. Starting with the left front tire, active the sensor by holding the antenna of the J-46079 aimed upward against the tire sidewall close to the wheel rim at the valve stem location. Press and release the Activate button and wait for a horn chirp. Once the horn chirp has sounded, the sensor information is learned and the turn signal in the next location to be learned will illuminate. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > Page 2504 3. After the horn chirp has sounded and the right front turn signal is illuminated, repeat step 2 for the remaining 3 sensors in the following order: 1. Right front 2. Right rear 3. Left rear 4. When the left rear sensor has been learned and a double horn chirp has sounded, the learn process is complete and the RCDLR exits the learn mode. 5. Ignition OFF, adjust all tires to the recommended pressures. Refer to Vehicle Certification, Tire Placard, Anti-Theft, and Service Parts ID Label ( See: Application and ID/Vehicle Certification, Tire Placard, Anti-Theft and Service Parts ID Label). Alternate Keyless Entry Transmitter or DIC Learn Enable Method 1. Ignition ON, initiate the TPM Learn Mode using one of the following procedures: * On vehicles equipped with keyless entry, simultaneously press the keyless entry transmitters lock and unlock buttons until a double horn chirp sounds indicating the Learn Mode has been enabled. The left front turn signal will also be illuminated. * On vehicles not equipped with keyless entry, press and release the driver information center (DIC) INFO button until the TIRE LEARN message appears on the DIC display. Press and hold the SET/RESET button until a double horn chirp sounds indicating the Learn Mode has been enabled. The left front turn signal will also be illuminated. 2. Starting with the left front tire, learn the tire pressure using one of the following methods: * Hold the antenna of the J-46079 aimed upward against the tire sidewall close to the wheel rim at the valve stem location. Press and release the activate button and wait for a horn chirp. Once the horn chirp has sounded, the sensor information is learned and the turn signal in the next location to be learned will illuminate. Warning Over inflating tires may cause personal injury or damage to the tires and wheels. When increasing tire pressure do not exceed the maximum inflation pressure as noted on the tire sidewall. * Increase/decrease the tire pressure for 8-10 seconds then wait for a horn chirp. The horn chirp may occur before or up to 30 seconds after the 8-10 second pressure increase/decrease time period has been reached. Once the horn chirp has sounded, the sensor information is learned and the turn signal in the next location to be learned will illuminate. 3. After the horn chirp has sounded and the right front turn signal is illuminated, repeat step 2 for the remaining 3 sensors in the following order: 1. Right front 2. Right rear 3. Left rear 4. When the left rear sensor has been learned and a double horn chirp has sounded, the learn process is complete and the RCDLR exits the learn mode. 5. Ignition OFF, adjust all tires to the recommended pressures. Refer to Vehicle Certification, Tire Placard, Anti-Theft, and Service Parts ID Label ( See: Application and ID/Vehicle Certification, Tire Placard, Anti-Theft and Service Parts ID Label). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement (Clamp In Style) Tire Pressure Sensor: Service and Repair Tire Pressure Indicator Sensor Replacement (Clamp In Style) Tire Pressure Indicator Sensor Replacement (Clamp In Style) Removal Procedure 1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Remove the tire/wheel assembly from the vehicle. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). Note: Before the tire is removed from the wheel, note the following items to avoid tire pressure sensor damage upon tire dismounting: * Place the sensors cap and valve on a dry clean surface after removal. The cap is aluminum and the valve is nickel plated to prevent corrosion and are not to be substituted with a cap or valve made of any other material. * When separating the tire bead from the wheel, position the bead breaking fixture 90 degrees from the valve stem. * Position the mounting/dismounting head so the tire iron, or pry bar can be inserted slightly clockwise of the sensor body when prying the tire bead up and over the mounting/dismounting head. * Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the out side of the wheel rim. * Repeat items for inner bead. 3. Remove the tire from the wheel. Refer to Tire Dismounting and Mounting (See: Tires/Service and Repair/Removal and Replacement). Note: If any tire sealant is noted upon tire dismounting, remove all residual liquid sealant from the inside of the tire and wheel surfaces. 4. Remove the tire pressure sensor nut. 5. Remove the tire pressure sensor. Installation Procedure 1. Clean any dirt or debris from the grommet sealing area. 2. Insert the sensor in the wheel hole with the air passage facing away from the wheel. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the sensor nut and position the sensor body parallel to the inside wheel surface while torquing. Tighten the sensor nut to 7 Nm (62 lb in). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement (Clamp In Style) > Page 2507 Note: Before reinstalling the tire on the wheel, note the following items to avoid tire pressure sensor damage upon tire mounting: * Position the mounting/dismounting head 180 degrees from the valve stem. * Position the bead transition area 45 degrees counterclockwise of the valve stem. * Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the inside of the wheel rim. * Repeat items for outer bead. 4. Install the tire on the wheel. Refer to Tire Dismounting and Mounting (See: Tires/Service and Repair/Removal and Replacement). Note: A service replacement tire pressure sensor is shipped in OFF mode. In this mode the sensor unique identification code cannot be learned into the remote control door lock receiver (RCDLR) memory. The sensor must be taken out of OFF mode by spinning the tire/wheel assembly above 32 km/h (20 mph) in order to close the sensors internal roll switch for at least 10 seconds. 5. Install the tire/wheel assembly on the vehicle. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). 6. Lower the vehicle. 7. Learn the tire pressure sensors. Refer to Tire Pressure Indicator Sensor Learn (See: Tire Monitoring System/Service and Repair/Service Manual Tire Pressure Sensor Learn). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement (Clamp In Style) > Page 2508 Tire Pressure Sensor: Service and Repair Tire Pressure Indicator Sensor Replacement (Snap In Style) Tire Pressure Indicator Sensor Replacement (Snap In Style) Removal Procedure 1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Remove the tire/wheel assembly from the vehicle. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). 3. Dismount the tire from the rim. Refer to Tire Dismounting and Mounting (See: Tires/Service and Repair/Removal and Replacement). Note: When servicing the tire pressure sensor always use a new Schrader(R) tire pressure monitor (TPM) and a new TORX screw during installation. 4. Remove the TORX screw (1) from the tire pressure sensor (2) and pull it straight off the tire pressure valve stem (3). Caution: Do not scratch or damage the clear coating on aluminum wheels with the tire changing equipment. Scratching the clear coating could cause the aluminum wheel to corrode and the clear coating to peel from the wheel. 5. Remove the tire pressure valve stem by pulling it through the rim. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement (Clamp In Style) > Page 2509 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Note: * Ensure the flat of the valve, lines up with the flats of the snap in the enclosure. * TPM valves and TORX screws are one-time use only. 1. Assemble the tire pressure sensor (2) to the valve stem and install the new TORX screw (3) and tighten to 1.3 Nm (11.5 lb in). Note: Use and approved tire mounting lubricant. DO NOT use silicon or corrosive base compounds to lubricate the tire bead and the wheel rim. A corrosive type compound can cause tire or rim deterioration. 2. Apply tire soap to the rubber portion of the valve stem (1). 3. Using a tire valve stem mounting tool, pull the valve stem through in a direction parallel to the valve hole on the rim. Note: Snap Fit TPM sensors are still shipped in the OFF mode. However, the TPM no longer needs to be spun to remove it from the OFF mode. The sensor will exit its OFF state when the tire is inflated. The technician can then program the vehicle as normal. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement (Clamp In Style) > Page 2510 4. Mount the tire to the rim. Refer to Tire Dismounting and Mounting (See: Tires/Service and Repair/Removal and Replacement). 5. Install the tire/wheel assembly on the vehicle. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). 6. Lower the vehicle. 7. Learn the tire pressure sensors. Refer to Tire Pressure Indicator Sensor Learn (See: Tire Monitoring System/Service and Repair/Service Manual Tire Pressure Sensor Learn). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips Low Tire Pressure Indicator: Technical Service Bulletins Tire Pressure Monitor - TPM System Message/Service Tips # 09-03-16-002A: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire Pressure Monitor (TPM) System Message, Light and Customer Information - (Apr 27, 2010) Subject: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire Pressure Monitor (TPM) System Message, Light and Customer Information Models: 2006-2011 Cars and Light Duty Trucks (Including Saturn and Saab) 2006-2010 HUMMER H2, H3 ATTENTION The information found in this bulletin is to be used as a dealership service consultant procedures for customers coming into the service lane with an illuminated "low tire light" or comments on a check tire pressure/low tire pressure/add air to tire or service tire monitor system message. Maintaining proper tire pressures is an Owner's Maintenance item and is not covered under warranty. This bulletin is being revised to add model years and update additional bulletin reference information. Please discard Corporate Bulletin Number 09-03-16-002 (Section 03 -- Suspension). Customer Concerns and Confusion with the Tire Pressure Monitoring (TPM) System The following procedure should be used by dealership service consultants when a customer comes into the service drive with a "low tire light" on or comments on a check tire pressure/low tire pressure/add air to tire or service tire monitor system message. The service consultant should perform the following steps: Procedure Turn the key to ON, without starting the engine. ^ If the low tire light comes on and stays on solid with a check tire pressure/low tire pressure/add air to tire message (on vehicles equipped with DIC), advise the customer: - The system is working properly. - Properly adjusting all tire air pressures to the recommended levels and driving the vehicle will turn the light off (refer to the Tire and Loading Information label on the driver side door). - More detailed information can be found in the Owner Manual. - Service is not covered under warranty - this maintenance is the responsibility of the owner. - Give the customer a copy of the "GM Customer TPMS Information". ^ If the Tire Pressure Monitor (TPM) light blinks for one minute then stays on solid with a service tire monitor system message (on vehicles equipped with DIC): - A TPM system problem exists. The vehicle should be written up accordingly and sent to your service department for further DTC diagnosis and service. - If dashes (--) are displayed in only one or two of the tire pressure readouts, it is likely caused by a previous TPM system relearn that was performed incorrectly due to interference from another vehicle's TPM system during the relearn process (refer to the Important statement later in this bulletin regarding TPM relearn with a Tech 2(R)). - If dashes (--) are displayed in all four of the tire pressure readouts, there is a system problem. Follow the appropriate SI service procedures. ^ If a customer indicates the low tire light comes on for a few minutes when the vehicle is started, then goes off after driving a while, advise the customer: - The system is working properly. - Most likely, air pressure in one or more of the tires is low enough to turn the light on when tires are cold. After driving for a while, tires will heat Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 2516 up, allowing tire air pressure to increase above the threshold causing the light to go off. Properly adjusting all tire air pressures to the recommended levels will correct this (Refer to the Tire and Loading Information Label on the driver side door). - More detailed information can be found in the Owner Manual. - Service is not covered under warranty - this maintenance is the responsibility of the owner. - Give the customer a copy of the "GM Customer TPMS Information". For more detailed information, refer to Corporate Bulletin Number 07-03-16-004C and TPMS Training Course 13044.12T2. Tire Pressure Light At key on, without starting the vehicle: Steady Solid Glowing TPM Indicator If the TPM indicator appears as a steady glowing yellow lamp (as above), the system is functioning properly and you should add air to the tires to correct this condition. Blinking TPM Indicator If the TPM indicator appears as a BLINKING yellow lamp for one minute and then stays on solid, diagnostic service is needed. The Effect of Outside Temperature on Tire Pressures Important: As a rule of thumb, tire pressure will change about 7kPa (1 psi) for every 6°C (10°F) decrease in temperature - Tire pressure will drop when it gets colder outside, and rise when it gets warmer. Under certain situations such as extreme outside temperature changes, the system may bring on a solid light with a check tire pressure message. This should be considered normal and the system is working properly. The light will turn off upon adding the proper amount of air to the tires (refer to the Tire & Loading Information label in the driver's door opening). When properly adjusting tire air pressure, the following steps are important to help optimize the system and prolong bringing a tire pressure light on: ^ Use an accurate, high quality tire pressure gauge. ^ Never set the tire pressure below the specified placard value regardless of tire temperature or ambient temperature. ^ Tire pressure should be set to the specified placard pressure at the lowest seasonal temperature the vehicle will encounter during operation. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 2517 ^ When adding proper tire air pressure, it is important to remember fluctuations in outside air temperatures and tire temperatures effect tire air pressures. ^ After you have added the proper tire pressure, if the vehicle has a DIC (after the system has updated), check to see if DIC displays are the same readings as the tire pressure gauge used (adjust as necessary). ^ Only perform a TPM sensor re-learn after a tire rotation or system part replacements and use the Tech 2(R) to initiate the relearn whenever possible to avoid invalid sensor I.D. learns. Important: Always take outside temperature and tire temperature into consideration to properly set tire pressures. Foe example, on colder days (20°F/-7°C), if setting tire pressure when the vehicle has been indoors (60°F/16°C) or the tires are warm from being driven, it will be necessary to compensate for the low outside temperature by adding 21-27 kPa (3-4 psi) more then the placecard pressure. At some later time, when the vehicle has been parked outside for a while, the tires will cool off and the pressures will drop back into the placecard range. Important: Recently, nitrogen gas (for use in inflating tires) has become available to the general customer through some retailers. The use of nitrogen gas to inflate tires is a technology used in automobile racing. Tires inflated with nitrogen gas may exhibit less of a pressure change in response to outside temperature changes. Nitrogen gas inflation is compatible with GM TPM sensors. For additional information, refer to Corporate Service Bulletin 05-03-10-020C. Important: All Models (Except the Pontiac Vibe): Do not perform a TPM relearn at PDI, the system has already been set at the Assembly Plant. Do not perform a TPM relearn after adding air to the tires. The low tire light is similar to the low fuel indicator and adding something (fuel, air) to the vehicle makes that light turn back off again. Note that because of system behavior, some vehicles must be driven a short distance before the sensors recognize the increase in pressure and turns the light off again. Pontiac Vibe Only: Do not use the TPMS reset button to turn off the light. The system will update and light will turn off when all tire pressures have been adjusted followed by short distance drive. Important: All models (except the Pontiac Vibe): Each tire monitor sensor is learned to a specific vehicle corner. When performing a TPM relearn (only after a tire rotation or replacement of a TPM sensor or Module), always use the Tech2(R) to initiate the J 46079 relearned process. Tech 2(R) - initiated relearns lock out other vehicle TPM signals that may be broadcasting in the area. Only signals initiated by the J 46079 tool will be accepted. This method avoids storing false TPM I.D.s and will prevent customers from returning with dashes (--) displayed in tire pressure readouts and/or a flashing tire pressure monitor (TPM) light. Checking the four TPM I.D.s with the Tech 2(R) prior to and following relearn to verify they are the same can prevent invalid I.D. learns. Pontiac Vibe Only: Tire Monitor Sensors are not learned to a specific vehicle corner. Do not perform a TPM Reset after tire rotation. The TPMS Reset button must only be used during pre-delivery inspection by the dealer to initialize the system (after all tire pressures have been adjusted properly) or when a Tire Pressure Monitor System component is replaced. The J 46079 tool does not work on Vibe TPM sensors. A TPMS relearn on Vibe must be preformed with a Tech 2(R) to set the TPMS Module in learn mode. The TPMS sensor IDs are entered through the Tech 2(R). Refer to SI for further Vibe TPMS information. Labor Operation and Repair Order/Warranty System Claim Required Documentation Important: The ONLY time labor operation E0726 or E0722 should be used is to diagnose for a system issue. That should ONLY occur if, at key ON, without starting the engine, the Tire Pressure Monitor (TPM) blinks for one minute and then stays on solid with a Service Tire Monitor System message (on vehicles equipped with a DIC) If that occurs, a TPM system problem exists and the system will have set a DTC. If one of these operastions is used, the following Repair Order and Warranty System documentation are required: ^ Document the customer complaint on the Repair Order. ^ Document the TPMS DTC that has set on the Repair Order. ^ Enter the TPMS DTC in the Warranty System (WINS) in the Failure Code/DTC field on the claim submission (refer to the Claims Processing Manual, Section IV, Warranty claim Data, Page 6, Item G). If the above information is not documented on the Repair Order and Warranty System, the claim may be rejected. If the Warranty Parts Center (WPC) generates a request, this repair order documentation must be sent back. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 2518 Customer TPMS Information Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 2519 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 2520 Frequently Asked Questions Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Module > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Technical Service Bulletins > Page 2529 Tire Pressure Sensor: Testing and Inspection Tire Pressure Indicator Sensor Learn Special Tools J-46079 Tire Pressure Monitor Diagnostic Tool Learn Mode Description The tire pressure monitor (TPM) system uses the instrument panel cluster (IPC), body control module (BCM), remote control door lock receiver (RCDLR), keyless entry transmitter, 4 radio frequency transmitting pressure sensors, and the serial data circuit to perform the TPM learn mode functions. The sensor learn procedure must be performed after every tire rotation, RCDLR replacement, or sensor replacement. Once the learn mode has been enabled, each of the sensors unique identification codes can be learned into the RCDLR memory. When a sensor ID has been learned, the RCDLR sends a serial data message to the BCM to sound a horn chirp. This verifies the sensor has transmitted its ID and the RCDLR has received and learned it. The RCDLR must learn the sensor IDs in the proper sequence to determine correct sensor location. The first learned ID is assigned to the left front location, the second to right front, the third to right rear and the fourth to left rear. The turn signals will individually illuminate indicating which location is to be learned in the proper sequence. Sensor Functions Using J-46079 Each sensor has an internal low frequency coil. When the J-46079 is used in activate mode, it produces a low frequency transmission that activates the sensor. The sensor responds to a low frequency activation by transmitting in learn mode. When the RCDLR receives a learn mode transmission while in TPM learn mode, it will assign that sensors ID to the location on the vehicle relative to the order in which it was learned. Sensor Functions Using Pressure Increase/Decrease Method Each sensor takes a pressure measurement sample once every 30 seconds while in stationary mode. If the tire pressure increases, or decreases by more than 8.3 kPa (1.2 psi) from the last pressure measurement, another measurement will occur immediately to verify the change in pressure. If a pressure change has indeed occurred, the sensor transmits in Learn mode. When the RCDLR receives a Learn mode transmission while in TPM learn mode, it will assign that sensor's ID to the location on the vehicle relative to the order in which it was learned. Learn Mode Cancellation The learn mode will cancel if the ignition is cycled to OFF or if more than 2 minutes has elapsed for any sensor that has not been learned. If the learn mode is cancelled before the first sensor is learned, the original sensor IDs will be maintained. If the learn mode is canceled after the first sensor is learned, the following will occur: * All stored sensor IDs will be invalidated in the RCDLR memory. * If equipped, the DIC will display dashes instead of tire pressures. * DTC C0775 will be set. These conditions will now require the learn procedure to be repeated for the system to function properly. TPM Learn Procedure Note: If using the scan tool to enable the learn mode, the J-46079 must be used to activate the sensors. When this preferred method is used, any stray sensor signals will not affect the learn procedure. In the event a particular sensor's information is displayed on the special tool upon activation but the horn does not chirp, it may be necessary to rotate the wheel valve stem to a different position due to the sensor signal is being blocked by another component. If using the keyless entry transmitter or DIC buttons to enable the learn mode, the J-46079 or Pressure Increase/Decrease Method may be used. Before proceeding with this method, ensure that no other learn procedure is being performed simultaneously or that tire pressures are not being adjusted on another TPM equipped vehicle within close proximity. Stray signals from other TPM equipped vehicles just driving by can be inadvertently learned. If any random horn chirps are heard from the vehicle while performing the learn procedure, most likely a stray sensor has been learned and the procedure will need to be cancelled and repeated. Under these circumstances, performing the TPM Learn Procedure away from other vehicles would be highly recommended. In the event a particular sensor activation does not cause the horn to chirp, it may be necessary to rotate the wheel valve stem to a different position due to the sensor signal is being blocked by another component. Preferred Scan Tool Learn Enable Method 1. Using a scan tool, initiate the TPM Learn Mode. A double horn chirp will sound indicating the Learn Mode has been enabled. The left front turn signal will also be illuminated. 2. Starting with the left front tire, active the sensor by holding the antenna of the J-46079 aimed upward against the tire sidewall close to the wheel rim at the valve stem location. Press and release the Activate button and wait for a horn chirp. Once the horn chirp has sounded, the sensor information is learned and the turn signal in the next location to be learned will illuminate. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Technical Service Bulletins > Page 2530 3. After the horn chirp has sounded and the right front turn signal is illuminated, repeat step 2 for the remaining 3 sensors in the following order: 1. Right front 2. Right rear 3. Left rear 4. When the left rear sensor has been learned and a double horn chirp has sounded, the learn process is complete and the RCDLR exits the learn mode. 5. Ignition OFF, adjust all tires to the recommended pressures. Refer to Vehicle Certification, Tire Placard, Anti-Theft, and Service Parts ID Label ( See: Application and ID/Vehicle Certification, Tire Placard, Anti-Theft and Service Parts ID Label). Alternate Keyless Entry Transmitter or DIC Learn Enable Method 1. Ignition ON, initiate the TPM Learn Mode using one of the following procedures: * On vehicles equipped with keyless entry, simultaneously press the keyless entry transmitters lock and unlock buttons until a double horn chirp sounds indicating the Learn Mode has been enabled. The left front turn signal will also be illuminated. * On vehicles not equipped with keyless entry, press and release the driver information center (DIC) INFO button until the TIRE LEARN message appears on the DIC display. Press and hold the SET/RESET button until a double horn chirp sounds indicating the Learn Mode has been enabled. The left front turn signal will also be illuminated. 2. Starting with the left front tire, learn the tire pressure using one of the following methods: * Hold the antenna of the J-46079 aimed upward against the tire sidewall close to the wheel rim at the valve stem location. Press and release the activate button and wait for a horn chirp. Once the horn chirp has sounded, the sensor information is learned and the turn signal in the next location to be learned will illuminate. Warning Over inflating tires may cause personal injury or damage to the tires and wheels. When increasing tire pressure do not exceed the maximum inflation pressure as noted on the tire sidewall. * Increase/decrease the tire pressure for 8-10 seconds then wait for a horn chirp. The horn chirp may occur before or up to 30 seconds after the 8-10 second pressure increase/decrease time period has been reached. Once the horn chirp has sounded, the sensor information is learned and the turn signal in the next location to be learned will illuminate. 3. After the horn chirp has sounded and the right front turn signal is illuminated, repeat step 2 for the remaining 3 sensors in the following order: 1. Right front 2. Right rear 3. Left rear 4. When the left rear sensor has been learned and a double horn chirp has sounded, the learn process is complete and the RCDLR exits the learn mode. 5. Ignition OFF, adjust all tires to the recommended pressures. Refer to Vehicle Certification, Tire Placard, Anti-Theft, and Service Parts ID Label ( See: Application and ID/Vehicle Certification, Tire Placard, Anti-Theft and Service Parts ID Label). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement (Clamp In Style) Tire Pressure Sensor: Service and Repair Tire Pressure Indicator Sensor Replacement (Clamp In Style) Tire Pressure Indicator Sensor Replacement (Clamp In Style) Removal Procedure 1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Remove the tire/wheel assembly from the vehicle. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). Note: Before the tire is removed from the wheel, note the following items to avoid tire pressure sensor damage upon tire dismounting: * Place the sensors cap and valve on a dry clean surface after removal. The cap is aluminum and the valve is nickel plated to prevent corrosion and are not to be substituted with a cap or valve made of any other material. * When separating the tire bead from the wheel, position the bead breaking fixture 90 degrees from the valve stem. * Position the mounting/dismounting head so the tire iron, or pry bar can be inserted slightly clockwise of the sensor body when prying the tire bead up and over the mounting/dismounting head. * Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the out side of the wheel rim. * Repeat items for inner bead. 3. Remove the tire from the wheel. Refer to Tire Dismounting and Mounting (See: Tires/Service and Repair/Removal and Replacement). Note: If any tire sealant is noted upon tire dismounting, remove all residual liquid sealant from the inside of the tire and wheel surfaces. 4. Remove the tire pressure sensor nut. 5. Remove the tire pressure sensor. Installation Procedure 1. Clean any dirt or debris from the grommet sealing area. 2. Insert the sensor in the wheel hole with the air passage facing away from the wheel. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the sensor nut and position the sensor body parallel to the inside wheel surface while torquing. Tighten the sensor nut to 7 Nm (62 lb in). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement (Clamp In Style) > Page 2533 Note: Before reinstalling the tire on the wheel, note the following items to avoid tire pressure sensor damage upon tire mounting: * Position the mounting/dismounting head 180 degrees from the valve stem. * Position the bead transition area 45 degrees counterclockwise of the valve stem. * Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the inside of the wheel rim. * Repeat items for outer bead. 4. Install the tire on the wheel. Refer to Tire Dismounting and Mounting (See: Tires/Service and Repair/Removal and Replacement). Note: A service replacement tire pressure sensor is shipped in OFF mode. In this mode the sensor unique identification code cannot be learned into the remote control door lock receiver (RCDLR) memory. The sensor must be taken out of OFF mode by spinning the tire/wheel assembly above 32 km/h (20 mph) in order to close the sensors internal roll switch for at least 10 seconds. 5. Install the tire/wheel assembly on the vehicle. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). 6. Lower the vehicle. 7. Learn the tire pressure sensors. Refer to Tire Pressure Indicator Sensor Learn (See: Service and Repair/Service Manual Tire Pressure Sensor Learn). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement (Clamp In Style) > Page 2534 Tire Pressure Sensor: Service and Repair Tire Pressure Indicator Sensor Replacement (Snap In Style) Tire Pressure Indicator Sensor Replacement (Snap In Style) Removal Procedure 1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Remove the tire/wheel assembly from the vehicle. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). 3. Dismount the tire from the rim. Refer to Tire Dismounting and Mounting (See: Tires/Service and Repair/Removal and Replacement). Note: When servicing the tire pressure sensor always use a new Schrader(R) tire pressure monitor (TPM) and a new TORX screw during installation. 4. Remove the TORX screw (1) from the tire pressure sensor (2) and pull it straight off the tire pressure valve stem (3). Caution: Do not scratch or damage the clear coating on aluminum wheels with the tire changing equipment. Scratching the clear coating could cause the aluminum wheel to corrode and the clear coating to peel from the wheel. 5. Remove the tire pressure valve stem by pulling it through the rim. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement (Clamp In Style) > Page 2535 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Note: * Ensure the flat of the valve, lines up with the flats of the snap in the enclosure. * TPM valves and TORX screws are one-time use only. 1. Assemble the tire pressure sensor (2) to the valve stem and install the new TORX screw (3) and tighten to 1.3 Nm (11.5 lb in). Note: Use and approved tire mounting lubricant. DO NOT use silicon or corrosive base compounds to lubricate the tire bead and the wheel rim. A corrosive type compound can cause tire or rim deterioration. 2. Apply tire soap to the rubber portion of the valve stem (1). 3. Using a tire valve stem mounting tool, pull the valve stem through in a direction parallel to the valve hole on the rim. Note: Snap Fit TPM sensors are still shipped in the OFF mode. However, the TPM no longer needs to be spun to remove it from the OFF mode. The sensor will exit its OFF state when the tire is inflated. The technician can then program the vehicle as normal. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement (Clamp In Style) > Page 2536 4. Mount the tire to the rim. Refer to Tire Dismounting and Mounting (See: Tires/Service and Repair/Removal and Replacement). 5. Install the tire/wheel assembly on the vehicle. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). 6. Lower the vehicle. 7. Learn the tire pressure sensors. Refer to Tire Pressure Indicator Sensor Learn (See: Service and Repair/Service Manual Tire Pressure Sensor Learn). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Spare Tire > Component Information > Service and Repair Spare Tire: Service and Repair Spare Wheel Hoist Replacement Tire Hoist Secondary Latch Mechanism Note: If the spare tire hoist has been fully raised without a spare tire in place, the secondary latch mechanism may have become engaged. If this has occurred the hoist will not lower and the following steps will need to be followed: 1. Rotate the hoist shaft counterclockwise until approximately 15 cm (6 in) of cable (1) is exposed. 2. While holding the latch pin (3), fully depress the latch button (2) and release the secondary latch from the hoist assembly. Some side-to-side and/or up-and-down movement may be necessary to disengage the latch mechanism. 3. Continue rotating the hoist shaft counterclockwise in order to lower the hoist the rest of the way. 4. If this does not release the secondary latch, the spare tire hoist will need to be replaced. See the following procedure. Removal Procedure 1. If the vehicle is equipped with a spare tire stowage lock cylinder, open the spare tire lock cover on the bumper and using the ignition key, remove the lock. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Spare Tire > Component Information > Service and Repair > Page 2541 Caution: Use only hand tools to lower and raise the spare tire hoist assembly. Do not use air tools. The use of air tools at high speeds will damage the spare tire hoist assembly. 2. Rotate the hoist shaft counterclockwise in order to lower the spare tire to the ground. Continue to rotate the shaft until the spare tire can be pulled out from under the vehicle and removed. If the spare tire does not lower to the ground, the secondary latch is engaged causing the tire not to lower. 3. If the secondary latch is engaged and the cable end is visible, perform the following procedure: 1. Tighten the cable by rotating the hoist shaft clockwise until you hear 2 clicks or feel it skip twice. You cannot overtighten the cable. 2. Loosen the cable by rotating the hoist shaft counterclockwise 3 or 4 turns. 3. If the spare tire can be lowered, repeat steps 1 and 2 to see if the spare tire can be removed. 4. If the spare tire cannot be lowered, rotate the hoist shaft counterclockwise until approximately 15 cm (6 in) of cable is exposed. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 6. Place a transmission jack, or equivalent, under the spare tire. 7. Position the center of the transmission jack under the secondary latch release button at the center of the spare tire. Arrange the arms of the transmission jack so they will support the tire after it has been released. 8. Raise the jack until the spare tire stops moving upward and is firmly held in place, releasing the secondary latch. 9. Lower the tire. If the spare tire is hanging by the cable, rotate the hoist shaft counterclockwise until the tire is low enough to remove. 4. If the secondary latch is engaged and the cable end is NOT visible, perform the following procedure: 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Place a transmission jack, or equivalent, under the spare tire. 3. Position the center of the transmission jack under the secondary latch release button at the center of the spare tire. Arrange the arms of the transmission jack so they will support the tire after it has been released. 4. Raise the jack until the spare tire stops moving upward and is firmly held in place, releasing the secondary latch. 5. Lower the tire and remove it from the jack. 5. Raise and support the vehicle if it is not already raised. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 6. Depress the tabs, remove the guide shaft from the hoist collar, and slide the shaft toward the bumper. 7. Remove the collar from the hoist. 8. Remove the bolt. 9. Remove the hoist from the bracket. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Spare Tire > Component Information > Service and Repair > Page 2542 10. Remove the spare tire hoist shaft guide from the bumper. Installation Procedure 1. Install the spare tire hoist shaft guide to the bumper. 2. Install the hoist to the crossmember. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the bolt and tighten to 40 Nm (30 lb ft). 4. Install the collar to the hoist. 5. Install the shaft to the hoist. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Spare Tire > Component Information > Service and Repair > Page 2543 6. Install the spare tire to the hoist. Caution: Use only hand tools to lower and raise the spare tire hoist assembly. Do not use air tools. The use of air tools at high speeds will damage the spare tire hoist assembly. 7. Rotate the hoist shaft clockwise until the spare tire is in position and the hoist clicks 2 times or it skips twice. You cannot overtighten the cable. 8. Remove the safety stands. 9. Lower the vehicle. 10. Install the spare tire stowage lock cylinder. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 07-03-10-012D > Apr > 11 > Tires/Wheels - Rattle Noise from Wheel Or Hub Cap Wheels: Customer Interest Tires/Wheels - Rattle Noise from Wheel Or Hub Cap TECHNICAL Bulletin No.: 07-03-10-012D Date: April 12, 2011 Subject: Rattle Noise from Wheel or Hub Cap While Driving, Loose Wheel Nut Caps or Wheel Nut Caps May Not Tighten on Wheel Nuts (Inspect/Replace Wheel Nut Caps As Necessary) Models: 2007-2012 Chevrolet Express, Silverado, Suburban 1500, 2500 and 3500 Series 2007-2012 GMC Savana, Sierra, Yukon XL 1500, 2500 and 3500 Series with 8 Lug Wheel Nut Center Caps (RPOs NX7, NZ7, PY0, PY2, PY9, P03, P25, QB5, QC1, QR5, Q9A) Supercede: This bulletin is being revised to update the model year information. Please discard Corporate Bulletin Number 07-03-10-012C (Section 03 - Suspension). Condition Some customers may comment on a rattle noise from the wheel or hub cap while driving. Other customers may comment on loose wheel nut caps or caps that may not tighten on the wheel nuts. Cause Depending on the generation of the wheel caps, the issue may be overtorqued wheel nut caps or may be caused by the lack of internal threads inside the wheel nut caps. The wheel nut cap (1) is correctly threaded. The wheel nut cap (2) shows the insufficient threads. Correction Important The wheel nut caps are serviced separately from the center wheel hub cap for most hub caps. Refer to the GM electronic parts catalog (EPC) for details. Inspect each wheel nut cap and replace as necessary using the steps below. 1. Remove the wheel hub cap from the vehicle. 2. Place the front of the wheel hub cap down on a protected clean work bench being careful not to scratch or damage the hub cap surface. 3. Inspect all the wheel nut caps, marking any bad wheel nut caps. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 07-03-10-012D > Apr > 11 > Tires/Wheels - Rattle Noise from Wheel Or Hub Cap > Page 2552 Tip The bad wheel nut cap can be removed by placing a drift or punch inside the center of the nut cap and using a hammer to tap the wheel nut cap out of the hub cap. 4. From inside the hub cap, apply direct pressure to one side of the wheel nut cap rim (1). The wheel nut cap will tip down and pop out of the wheel hub cap hole when enough pressure is applied. Repeat this procedure for any additional wheel nut caps that need to be replaced. 5. Flip the hub cap over on the work bench. The emblem side should be up. Tip A 22 mm (7/8 in) socket placed over the wheel nut cap may be used along with a hammer to tap the new wheel nut cap back into the hub cap hole. 6. Install the new wheel nut cap into the existing hub cap hole by applying direct pressure to the front center of the wheel nut cap. 7. Install the wheel hub cap onto the vehicle and tighten the wheel nut caps. 8. Repeat this entire procedure for each additional hub cap. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) Wheels: Customer Interest Wheels/Tires - Tire Radial Force Variation (RFV) INFORMATION Bulletin No.: 00-03-10-006F Date: May 04, 2010 Subject: Information on Tire Radial Force Variation (RFV) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION Supercede: This bulletin is being revised to considerably expand the available information on Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin Number 00-03-10-006E (Section 03 - Suspension). Important - Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires. - Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel assemblies for each vehicle. The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force variation is highway speed shake on smooth roads. Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out of round and tire force variation. These three conditions are not necessarily related. All three conditions must be addressed. Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle, two plane dynamic wheel balancers are readily available and can accurately correct any imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer, and proper balance weights, are all factors required for a quality balance. However, a perfectly balanced tire/wheel assembly can still be "oval shaped" and cause a vibration. Before balancing, perform the following procedures. Tire and Wheel Diagnosis 1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick. 3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and correct as necessary: - Missing balance weights - Bent rim flange - Irregular tire wear - Incomplete bead seating - Tire irregularities (including pressure settings) - Mud/ice build-up in wheel - Stones in the tire tread - Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to diagnosing a smooth road shake condition. 4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a sufficient distance on a known, smooth road surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order (one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high enough in frequency that most humans can start to hear them at highway speeds, but are too high to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment. If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a throbbing), chances are good that the vehicle could have driveline vibration. This type Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 2557 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 2558 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 2559 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels Wheels: Customer Interest Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels TECHNICAL Bulletin No.: 05-03-10-003F Date: April 27, 2010 Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels Supercede: This bulletin is being revised to update the model years and the bulletin reference information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension). Condition Some customers may comment on a low tire pressure condition. Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel. Cause Porosity in the cast aluminum wheel may be the cause. Notice This bulletin specifically addresses issues related to the wheel casting that may result in an air leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat). Correction 1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the tire/wheel assembly in a water bath, or use a spray bottle with soap and water to locate the specific leak location. Important - If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim), the wheel should be replaced. - If two or more leaks are located on one wheel, the wheel should be replaced. 3. If air bubbles are observed, mark the location. - If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks. - If the leak is located on the aluminum wheel area, continue with the next step. 4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose cleaner, such as 3M(R) General Purpose Adhesive Cleaner, P/N 08984, or equivalent. 8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use 88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry. Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging the repair area may result in an air leak. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels > Page 2564 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON Wheels: Customer Interest Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON TECHNICAL Bulletin No.: 08-03-10-006C Date: April 27, 2010 Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat) Models: 2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-03-10-006B (Section 03 - Suspension). Condition Some customers may comment on a tire that slowly loses air pressure over a period of days or weeks. Cause Abrasive elements in the environment may intrude between the tire and wheel at the bead seat. There is always some relative motion between the tire and wheel (when the vehicle is driven) and this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear continues, there may also be intrusion at the tire/wheel interface by corrosive media from the environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be visible until the tire is dismounted from the wheel. Notice This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Correction In most cases, this type of air loss can be corrected by following the procedure below. Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to repair the wheel with the procedure below. Notice The repair is no longer advised or applicable for chromed aluminum wheels. 1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to be around the bead seat of the wheel, dismount the tire to examine the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat Corrosion Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 2569 Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for additional information on possible wheel porosity issues. 3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a rough or uneven surface that is difficult for the tire to maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion 4. If corrosion is found on the wheel bead seat, measure the affected area as shown below. - For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. - For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. 5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the corrosion and any flaking paint. You should remove the corrosion back far enough until you reach material that is stable and firmly bonded to the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired surface. Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend to the visible surfaces on the FACE of the wheel, that wheel must be replaced. Important Remove ONLY the material required to eliminate the corrosion from the bead seating surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as smooth and level as possible. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 2570 Acceptably Prepared (Cleaned-Up) Wheel Surface 6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially available tire sealant such as Patch Brand Bead Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat 7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in SI. Parts Information Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 2571 Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion INFORMATION Bulletin No.: 00-03-10-002F Date: April 21, 2011 Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum Wheels Models: 2012 and Prior GM Cars and Trucks Supercede: This bulletin is being revised to update model years, suggest additional restorative products and add additional corrosion information. Please discard Corporate Bulletin Number 00-03-10-002E (Section 03 - Suspension). Important You may give a copy of this bulletin to the customer. What is Chemical Staining of Chrome Wheels? Figure 1 Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an example). These stains are frequently milky, black, or greenish in appearance. They result from using cleaning solutions that contain acids on chrome wheels. Soap and water is usually sufficient to clean wheels. If the customer insists on using a wheel cleaner they should only use one that specifically states that it is safe for chromed wheels and does not contain anything in the following list. (Dealers should also survey any products they use during prep or normal cleaning of stock units for these chemicals.) - Ammonium Bifluoride (fluoride source for dissolution of chrome) - Hydrofluoric Acid (directly dissolves chrome) - Hydrochloric Acid (directly dissolves chrome) - Sodium Dodecylbenzenesulfonic Acid - Sulfamic Acid - Phosphoric Acid - Hydroxyacetic Acid Notice Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal. Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car warranty. Soap and water applied with a soft brush is usually all that is required to clean the calipers. Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean, clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts, lug nut caps, between the wheel cladding and off the back side of the wheel. Wheels returned to the Warranty Parts Center (WPC) that exhibit damage from wheel cleaners most often have the damage around and under the wheel weight where the cleaner was incompletely flushed away. Notice Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 2577 Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome wheels (or any wheels). If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be avoided. For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and Instructions below. Warranty of Stained Chrome Wheels Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be charged back to the dealership. To assist the customer, refer to Customer Assistance and Instructions below. Pitting or Spotted Appearance of Chrome Wheels Figure 2 A second type or staining or finish disturbance may result from road chemicals, such as calcium chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can also stain chrome wheels. The staining will look like small pitting. This staining will usually be on the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward direction while being splashed by the road chemical. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Warranty of Pitted or Spotted Chrome Wheels Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time. Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish and may cause damage if the wheels are not kept clean. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean if they are operating the vehicle in an area that applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). "Stardust" Corrosion of Chrome Wheels Figure 3 A third type of finish disturbance results from prolonged exposure to brake dust and resultant penetration of brake dust through the chrome. As brakes are applied hot particles of brake material are thrown off and tend to be forced through the leading edge of the wheel spoke windows by airflow. These Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 2578 hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the chrome leaving a pit or small blister in the chrome. Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax #M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may be used. It will clean and shine the chrome and leave behind a wax coating that may help protect the finish. Warranty of Stardust Corroded Chrome Wheels Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be replaced one time. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). Customer Assistance and Instructions GM has looked for ways customers may improve the appearance of wheels damaged by acidic cleaners. The following product and procedure has been found to dramatically improve the appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the following: Notice THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER, EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS EXACTLY. 1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce wheel staining. Flood all areas of the wheel with water to rinse. 2. Dry the wheels completely. Notice Begin with a small section of the wheel and with light pressure buff off polish and examine results. ONLY apply and rub with sufficient force and time to remove enough staining that you are satisfied with the results. Some wheels may be stained to the extent that you may only achieve a 50% improvement while others may be able to be restored to the original lustre. IN ALL CASES, only apply until the results are satisfactory. 3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If continued applications fail to improve the appearance further discontinue use. This procedure will improve the appearance of the wheels and may, with repeated applications, restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above procedure may marginally improve the condition but will not restore the finish or remove the pitting. In this type of staining the wheel finish has actually been removed in spots and no manner of cleaning will restore the finish. †*We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 2579 *This product is currently available from 3M. To obtain information for your local retail location please call 3M at 1-888-364-3577. **This product is currently available from Meguiars (Canada). To obtain information for your local retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com. ^ This product is currently available from Tri-Peek International. To obtain information for your local retail location please call Tri-Peek at 1-877-615-4272 or at www.tripeek.com. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 07-03-10-012D > Apr > 11 > Tires/Wheels - Rattle Noise from Wheel Or Hub Cap Wheels: All Technical Service Bulletins Tires/Wheels - Rattle Noise from Wheel Or Hub Cap TECHNICAL Bulletin No.: 07-03-10-012D Date: April 12, 2011 Subject: Rattle Noise from Wheel or Hub Cap While Driving, Loose Wheel Nut Caps or Wheel Nut Caps May Not Tighten on Wheel Nuts (Inspect/Replace Wheel Nut Caps As Necessary) Models: 2007-2012 Chevrolet Express, Silverado, Suburban 1500, 2500 and 3500 Series 2007-2012 GMC Savana, Sierra, Yukon XL 1500, 2500 and 3500 Series with 8 Lug Wheel Nut Center Caps (RPOs NX7, NZ7, PY0, PY2, PY9, P03, P25, QB5, QC1, QR5, Q9A) Supercede: This bulletin is being revised to update the model year information. Please discard Corporate Bulletin Number 07-03-10-012C (Section 03 - Suspension). Condition Some customers may comment on a rattle noise from the wheel or hub cap while driving. Other customers may comment on loose wheel nut caps or caps that may not tighten on the wheel nuts. Cause Depending on the generation of the wheel caps, the issue may be overtorqued wheel nut caps or may be caused by the lack of internal threads inside the wheel nut caps. The wheel nut cap (1) is correctly threaded. The wheel nut cap (2) shows the insufficient threads. Correction Important The wheel nut caps are serviced separately from the center wheel hub cap for most hub caps. Refer to the GM electronic parts catalog (EPC) for details. Inspect each wheel nut cap and replace as necessary using the steps below. 1. Remove the wheel hub cap from the vehicle. 2. Place the front of the wheel hub cap down on a protected clean work bench being careful not to scratch or damage the hub cap surface. 3. Inspect all the wheel nut caps, marking any bad wheel nut caps. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 07-03-10-012D > Apr > 11 > Tires/Wheels - Rattle Noise from Wheel Or Hub Cap > Page 2584 Tip The bad wheel nut cap can be removed by placing a drift or punch inside the center of the nut cap and using a hammer to tap the wheel nut cap out of the hub cap. 4. From inside the hub cap, apply direct pressure to one side of the wheel nut cap rim (1). The wheel nut cap will tip down and pop out of the wheel hub cap hole when enough pressure is applied. Repeat this procedure for any additional wheel nut caps that need to be replaced. 5. Flip the hub cap over on the work bench. The emblem side should be up. Tip A 22 mm (7/8 in) socket placed over the wheel nut cap may be used along with a hammer to tap the new wheel nut cap back into the hub cap hole. 6. Install the new wheel nut cap into the existing hub cap hole by applying direct pressure to the front center of the wheel nut cap. 7. Install the wheel hub cap onto the vehicle and tighten the wheel nut caps. 8. Repeat this entire procedure for each additional hub cap. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires - Refinishing Aluminum Wheels Wheels: All Technical Service Bulletins Wheels/Tires - Refinishing Aluminum Wheels INFORMATION Bulletin No.: 99-08-51-007E Date: March 17, 2011 Subject: Refinishing Aluminum Wheels Models: 2012 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 99-08-51-007D (Section 08 - Body and Accessories). This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic refinishing of the wheel's coatings, using recommended procedures, is allowed. Evaluating Damage In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion, scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been refinished by an outside company must be returned to the same vehicle. The Dealer must record the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. Aluminum Wheel Refinishing Recommendations - Chrome-plated aluminum wheels Re-plating these wheels is not recommended. - Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. - Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel. - Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them. In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel should be resurfaced by using a sanding process rather than a machining process. This allows the least amount of material to be removed. Important Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using any of the painting options, it is recommended that all four wheels be refinished in order to maintain color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures and product recommendations. Refinisher's Responsibility - Outside Company Important Some outside companies are offering wheel refinishing services. Such refinished wheels will be permanently marked by the refinisher and are warranted by the refinisher. Any process that re-machines or otherwise re-manufactures the wheel should not be used. A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to assure that the same wheel is returned. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Re-machining of the wheel is not allowed. Paint and/or clear coat must not be present on the following surfaces: the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires - Refinishing Aluminum Wheels > Page 2589 longer. Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions Wheels: All Technical Service Bulletins Wheels - Changing Procedures/Precautions INFORMATION Bulletin No.: 06-03-10-010A Date: June 09, 2010 Subject: Information on Proper Wheel Changing Procedures and Cautions Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER Models 2005-2009 Saab 9-7X 2005-2009 Saturn Vehicles Attention: Complete wheel changing instructions for each vehicle line can be found under Tire and Wheel Removal and Installation in Service Information (SI). This bulletin is intended to quickly review and reinforce simple but vital procedures to reduce the possibility of achieving low torque during wheel installation. Always refer to SI for wheel lug nut torque specifications and complete jacking instructions for safe wheel changing. Supercede: This bulletin is being revised to include the 2011 model year and update the available special tool list. Please discard Corporate Bulletin Number 06-03-10-010 (Section 03 Suspension). Frequency of Wheel Changes - Marketplace Driven Just a few years ago, the increasing longevity of tires along with greater resistance to punctures had greatly reduced the number of times wheels were removed to basically required tire rotation intervals. Today with the booming business in accessory wheels/special application tires (such as winter tires), consumers are having tire/wheel assemblies removed - replaced - or installed more than ever. With this increased activity, it opens up more of a chance for error on the part of the technician. This bulletin will review a few of the common concerns and mistakes to make yourself aware of. Proper Servicing Starts With the Right Tools The following tools have been made available to assist in proper wheel and tire removal and installation. - J 41013 Rotor Resurfacing Kit (or equivalent) - J 42450-A Wheel Hub Resurfacing Kit (or equivalent) Corroded Surfaces One area of concern is corrosion on the mating surfaces of the wheel to the hub on the vehicle. Excessive corrosion, dirt, rust or debris built up on these surfaces can mimic a properly tightened wheel in the service stall. Once the vehicle is driven, the debris may loosen, grind up or be washed away from water splash. This action may result in clearance at the mating surface of the wheel and an under-torqued condition. Caution Before installing a wheel, remove any buildup on the wheel mounting surface and brake drum or brake disc mounting surface. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This may cause a wheel to come off when the vehicle is moving, possibly resulting in a loss of control or personal injury. Whenever you remove the tire/wheel assemblies, you must inspect the mating surfaces. If corrosion is found, you should remove the debris with a die grinder equipped with a fine sanding pad, wire brush or cleaning disc. Just remove enough material to assure a clean, smooth mating surface. The J 41013 (or equivalent) can be used to clean the following surfaces: - The hub mounting surface - The brake rotor mounting surface - The wheel mounting surface Use the J 42450-A (or equivalent) to clean around the base of the studs and the hub. Lubricants, Grease and Fluids Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 2594 Some customers may use penetrating oils, grease or other lubricants on wheel studs to aid in removal or installation. Always use a suitable cleaner/solvent to remove these lubricants prior to installing the wheel and tire assemblies. Lubricants left on the wheel studs may cause improper readings of wheel nut torque. Always install wheels to clean, dry wheel studs ONLY. Notice Lubricants left on the wheel studs or vertical mounting surfaces between the wheel and the rotor or drum may cause the wheel to work itself loose after the vehicle is driven. Always install wheels to clean, dry wheel studs and surfaces ONLY. Beginning with 2011 model year vehicles, put a light coating of grease, GM P/N 1051344 (in Canada, P/N 9930370), on the inner surface of the wheel pilot hole to prevent wheel seizure to the axle or bearing hub. Wheel Stud and Lug Nut Damage Always inspect the wheel studs and lug nuts for signs of damage from crossthreading or abuse. You should never have to force wheel nuts down the stud. Lug nuts that are damaged may not retain properly, yet give the impression of fully tightening. Always inspect and replace any component suspected of damage. Tip Always start wheel nuts by hand! Be certain that all wheel nut threads have been engaged BEFORE tightening the nut. Important If the vehicle has directional tread tires, verify the directional arrow on the outboard side of the tire is pointing in the direction of forward rotation. Wheel Nut Tightening and Torque Improper wheel nut tightening can lead to brake pulsation and rotor damage. In order to avoid additional brake repairs, evenly tighten the wheel nuts to the proper torque specification as shown for each vehicle in SI. Always observe the proper wheel nut tightening sequence as shown below in order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off center resulting in vibration. The Most Important Service You Provide While the above information is well known, and wheel removal so common, technicians run the risk of becoming complacent on this very important Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 2595 service operation. A simple distraction or time constraint that rushes the job may result in personal injury if the greatest of care is not exercised. Make it a habit to double check your work and to always side with caution when installing wheels. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) Wheels: All Technical Service Bulletins Wheels/Tires - Tire Radial Force Variation (RFV) INFORMATION Bulletin No.: 00-03-10-006F Date: May 04, 2010 Subject: Information on Tire Radial Force Variation (RFV) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION Supercede: This bulletin is being revised to considerably expand the available information on Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin Number 00-03-10-006E (Section 03 - Suspension). Important - Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires. - Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel assemblies for each vehicle. The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force variation is highway speed shake on smooth roads. Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out of round and tire force variation. These three conditions are not necessarily related. All three conditions must be addressed. Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle, two plane dynamic wheel balancers are readily available and can accurately correct any imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer, and proper balance weights, are all factors required for a quality balance. However, a perfectly balanced tire/wheel assembly can still be "oval shaped" and cause a vibration. Before balancing, perform the following procedures. Tire and Wheel Diagnosis 1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick. 3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and correct as necessary: - Missing balance weights - Bent rim flange - Irregular tire wear - Incomplete bead seating - Tire irregularities (including pressure settings) - Mud/ice build-up in wheel - Stones in the tire tread - Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to diagnosing a smooth road shake condition. 4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a sufficient distance on a known, smooth road surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order (one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high enough in frequency that most humans can start to hear them at highway speeds, but are too high to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment. If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a throbbing), chances are good that the vehicle could have driveline vibration. This type Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 2600 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 2601 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 2602 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels Wheels: All Technical Service Bulletins Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels TECHNICAL Bulletin No.: 05-03-10-003F Date: April 27, 2010 Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels Supercede: This bulletin is being revised to update the model years and the bulletin reference information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension). Condition Some customers may comment on a low tire pressure condition. Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel. Cause Porosity in the cast aluminum wheel may be the cause. Notice This bulletin specifically addresses issues related to the wheel casting that may result in an air leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat). Correction 1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the tire/wheel assembly in a water bath, or use a spray bottle with soap and water to locate the specific leak location. Important - If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim), the wheel should be replaced. - If two or more leaks are located on one wheel, the wheel should be replaced. 3. If air bubbles are observed, mark the location. - If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks. - If the leak is located on the aluminum wheel area, continue with the next step. 4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose cleaner, such as 3M(R) General Purpose Adhesive Cleaner, P/N 08984, or equivalent. 8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use 88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry. Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging the repair area may result in an air leak. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels > Page 2607 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON Wheels: All Technical Service Bulletins Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON TECHNICAL Bulletin No.: 08-03-10-006C Date: April 27, 2010 Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat) Models: 2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-03-10-006B (Section 03 - Suspension). Condition Some customers may comment on a tire that slowly loses air pressure over a period of days or weeks. Cause Abrasive elements in the environment may intrude between the tire and wheel at the bead seat. There is always some relative motion between the tire and wheel (when the vehicle is driven) and this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear continues, there may also be intrusion at the tire/wheel interface by corrosive media from the environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be visible until the tire is dismounted from the wheel. Notice This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Correction In most cases, this type of air loss can be corrected by following the procedure below. Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to repair the wheel with the procedure below. Notice The repair is no longer advised or applicable for chromed aluminum wheels. 1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to be around the bead seat of the wheel, dismount the tire to examine the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat Corrosion Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 2612 Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for additional information on possible wheel porosity issues. 3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a rough or uneven surface that is difficult for the tire to maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion 4. If corrosion is found on the wheel bead seat, measure the affected area as shown below. - For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. - For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. 5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the corrosion and any flaking paint. You should remove the corrosion back far enough until you reach material that is stable and firmly bonded to the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired surface. Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend to the visible surfaces on the FACE of the wheel, that wheel must be replaced. Important Remove ONLY the material required to eliminate the corrosion from the bead seating surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as smooth and level as possible. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 2613 Acceptably Prepared (Cleaned-Up) Wheel Surface 6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially available tire sealant such as Patch Brand Bead Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat 7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in SI. Parts Information Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 2614 Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion INFORMATION Bulletin No.: 00-03-10-002F Date: April 21, 2011 Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum Wheels Models: 2012 and Prior GM Cars and Trucks Supercede: This bulletin is being revised to update model years, suggest additional restorative products and add additional corrosion information. Please discard Corporate Bulletin Number 00-03-10-002E (Section 03 - Suspension). Important You may give a copy of this bulletin to the customer. What is Chemical Staining of Chrome Wheels? Figure 1 Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an example). These stains are frequently milky, black, or greenish in appearance. They result from using cleaning solutions that contain acids on chrome wheels. Soap and water is usually sufficient to clean wheels. If the customer insists on using a wheel cleaner they should only use one that specifically states that it is safe for chromed wheels and does not contain anything in the following list. (Dealers should also survey any products they use during prep or normal cleaning of stock units for these chemicals.) - Ammonium Bifluoride (fluoride source for dissolution of chrome) - Hydrofluoric Acid (directly dissolves chrome) - Hydrochloric Acid (directly dissolves chrome) - Sodium Dodecylbenzenesulfonic Acid - Sulfamic Acid - Phosphoric Acid - Hydroxyacetic Acid Notice Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal. Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car warranty. Soap and water applied with a soft brush is usually all that is required to clean the calipers. Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean, clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts, lug nut caps, between the wheel cladding and off the back side of the wheel. Wheels returned to the Warranty Parts Center (WPC) that exhibit damage from wheel cleaners most often have the damage around and under the wheel weight where the cleaner was incompletely flushed away. Notice Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 2620 Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome wheels (or any wheels). If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be avoided. For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and Instructions below. Warranty of Stained Chrome Wheels Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be charged back to the dealership. To assist the customer, refer to Customer Assistance and Instructions below. Pitting or Spotted Appearance of Chrome Wheels Figure 2 A second type or staining or finish disturbance may result from road chemicals, such as calcium chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can also stain chrome wheels. The staining will look like small pitting. This staining will usually be on the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward direction while being splashed by the road chemical. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Warranty of Pitted or Spotted Chrome Wheels Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time. Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish and may cause damage if the wheels are not kept clean. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean if they are operating the vehicle in an area that applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). "Stardust" Corrosion of Chrome Wheels Figure 3 A third type of finish disturbance results from prolonged exposure to brake dust and resultant penetration of brake dust through the chrome. As brakes are applied hot particles of brake material are thrown off and tend to be forced through the leading edge of the wheel spoke windows by airflow. These Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 2621 hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the chrome leaving a pit or small blister in the chrome. Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax #M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may be used. It will clean and shine the chrome and leave behind a wax coating that may help protect the finish. Warranty of Stardust Corroded Chrome Wheels Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be replaced one time. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). Customer Assistance and Instructions GM has looked for ways customers may improve the appearance of wheels damaged by acidic cleaners. The following product and procedure has been found to dramatically improve the appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the following: Notice THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER, EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS EXACTLY. 1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce wheel staining. Flood all areas of the wheel with water to rinse. 2. Dry the wheels completely. Notice Begin with a small section of the wheel and with light pressure buff off polish and examine results. ONLY apply and rub with sufficient force and time to remove enough staining that you are satisfied with the results. Some wheels may be stained to the extent that you may only achieve a 50% improvement while others may be able to be restored to the original lustre. IN ALL CASES, only apply until the results are satisfactory. 3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If continued applications fail to improve the appearance further discontinue use. This procedure will improve the appearance of the wheels and may, with repeated applications, restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above procedure may marginally improve the condition but will not restore the finish or remove the pitting. In this type of staining the wheel finish has actually been removed in spots and no manner of cleaning will restore the finish. †*We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 2622 *This product is currently available from 3M. To obtain information for your local retail location please call 3M at 1-888-364-3577. **This product is currently available from Meguiars (Canada). To obtain information for your local retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com. ^ This product is currently available from Tri-Peek International. To obtain information for your local retail location please call Tri-Peek at 1-877-615-4272 or at www.tripeek.com. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires - Refinishing Aluminum Wheels Wheels: All Technical Service Bulletins Wheels/Tires - Refinishing Aluminum Wheels INFORMATION Bulletin No.: 99-08-51-007E Date: March 17, 2011 Subject: Refinishing Aluminum Wheels Models: 2012 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 99-08-51-007D (Section 08 - Body and Accessories). This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic refinishing of the wheel's coatings, using recommended procedures, is allowed. Evaluating Damage In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion, scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been refinished by an outside company must be returned to the same vehicle. The Dealer must record the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. Aluminum Wheel Refinishing Recommendations - Chrome-plated aluminum wheels Re-plating these wheels is not recommended. - Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. - Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel. - Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them. In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel should be resurfaced by using a sanding process rather than a machining process. This allows the least amount of material to be removed. Important Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using any of the painting options, it is recommended that all four wheels be refinished in order to maintain color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures and product recommendations. Refinisher's Responsibility - Outside Company Important Some outside companies are offering wheel refinishing services. Such refinished wheels will be permanently marked by the refinisher and are warranted by the refinisher. Any process that re-machines or otherwise re-manufactures the wheel should not be used. A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to assure that the same wheel is returned. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Re-machining of the wheel is not allowed. Paint and/or clear coat must not be present on the following surfaces: the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires - Refinishing Aluminum Wheels > Page 2627 longer. Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions Wheels: All Technical Service Bulletins Wheels - Changing Procedures/Precautions INFORMATION Bulletin No.: 06-03-10-010A Date: June 09, 2010 Subject: Information on Proper Wheel Changing Procedures and Cautions Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER Models 2005-2009 Saab 9-7X 2005-2009 Saturn Vehicles Attention: Complete wheel changing instructions for each vehicle line can be found under Tire and Wheel Removal and Installation in Service Information (SI). This bulletin is intended to quickly review and reinforce simple but vital procedures to reduce the possibility of achieving low torque during wheel installation. Always refer to SI for wheel lug nut torque specifications and complete jacking instructions for safe wheel changing. Supercede: This bulletin is being revised to include the 2011 model year and update the available special tool list. Please discard Corporate Bulletin Number 06-03-10-010 (Section 03 Suspension). Frequency of Wheel Changes - Marketplace Driven Just a few years ago, the increasing longevity of tires along with greater resistance to punctures had greatly reduced the number of times wheels were removed to basically required tire rotation intervals. Today with the booming business in accessory wheels/special application tires (such as winter tires), consumers are having tire/wheel assemblies removed - replaced - or installed more than ever. With this increased activity, it opens up more of a chance for error on the part of the technician. This bulletin will review a few of the common concerns and mistakes to make yourself aware of. Proper Servicing Starts With the Right Tools The following tools have been made available to assist in proper wheel and tire removal and installation. - J 41013 Rotor Resurfacing Kit (or equivalent) - J 42450-A Wheel Hub Resurfacing Kit (or equivalent) Corroded Surfaces One area of concern is corrosion on the mating surfaces of the wheel to the hub on the vehicle. Excessive corrosion, dirt, rust or debris built up on these surfaces can mimic a properly tightened wheel in the service stall. Once the vehicle is driven, the debris may loosen, grind up or be washed away from water splash. This action may result in clearance at the mating surface of the wheel and an under-torqued condition. Caution Before installing a wheel, remove any buildup on the wheel mounting surface and brake drum or brake disc mounting surface. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This may cause a wheel to come off when the vehicle is moving, possibly resulting in a loss of control or personal injury. Whenever you remove the tire/wheel assemblies, you must inspect the mating surfaces. If corrosion is found, you should remove the debris with a die grinder equipped with a fine sanding pad, wire brush or cleaning disc. Just remove enough material to assure a clean, smooth mating surface. The J 41013 (or equivalent) can be used to clean the following surfaces: - The hub mounting surface - The brake rotor mounting surface - The wheel mounting surface Use the J 42450-A (or equivalent) to clean around the base of the studs and the hub. Lubricants, Grease and Fluids Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 2632 Some customers may use penetrating oils, grease or other lubricants on wheel studs to aid in removal or installation. Always use a suitable cleaner/solvent to remove these lubricants prior to installing the wheel and tire assemblies. Lubricants left on the wheel studs may cause improper readings of wheel nut torque. Always install wheels to clean, dry wheel studs ONLY. Notice Lubricants left on the wheel studs or vertical mounting surfaces between the wheel and the rotor or drum may cause the wheel to work itself loose after the vehicle is driven. Always install wheels to clean, dry wheel studs and surfaces ONLY. Beginning with 2011 model year vehicles, put a light coating of grease, GM P/N 1051344 (in Canada, P/N 9930370), on the inner surface of the wheel pilot hole to prevent wheel seizure to the axle or bearing hub. Wheel Stud and Lug Nut Damage Always inspect the wheel studs and lug nuts for signs of damage from crossthreading or abuse. You should never have to force wheel nuts down the stud. Lug nuts that are damaged may not retain properly, yet give the impression of fully tightening. Always inspect and replace any component suspected of damage. Tip Always start wheel nuts by hand! Be certain that all wheel nut threads have been engaged BEFORE tightening the nut. Important If the vehicle has directional tread tires, verify the directional arrow on the outboard side of the tire is pointing in the direction of forward rotation. Wheel Nut Tightening and Torque Improper wheel nut tightening can lead to brake pulsation and rotor damage. In order to avoid additional brake repairs, evenly tighten the wheel nuts to the proper torque specification as shown for each vehicle in SI. Always observe the proper wheel nut tightening sequence as shown below in order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off center resulting in vibration. The Most Important Service You Provide While the above information is well known, and wheel removal so common, technicians run the risk of becoming complacent on this very important Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 2633 service operation. A simple distraction or time constraint that rushes the job may result in personal injury if the greatest of care is not exercised. Make it a habit to double check your work and to always side with caution when installing wheels. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Description and Operation > Replacement Wheels Description Wheels: Description and Operation Replacement Wheels Description Replacement Wheels Description Replace the wheel if any of the following conditions exist: * The wheel exhibits excessive runout. * The wheel is bent. * The wheel is cracked. * The wheel is severely rusted. * The wheel is severely corroded. Note: Air leaks caused by porosity on aluminum wheels are repairable. * The wheel leaks air. Warning If you are replacing the wheel(s), the wheel stud(s), the wheel nut(s) or the wheel bolt(s), install only new GM original equipment parts. Installation of used parts or non-GM original equipment parts may cause the wheel to loosen, loss of tire air pressure, poor vehicle handling and loss of vehicle control resulting in personal injury. Caution: The use of non-GM original equipment wheels may cause: * Damage to the wheel bearing, the wheel fasteners and the wheel * Tire damage caused by the modified clearance to the adjacent vehicle components * Adverse vehicle steering stability caused by the modified scrub radius * Damage to the vehicle caused by the modified ground clearance * Speedometer and odometer inaccuracy Replace the wheel, the wheel studs and the wheel/nuts, or the wheel bolts if applicable, if any of the following conditions exist: * The wheel has elongated bolt holes. * The wheel/nuts, or bolts if applicable, loosen repeatedly. Steel wheel identification is stamped into the wheel near the valve stem. Aluminum wheel identification is cast into the inboard side of the wheel. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Description and Operation > Replacement Wheels Description > Page 2636 Wheels: Description and Operation Steel Wheel Repair Description Steel Wheel Repair Description Caution: Do not heat wheels in an attempt to soften them for straightening or repair damage from striking curbs, etc. Do not weld wheels. The alloy used in these wheels is heat-treated and uncontrolled heating from welding affects the properties of the material. Caution: The use of tubes in tubeless tires is not a recommended repair due to the fact that speed ratings are greatly reduced. You can repair porosity in aluminum wheels. If leaks are found in a steel wheel, replace the wheel with a wheel of original equipment quality. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Description and Operation > Page 2637 Wheels: Service and Repair Aluminum Wheel Refinishing Aluminum Wheel Refinishing Guidelines Warning To avoid personal injury when exposed to plastic media blast, hand and/or lathe sanding dust, primer, color coat, and clearcoat, you must work in a properly ventilated area, wearing an approved respirator, eye protection, earplugs and protective gloves and clothing. Evaluating Damage Note: * Inspect the wheel for corrosion, scrapes, gouges, etc. Damage MUST NOT be deeper than what can be sanded or polished off. * Inspect the wheel for cracks. If cracks are found, discard the wheel. * ALL wheels with bent rim flanges must not be repaired or refinished. * The re-machining and the re-clear coating of aluminum wheels is not recommended in the dealer environment due to concerns of repair durability. * Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Aluminum Wheel Refinishing General Recommendations/Options * Painted aluminum wheels use a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. (See option number 1). * If the clearcoat is damaged, it is possible to refinish with clearcoat only, however, the required refinishing process cannot be performed in the dealer environment. Refer to Refinishers Responsibility (Repair option number 2). * Re-plating of chrome-plated aluminum wheels is not recommended. Repair Option Number 1 Material Required/Information Resources * The Paint Manufacturer's Color Book * Refer to the latest GM Approved Refinish Materials Booklet (GM 4901 MD-2005) for specific products for aluminum refinishing. * To access the booklet, go to www.gmgoodwrench.com. Click on GM Collision Parts. Click on GM Technical Repair Information, select Paint Shop. * A Color Compatibility chart is also at this site defining what colors are used on what models. Note: Chemical strippers are not recommended. * Refer to specific Paint Manufacturers for refinish procedures and process pertaining to "Aluminum Refinishing". The procedure requires the wheel surface to be plastic media blasted to remove old paint or clearcoat. General Color Selection * If the wheels being painted were previously clearcoated aluminum, and a painted aluminum look is desired, using Corsican Silver WAEQ9283 for a fine "aluminum-like" look, or Sparkle Silver WA9967 for a very bright look. Body color is another option to the customer that may also be used. * Some specific colors may be recommended on certain models. * If painting wheels that were previously clearcoated aluminum, it is recommended that all 4 wheels and their center caps be refinished to maintain color uniformity. General Refinishing Procedures - Removal 1. Remove the wheels from the vehicle. The tires may remain mounted on the wheels. 2. Remove the balance weights and mark their locations on the tire. 3. Remove excess grease, etc. from the wheels with wax and grease remover. 4. Have the wheels plastic media blasted to remove the clearcoat. Note: MASK OFF ALL MOUNTING SURFACES, whenever a wheel is refinished. The mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. 5. Clean and mask and paint the wheels. General Refinishing Procedures - Installation 1. Unmask the wheels. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Description and Operation > Page 2638 2. Clean all wheel mounting surface of any corrosion, overspray, or dirt. Note: When re-balancing a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. 3. Install NEW coated balance weights at marked locations. Note: Use a torque stick on an impact wrench, or a torque wrench to consistently and uniformly fasten the wheel to the specified torque for the vehicle. The star pattern must be followed. 4. Install wheels on vehicle. Repair Option Number 2 - Outside Companies * Some outside companies are offering wheel refinishing services. One such company, Transwheel Corporation (800-892-3733), provides this service with GM guidelines. Other companies may also exist. * Any process that re-machines or otherwise remanufactures the wheel should not be used. * The wheel ID must be recorded and follow the wheel throughout the process to assure that the same wheel is returned. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is longer. * Paint and/or clearcoat must not be present on the following surfaces, the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. * A refinishers responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications FRONT WHEEL BEARINGS Wheel bearing lubricant meeting requirements of NLGI #2, Category GC or GC-LB (GM Part No. U.S. 1051344, in Canada 993037). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 2642 Wheel Bearing: Testing and Inspection Wheel Bearings Diagnosis Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Wheel Drive Shaft Nut ......................................................................................................................... .................................................... 240 Nm (177 lb ft) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Customer Interest for Wheel Fastener: > 07-03-10-012D > Apr > 11 > Tires/Wheels - Rattle Noise from Wheel Or Hub Cap Wheel Fastener: Customer Interest Tires/Wheels - Rattle Noise from Wheel Or Hub Cap TECHNICAL Bulletin No.: 07-03-10-012D Date: April 12, 2011 Subject: Rattle Noise from Wheel or Hub Cap While Driving, Loose Wheel Nut Caps or Wheel Nut Caps May Not Tighten on Wheel Nuts (Inspect/Replace Wheel Nut Caps As Necessary) Models: 2007-2012 Chevrolet Express, Silverado, Suburban 1500, 2500 and 3500 Series 2007-2012 GMC Savana, Sierra, Yukon XL 1500, 2500 and 3500 Series with 8 Lug Wheel Nut Center Caps (RPOs NX7, NZ7, PY0, PY2, PY9, P03, P25, QB5, QC1, QR5, Q9A) Supercede: This bulletin is being revised to update the model year information. Please discard Corporate Bulletin Number 07-03-10-012C (Section 03 - Suspension). Condition Some customers may comment on a rattle noise from the wheel or hub cap while driving. Other customers may comment on loose wheel nut caps or caps that may not tighten on the wheel nuts. Cause Depending on the generation of the wheel caps, the issue may be overtorqued wheel nut caps or may be caused by the lack of internal threads inside the wheel nut caps. The wheel nut cap (1) is correctly threaded. The wheel nut cap (2) shows the insufficient threads. Correction Important The wheel nut caps are serviced separately from the center wheel hub cap for most hub caps. Refer to the GM electronic parts catalog (EPC) for details. Inspect each wheel nut cap and replace as necessary using the steps below. 1. Remove the wheel hub cap from the vehicle. 2. Place the front of the wheel hub cap down on a protected clean work bench being careful not to scratch or damage the hub cap surface. 3. Inspect all the wheel nut caps, marking any bad wheel nut caps. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Customer Interest for Wheel Fastener: > 07-03-10-012D > Apr > 11 > Tires/Wheels - Rattle Noise from Wheel Or Hub Cap > Page 2655 Tip The bad wheel nut cap can be removed by placing a drift or punch inside the center of the nut cap and using a hammer to tap the wheel nut cap out of the hub cap. 4. From inside the hub cap, apply direct pressure to one side of the wheel nut cap rim (1). The wheel nut cap will tip down and pop out of the wheel hub cap hole when enough pressure is applied. Repeat this procedure for any additional wheel nut caps that need to be replaced. 5. Flip the hub cap over on the work bench. The emblem side should be up. Tip A 22 mm (7/8 in) socket placed over the wheel nut cap may be used along with a hammer to tap the new wheel nut cap back into the hub cap hole. 6. Install the new wheel nut cap into the existing hub cap hole by applying direct pressure to the front center of the wheel nut cap. 7. Install the wheel hub cap onto the vehicle and tighten the wheel nut caps. 8. Repeat this entire procedure for each additional hub cap. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 07-03-10-012D > Apr > 11 > Tires/Wheels - Rattle Noise from Wheel Or Hub Cap Wheel Fastener: All Technical Service Bulletins Tires/Wheels - Rattle Noise from Wheel Or Hub Cap TECHNICAL Bulletin No.: 07-03-10-012D Date: April 12, 2011 Subject: Rattle Noise from Wheel or Hub Cap While Driving, Loose Wheel Nut Caps or Wheel Nut Caps May Not Tighten on Wheel Nuts (Inspect/Replace Wheel Nut Caps As Necessary) Models: 2007-2012 Chevrolet Express, Silverado, Suburban 1500, 2500 and 3500 Series 2007-2012 GMC Savana, Sierra, Yukon XL 1500, 2500 and 3500 Series with 8 Lug Wheel Nut Center Caps (RPOs NX7, NZ7, PY0, PY2, PY9, P03, P25, QB5, QC1, QR5, Q9A) Supercede: This bulletin is being revised to update the model year information. Please discard Corporate Bulletin Number 07-03-10-012C (Section 03 - Suspension). Condition Some customers may comment on a rattle noise from the wheel or hub cap while driving. Other customers may comment on loose wheel nut caps or caps that may not tighten on the wheel nuts. Cause Depending on the generation of the wheel caps, the issue may be overtorqued wheel nut caps or may be caused by the lack of internal threads inside the wheel nut caps. The wheel nut cap (1) is correctly threaded. The wheel nut cap (2) shows the insufficient threads. Correction Important The wheel nut caps are serviced separately from the center wheel hub cap for most hub caps. Refer to the GM electronic parts catalog (EPC) for details. Inspect each wheel nut cap and replace as necessary using the steps below. 1. Remove the wheel hub cap from the vehicle. 2. Place the front of the wheel hub cap down on a protected clean work bench being careful not to scratch or damage the hub cap surface. 3. Inspect all the wheel nut caps, marking any bad wheel nut caps. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 07-03-10-012D > Apr > 11 > Tires/Wheels - Rattle Noise from Wheel Or Hub Cap > Page 2661 Tip The bad wheel nut cap can be removed by placing a drift or punch inside the center of the nut cap and using a hammer to tap the wheel nut cap out of the hub cap. 4. From inside the hub cap, apply direct pressure to one side of the wheel nut cap rim (1). The wheel nut cap will tip down and pop out of the wheel hub cap hole when enough pressure is applied. Repeat this procedure for any additional wheel nut caps that need to be replaced. 5. Flip the hub cap over on the work bench. The emblem side should be up. Tip A 22 mm (7/8 in) socket placed over the wheel nut cap may be used along with a hammer to tap the new wheel nut cap back into the hub cap hole. 6. Install the new wheel nut cap into the existing hub cap hole by applying direct pressure to the front center of the wheel nut cap. 7. Install the wheel hub cap onto the vehicle and tighten the wheel nut caps. 8. Repeat this entire procedure for each additional hub cap. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Page 2662 Wheel Fastener: Specifications Wheel Nuts .......................................................................................................................................... ..................................................... 190 Nm (140 lb ft) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Page 2663 Wheel Fastener: Description and Operation Metric Wheel Nuts and Bolts Description Metric wheel/nuts and bolts are identified in the following way: * The wheel/nut has the word Metric stamped on the face. * The letter M is stamped on the end of the wheel bolt. The thread sizes of metric wheel/nuts and the bolts are indicated by the following example: M12 x 1.5. * M = Metric * 12 = Diameter in millimeters * 1.5 = Millimeters gap per thread Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Suspension Wheel Fastener: Service and Repair Front Suspension Wheel Stud Replacement Tools Required J 43631 Ball Joint Remover Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). 3. Remove the brake rotor. Refer to Front Brake Rotor Replacement (JD9, JF3, JF7, JG4) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Front Brake Rotor Replacement (JD9, JF3, JF7, JG4))Front Brake Rotor Replacement (JH6, JH7) ( See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Front Brake Rotor Replacement (JH6, JH7)). 4. Use the J 43631 to press the stud from the wheel bearing/hub. Installation Procedure 1. Install a new stud. Use washers and a wheel nut and pull the new stud into the hub. 2. Install the brake rotor. Refer to Front Brake Rotor Replacement (JD9, JF3, JF7, JG4) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Front Brake Rotor Replacement (JD9, JF3, JF7, JG4))Front Brake Rotor Replacement (JH6, JH7) ( See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Front Brake Rotor Replacement (JH6, JH7)). 3. Install the tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). 4. Lower the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Suspension > Page 2666 Wheel Fastener: Service and Repair Rear Suspension Wheel Stud Replacement Special Tools J 43631 - Ball Joint Remover For equivalent regional tools, refer to Special Tools (See: Steering and Suspension/Suspension/Tools and Equipment/Rear Suspension) Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). 3. Remove the rear brake drum, if equipped. Refer to Brake Drum Replacement (See: Brakes and Traction Control/Drum Brake System/Brake Drum/Service and Repair/Removal and Replacement). 4. Remove the rear brake rotor, if equipped. Refer to Rear Brake Rotor Replacement (JD9) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JD9))Rear Brake Rotor Replacement (JH6) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JH6))Rear Brake Rotor Replacement (JH7) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JH7)). 5. Using the J 43631 - remover , remove wheel stud from the rear axle shaft. 6. For those vehicles equipped with RPO codes JH6 or JH7, remove the rear axle hub assembly. Refer to Rear Axle Hub, Bearing, Cup, and/or Seal Replacement (See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Bearing/Service and Repair/Rear Axle Hub, Bearing, Cup, and/or Seal Replacement). Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Suspension > Page 2667 1. Position the wheel stud in the rear axle shaft. 2. Using washers and a wheel nut, tighten the wheel nut until the wheel stud is firmly seated in the rear axle shaft. 3. Remove the wheel nut and the washers. 4. Install the rear axle hub assembly, if removed. Refer to Rear Axle Hub, Bearing, Cup, and/or Seal Replacement (See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Bearing/Service and Repair/Rear Axle Hub, Bearing, Cup, and/or Seal Replacement). 5. Install the brake rotor. Refer to Rear Brake Rotor Replacement (JD9) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JD9))Rear Brake Rotor Replacement (JH6) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JH6))Rear Brake Rotor Replacement (JH7) ( See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JH7)). 6. Install the rear brake drum. Refer to Brake Drum Replacement (See: Brakes and Traction Control/Drum Brake System/Brake Drum/Service and Repair/Removal and Replacement). 7. Install the tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). 8. Remove the supports and lower the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Service and Repair Vehicle Lifting: Service and Repair Lifting and Jacking the Vehicle Danger: To avoid any vehicle damage, serious personal injury or death, always use the jackstands to support the vehicle when lifting the vehicle with a jack. Danger: To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed and strap the vehicle to the hoist. Caution: Perform the following steps before beginning any vehicle lifting or jacking procedure: * Remove or secure all of the vehicle contents in order to avoid any shifting or any movement that may occur during the vehicle lifting or jacking procedure. * The lifting equipment or the jacking equipment weight rating must meet or exceed the weight of the vehicle and any vehicle contents. * The lifting equipment or the jacking equipment must meet the operational standards of the lifting equipment or jacking equipment manufacturer. * Perform the vehicle lifting or jacking procedure on a clean, hard, dry, level surface. * Perform the vehicle lifting or jacking procedure only at the identified lift points. DO NOT allow the lifting equipment or jacking equipment to contact any other vehicle components. Failure to perform the previous steps could result in damage to the lifting equipment or the jacking equipment, the vehicle, and/or the vehicle contents. For lifting the vehicle, various lift points are recommended. Before you begin any lifting procedure, place the vehicle on a clean, hard, level surface. Verify that all the lifting equipment meets weight standards and is in good working order. Verify that all of the vehicle loads are equally distributed and secure. If you are only supporting the vehicle at the frame side rails, verify that the lifting equipment does not put too much stress on, or weaken, the frame side rails. During hoisting, do NOT damage the fuel tanks, the exhaust system, or the underbody. 1 - Lower Control Arm Contact Points 2 - Front Frame Contact Points 3 - Rear Frame Contact Points 4 - Rear Axle Contact Points Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Service and Repair > Page 2671 5 - Differential Contact Points Frame Contact Hoist Front Hoist Pads Note: The front hoist pads must not contact the rocker panels, the front fenders, or the floor pan. Position the front hoist pads under the front frame between the lower control arm and the frame pad. Rear Hoist Pads Note: The rear hoist pads must not contact the body rocker panels or the floor pan. Position the rear hoist pads under the rear spring, just behind the hanger Suspension Contact Hoist Front Lift Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Service and Repair > Page 2672 Position the front lift under the outer edge of the front suspension lower control arms. Rear Lift Position the rear lift under the axle housing tubes on each side of the differential. Do not damage the stabilizer bar. Jacking When you are lifting a vehicle with a vehicle jack or a floor jack, block the wheels at the opposite end from which you are lifting. Use jack stands to provide additional support. Under the Frame Rails Note: The floor jack pad must not contact rocker panel or the floor pan. Position the floor jack pad under the frame rail pad. Under the Rear Differential Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Service and Repair > Page 2673 Position the floor jack pad under the center of the rear axle differential. Do not damage the establisher bar. Under the Rear Spring Hanger Position the jack under the rear spring hanger. Jack Stands When you support the vehicle with jack stands, place the jack stands under the frame, the front suspension crossmember, or the rear axle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Valve Deactivation Solenoid > Component Information > Diagrams Valve Deactivation Solenoid: Diagrams Component Connector End Views Valve Lifter Oil Manifold (VLOM) Assembly (LMG, LC9, LZ1 or L96) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications Compression Check: Specifications The minimum compression in any one cylinder is 2069 kPa (300 psi). There should not be more than 345 kPa (50 psi) difference between a suspect cylinder and the average compression of all 8 cylinders. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications > Page 2683 Compression Check: Testing and Inspection Engine Compression Test Special Tools * J 26999 - Compression Gauge * EN-47603 - Compression Gauge Adapter For equivalent regional tools, refer to Special Tools (See: Tools and Equipment/Special Tools). 1. Ensure that the vehicle's batteries are in good condition, and fully charged. 2. Operate the vehicle until the engine is at normal operating temperature. 3. Shut off engine. 4. Disconnect glow plug nut; remove all 8 glow plugs. All 8 glow plugs must be removed from the engine during each cylinder test to obtain valid test results. 5. Prior to taking a compression reading, verify the cranking speed is greater than 140 RPM. If the cranking speed is below 140 RPM, repair the slow cranking speed condition before continuing with the compression test. Refer to Engine Cranks Slowly (See: Starting and Charging/Testing and Inspection/Symptom Related Diagnostic Procedures/Engine Cranks Slowly). 6. Install the EN-47603 - adapter in the glow plug hole for the cylinder that is being checked. Caution: Do not add oil to any cylinder during a compression test as extensive engine damage may result. 7. Connect the J 26999 - gauge to the EN-47603 - adapter. Caution: Do not crank the engine using the ignition switch, as the fuel injectors and the glow plug circuits will be energized and engine damage may result. 8. Using a remote start switch, crank the engine for 6 compression strokes, puffs, for the cylinder being tested. 9. Observe the J 26999 - gauge and note the reading as the compression test is being performed. A normal cylinder reading will be indicated if compression builds up quickly and evenly to the specified level. An abnormal reading will be indicated if compression is low on the first compression stroke, starts increasing on the following compression strokes but does not reach the specified level. 10. Record the compression reading for the cylinder just tested. 11. Disconnect the J 26999 gauge from the EN-47603 - adapter and remove adapter from the glow plug hole. 12. Repeat steps 8 through 13 for all remaining cylinders. All 8 cylinders must be tested to obtain valid test results. Record the readings. 13. The minimum compression in any one cylinder is 2069 kPa (300 psi). There should not be more than 345 kPa (50 psi) difference between a suspect cylinder and the average compression of all 8 cylinders. Note: Cylinder to cylinder variation may be at the high end of the specification on engines with less than 20,000 km (12,427 miles). * Normal-Compression builds up quickly and evenly to the specified compression for each cylinder. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications > Page 2684 * Piston Rings Leaking-Compression is low on the first stroke. Compression builds up with the following strokes but does not reach normal. * Valves Leaking-Compression is low on the first stroke. Compression usually does not build up on the following strokes. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Specifications Camshaft Gear/Sprocket: Specifications Camshaft Gear Bolt.............................................................................................................................. ......................................................234 Nm (173 lb ft.) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Camshaft Position Sensor Exciter Ring Replacement Camshaft: Service and Repair Camshaft Position Sensor Exciter Ring Replacement Camshaft Position Sensor Exciter Ring Replacement Removal Procedure 1. Remove the engine front cover. Refer to Engine Front Cover Replacement (See: Timing Components/Timing Cover/Service and Repair). Caution: Do not use an impact driver to remove or install the oil pump driven gear nut. Use of an impact driver may shear the oil pump drive gear pin in the crankshaft. 2. While holding the secondary oil pump shaft with a hex driver, remove the oil pump driven gear nut. 3. Remove the oil pump driven gear. Note: DO NOT remove the reluctor from the oil pump drive gear. The reluctor is timed to the gear and once removed the correct timing will be Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Camshaft Position Sensor Exciter Ring Replacement > Page 2693 lost. 4. Remove the oil pump drive gear and crankshaft sensor reluctor. 5. Remove the camshaft reluctor screws. 6. Remove the camshaft reluctor. 7. Clean and inspect the camshaft reluctor for damage. Replace the reluctor if damage is found. Installation Procedure 1. Position the camshaft reluctor to the camshaft gear. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the camshaft reluctor bolts. Tighten the bolts to 9 Nm (80 lb in). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Camshaft Position Sensor Exciter Ring Replacement > Page 2694 Note: Do not damage the teeth on the reluctor. 3. Install the oil pump drive gear and reluctor to the crankshaft. 4. Install the oil pump driven gear. Caution: Do not use an impact driver to remove or install the oil pump driven gear nut. Use of an impact driver may shear the oil pump drive gear pin in the crankshaft. 5. While holding the secondary oil pump shaft with a hex driver, install the oil pump driven gear nut. Tighten the nut to 100 Nm (74 lb ft). 6. Install the engine front cover. Refer to Engine Front Cover Replacement (See: Timing Components/Timing Cover/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Camshaft Position Sensor Exciter Ring Replacement > Page 2695 Camshaft: Service and Repair Camshaft Replacement Camshaft Replacement Special Tools * J-26900-12 - Dial Indicator * J-26900-13 - Magnetic Base * J-44643 - Flywheel Holding Tool For equivalent regional tools, refer to Special Tools (See: Tools and Equipment/Special Tools). Removal Procedure 1. Remove the engine assembly. Refer to Engine Replacement (See: Service and Repair/Removal and Replacement). 2. Remove the valve lifters. Refer to Valve Lifter Replacement (See: Lifter / Lash Adjuster/Service and Repair). 3. Install J-44643 - tool flush to the flywheel opening. 4. Remove the engine front cover. Refer to Engine Front Cover Replacement (See: Timing Components/Timing Cover/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Camshaft Position Sensor Exciter Ring Replacement > Page 2696 5. Remove the oil pump driven gear nut. 6. Remove the oil pump driven gear. Note: The crankshaft reluctor and the oil pump drive gear are timed together at the factory. Do not remove the crankshaft reluctor from the oil pump drive gear. 7. Remove the oil pump drive gear and crankshaft reluctor. * Do not remove the crankshaft reluctor bolts. * Do not damage the reluctor teeth. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Camshaft Position Sensor Exciter Ring Replacement > Page 2697 8. Using J-26900-12 - indicator (1) and J-26900-13 - base (2), measure the camshaft end play. * The production value is 0.050-0.114 mm (0.002-0.0045 in) and service limit is 0.20 mm (0.008 in). * Replace the camshaft gear or the camshaft thrust plate if measured value exceeds service limit. 9. Remove the camshaft reluctor screws. 10. Remove the camshaft reluctor. Warning The two piece cam gear must be bolted together to prevent the spring tension from unloading upon removal. Additionally, the two piece cam gear must remain bolted together until it is re-installed to the camshaft and fully engaged to the crankshaft gear. Failure to do so may result in personal injury. 11. Remove the camshaft exciter ring. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Camshaft Position Sensor Exciter Ring Replacement > Page 2698 12. Align the threaded hole with a suitable tool and install an exciter ring bolt to secure the spring tension. 13. Remove the camshaft thrust plate bolts through the holes in the camshaft gear. 14. In order to loosen the camshaft gear bolt use J-44643 - tool in order to hold the engine from turning. 15. Loosen the camshaft gear bolt and leave the bolt finger tight. 16. Remove the camshaft thrust plate bolts through the holes in the camshaft gear. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Camshaft Position Sensor Exciter Ring Replacement > Page 2699 17. Remove the camshaft with the camshaft gear attached. 18. Remove the camshaft gear bolt and discard. 19. Remove the camshaft gear. 20. Remove the camshaft thrust plate. 21. Clean and inspect the camshaft and bearings. Refer to Camshaft and Bearings Cleaning and Inspection (See: Service and Repair/Overhaul/21. Camshaft and Bearings Cleaning and Inspection). Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Camshaft Position Sensor Exciter Ring Replacement > Page 2700 1. Install the camshaft thrust plate to the camshaft. 2. Install the camshaft driven gear. 3. Install a NEW camshaft driven gear bolt. Leave the bolt finger tight. 4. Install the camshaft into the cylinder block, align the camshaft gear to the crankshaft gear as shown. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Camshaft Position Sensor Exciter Ring Replacement > Page 2701 5. Apply threadlock to the threads of the camshaft thrust plate bolts. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Specifications/Adhesives, Fluids, Lubricants, and Sealers) for the correct part number. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 6. Install the camshaft thrust plate bolts and tighten to 22 Nm (16 lb ft). Note: Use a suitable tool to relieve the spring tension wile removing the locking bolt. 7. Remove the exciter ring bolt that was installed to hold the spring tension of the two piece cam gear. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Camshaft Position Sensor Exciter Ring Replacement > Page 2702 8. Install the camshaft reluctor to the camshaft gear. 9. Install the camshaft reluctor bolts. Tighten the bolts in a cross-bolt pattern to 9 Nm (80 lb in). 10. Reinstall J-44643 - tool in the starter opening, if removed. 11. Install a NEW camshaft gear bolt and tighten to 234 Nm (173 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Camshaft Position Sensor Exciter Ring Replacement > Page 2703 12. Using J-26900-12 - indicator (1) and J-26900-13 - base (2) measure the camshaft end play. * The production value is 0.050-0.114 mm (0.002-0.0045 in) and service limit is 0.20 mm (0.008 in). * Replace the camshaft gear or the camshaft thrust plate if measured value exceeds the service limit. Note: Do not damage the teeth on the crankshaft reluctor. 13. Install the oil pump drive gear and reluctor to the crankshaft. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Camshaft Position Sensor Exciter Ring Replacement > Page 2704 14. Install the oil pump driven gear. 15. Install the oil pump driven gear nut and tighten to 100 Nm (74 lb ft). 16. Install the engine front cover. Refer to Engine Front Cover Replacement (See: Timing Components/Timing Cover/Service and Repair). 17. Install the engine assembly. Refer to Engine Replacement (See: Service and Repair/Removal and Replacement). 18. Install the valve lifters. Refer to Valve Lifter Replacement (See: Lifter / Lash Adjuster/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Service and Repair Lifter / Lash Adjuster: Service and Repair Valve Lifter Replacement Removal Procedure 1. Remove the cylinder head. Refer to Cylinder Head Replacement - Left Side (See: Cylinder Head Assembly/Service and Repair/Cylinder Head Replacement) or Cylinder Head Replacement - Right Side (See: Cylinder Head Assembly/Service and Repair/Cylinder Head Replacement). 2. Loosen the valve lifter guide retainer bolts. 3. Remove the valve lifter guide retainers. 4. Remove the valve lifter guides. 5. Remove the valve lifters. 6. If required, clean and inspect the lifters. Refer to Valve Lifter Cleaning and Inspection (See: Service and Repair/Overhaul/83. Valve Lifters and Guides Cleaning and Inspection). Installation Procedure 1. Apply clean engine oil to the roller and outside of the valve lifter. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Service and Repair > Page 2708 2. Install the valve lifter. 3. Install the valve lifter guides. 4. Install the valve lifter guide retainer. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Install the valve lifter guide retainer bolt. Tighten the bolt to 11 Nm (97 lb in). 6. Install the cylinder head. Refer to Cylinder Head Replacement - Left Side (See: Cylinder Head Assembly/Service and Repair/Cylinder Head Replacement) or Cylinder Head Replacement - Right Side (See: Cylinder Head Assembly/Service and Repair/Cylinder Head Replacement). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Push Rod > Component Information > Service and Repair Push Rod: Service and Repair Valve Rocker Arm, Shaft, and Push Rod Replacement Removal Procedure 1. Remove the lower valve rocker arm covers. Refer to Valve Rocker Arm Lower Cover Replacement - Left Side (See: Cylinder Head Assembly/Valve Cover/Service and Repair/Valve Rocker Arm Lower Cover Replacement - Left Side) or Valve Rocker Arm Lower Cover Replacement - Right Side (See: Cylinder Head Assembly/Valve Cover/Service and Repair/Valve Rocker Arm Lower Cover Replacement - Right Side). 2. Loosen the valve clearance lock nuts on each rocker arm. 3. Loosen the valve clearance adjusting screw on each rocker arm in order to relieve tension on the valvetrain. 4. Remove the rocker arm shaft assembly bolts in the sequence shown. Leave the bolts in the rocker arm shaft brackets. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Push Rod > Component Information > Service and Repair > Page 2712 5. Remove the rocker arm shaft assembly from the cylinder head. 6. Remove the valve bridge pins. 7. Remove the valve bridges. 8. Remove the pushrods. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Push Rod > Component Information > Service and Repair > Page 2713 9. Remove the rocker arm shaft bracket bolts (1), if necessary. 10. Remove the bracket (12), rocker arm (11), and spring (10), if necessary. 11. Remove the remaining rocker arms, springs, and brackets, if necessary. 12. If required, clean and inspect the valve rocker arm and shaft. Refer to Valve Rocker Arm and Shaft Cleaning and Inspection (See: Service and Repair/Overhaul/84. Valve Rocker Arm and Shaft Cleaning and Inspection). Installation Procedure 1. Lubricate the rocker arm shaft (7) and the inside of the rocker arms with clean engine oil, if necessary. 2. Install the rocker arm bracket (12) and bolt (1) on one end of the rocker arm shaft, if necessary. 3. Install the intake rocker arm (9), spring (10), exhaust rocker arm (11), and bracket (12) with bolt (1). Continue in the same sequence to the last bracket, if necessary. 4. Push the bracket (12) to compress the springs and then install the bolt (1), if necessary. 5. Lubricate the top of the valves, the valve bridge stem, the valve lifter bridge, and the valve spring caps with clean engine oil. 6. Install the valve bridge. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Push Rod > Component Information > Service and Repair > Page 2714 7. Install the valve bridge pins. 8. Lubricate the valve lifter end of the pushrod with clean engine oil. 9. Install the pushrods. To ensure the pushrod is properly installed, gently pull up on the pushrod. Resistance should be felt from the pushrod trying to lift the valve lifter. Caution: The pushrods must be correctly seated in the valve lifter and valve rocker arms before the rocker arm shaft assembly is torqued into place. Improper seating of the pushrods can cause damage to the pushrods or the valve rocker arm shaft assembly components. 10. Install the rocker arm shaft assembly. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 11. Tighten the rocker arm shaft bolts in the sequence shown. Tighten the bolts to 41 Nm (30 lb ft). 12. Adjust the valve clearance. Refer to Valve Clearance Adjustment (See: Cylinder Head Assembly/Valve Clearance/Adjustments). 13. Install the lower valve rocker arm covers. Refer to Valve Rocker Arm Lower Cover Replacement - Left Side (See: Cylinder Head Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Push Rod > Component Information > Service and Repair > Page 2715 Assembly/Valve Cover/Service and Repair/Valve Rocker Arm Lower Cover Replacement - Left Side) or Valve Rocker Arm Lower Cover Replacement - Right Side (See: Cylinder Head Assembly/Valve Cover/Service and Repair/Valve Rocker Arm Lower Cover Replacement - Right Side). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair Rocker Arm Assembly: Service and Repair Valve Rocker Arm, Shaft, and Push Rod Replacement Removal Procedure 1. Remove the lower valve rocker arm covers. Refer to Valve Rocker Arm Lower Cover Replacement - Left Side (See: Cylinder Head Assembly/Valve Cover/Service and Repair/Valve Rocker Arm Lower Cover Replacement - Left Side) or Valve Rocker Arm Lower Cover Replacement - Right Side (See: Cylinder Head Assembly/Valve Cover/Service and Repair/Valve Rocker Arm Lower Cover Replacement - Right Side). 2. Loosen the valve clearance lock nuts on each rocker arm. 3. Loosen the valve clearance adjusting screw on each rocker arm in order to relieve tension on the valvetrain. 4. Remove the rocker arm shaft assembly bolts in the sequence shown. Leave the bolts in the rocker arm shaft brackets. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair > Page 2719 5. Remove the rocker arm shaft assembly from the cylinder head. 6. Remove the valve bridge pins. 7. Remove the valve bridges. 8. Remove the pushrods. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair > Page 2720 9. Remove the rocker arm shaft bracket bolts (1), if necessary. 10. Remove the bracket (12), rocker arm (11), and spring (10), if necessary. 11. Remove the remaining rocker arms, springs, and brackets, if necessary. 12. If required, clean and inspect the valve rocker arm and shaft. Refer to Valve Rocker Arm and Shaft Cleaning and Inspection (See: Service and Repair/Overhaul/84. Valve Rocker Arm and Shaft Cleaning and Inspection). Installation Procedure 1. Lubricate the rocker arm shaft (7) and the inside of the rocker arms with clean engine oil, if necessary. 2. Install the rocker arm bracket (12) and bolt (1) on one end of the rocker arm shaft, if necessary. 3. Install the intake rocker arm (9), spring (10), exhaust rocker arm (11), and bracket (12) with bolt (1). Continue in the same sequence to the last bracket, if necessary. 4. Push the bracket (12) to compress the springs and then install the bolt (1), if necessary. 5. Lubricate the top of the valves, the valve bridge stem, the valve lifter bridge, and the valve spring caps with clean engine oil. 6. Install the valve bridge. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair > Page 2721 7. Install the valve bridge pins. 8. Lubricate the valve lifter end of the pushrod with clean engine oil. 9. Install the pushrods. To ensure the pushrod is properly installed, gently pull up on the pushrod. Resistance should be felt from the pushrod trying to lift the valve lifter. Caution: The pushrods must be correctly seated in the valve lifter and valve rocker arms before the rocker arm shaft assembly is torqued into place. Improper seating of the pushrods can cause damage to the pushrods or the valve rocker arm shaft assembly components. 10. Install the rocker arm shaft assembly. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 11. Tighten the rocker arm shaft bolts in the sequence shown. Tighten the bolts to 41 Nm (30 lb ft). 12. Adjust the valve clearance. Refer to Valve Clearance Adjustment (See: Cylinder Head Assembly/Valve Clearance/Adjustments). 13. Install the lower valve rocker arm covers. Refer to Valve Rocker Arm Lower Cover Replacement - Left Side (See: Cylinder Head Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair > Page 2722 Assembly/Valve Cover/Service and Repair/Valve Rocker Arm Lower Cover Replacement - Left Side) or Valve Rocker Arm Lower Cover Replacement - Right Side (See: Cylinder Head Assembly/Valve Cover/Service and Repair/Valve Rocker Arm Lower Cover Replacement - Right Side). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications Connecting Rod Bearing: Specifications Connecting Rod Connecting Rod Bearing Clearance - Service Limit.................................................. .........................................................................................................................................0.10 mm (0.0039 in.) Connecting Rod Bearing Clearance - Production Value................................................... .........................................................................................................0.036-0.077 mm (0.0014-0.0030 in.) Connecting Rod Bore Diameter - Bearing End - Production Value................................................ ........................................................................................................62.958-62.979 mm (2.4789-2.4795 in.) Connecting Rod Bore Diameter - Pin End - Service Limit..................................... ....................................................................................................................................................34.53 mm (1.3594 in.) Connecting Rod Bore Diameter - Pin End - Production Value................................... .....................................................................................................................34.512-34.522 mm (1.3587-1.3591 in.) Connecting Rod Length........................................................................................ .....................................................................................163.0 mm (6.42 in.) Connecting Rod Side Clearance - Service Limit..................................................................................................................... ......................................................................0.54 mm (0.0213 in.) Connecting Rod Side Clearance Production Value.................................................................................................................................. ..............................0.31-0.49 mm (0.0122-0.0193 in.) Crankshaft Connecting Rod Journal Diameter - Service Limit....................................................................................................................................... ..................................................62.88 mm (2.4756 in.) Connecting Rod Journal Diameter Production Value.................................................................................................................................. ......................62.902-62.922 mm (2.4764-2.4772 in.) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications Connecting Rod: Specifications Connecting Rod Connecting Rod Bearing Clearance - Service Limit.................................................. .........................................................................................................................................0.10 mm (0.0039 in.) Connecting Rod Bearing Clearance - Production Value................................................... .........................................................................................................0.036-0.077 mm (0.0014-0.0030 in.) Connecting Rod Bore Diameter - Bearing End - Production Value................................................ ........................................................................................................62.958-62.979 mm (2.4789-2.4795 in.) Connecting Rod Bore Diameter - Pin End - Service Limit..................................... ....................................................................................................................................................34.53 mm (1.3594 in.) Connecting Rod Bore Diameter - Pin End - Production Value................................... .....................................................................................................................34.512-34.522 mm (1.3587-1.3591 in.) Connecting Rod Length........................................................................................ .....................................................................................163.0 mm (6.42 in.) Connecting Rod Side Clearance - Service Limit..................................................................................................................... ......................................................................0.54 mm (0.0213 in.) Connecting Rod Side Clearance Production Value.................................................................................................................................. ..............................0.31-0.49 mm (0.0122-0.0193 in.) Crankshaft Connecting Rod Journal Diameter - Service Limit....................................................................................................................................... ..................................................62.88 mm (2.4756 in.) Connecting Rod Journal Diameter Production Value.................................................................................................................................. ......................62.902-62.922 mm (2.4764-2.4772 in.) Connecting Rod Cap Bolt - Angular Tightening Method ...................................................................... ....................................................................................................................................1st Step 64 Nm (47 lb ft.) .............................................................................................................................................. ....................................................................2nd Step 30 degrees ....................................................... ............................................................................................................................................................3 rd Step 30 degrees Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications Crankshaft Main Bearing: Specifications Crankshaft Main Bearing Clearance - Service Limit............................................................................. ..............................................................................................................0.14 mm (0.0055 in.) Crankshaft Main Bearing Clearance - Production Value...................................................................... ......................................................................................0.039-0.070 mm (0.0015-0.0028 in.) Crankshaft Bearing Cap Bolt 1st Step ................................................................................................. ....................................................................................................... 98 Nm (72 lb ft.) 2nd Step ........... .............................................................................................................................................................. ........................... 132 Nm (97 lb ft.) 3rd Step ...................................................................................... ........................................................................................................................... 60 degrees Crankshaft Bearing Cap Side Bolt........................................................................................................ .........................................................70 Nm (52 lb ft.) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications Crankshaft: Specifications Crankshaft Connecting Rod Journal Diameter - Service Limit............................................................. ............................................................................................................................62.88 mm (2.4756 in.) Connecting Rod Journal Diameter - Production Value................................................................... .....................................................................................62.902-62.922 mm (2.4764-2.4772 in.) Crankshaft End Play - Service Limit..................................................................................................... ......................................................................................0.54 mm (0.0213 in.) Crankshaft End Play Production Value.................................................................................................................................. ............................0.04-0.205 mm (0.0016-0.0081 in.) Crankshaft Main Bearing Clearance - Service Limit...................................................................................................................................................... .....................................0.14 mm (0.0055 in.) Crankshaft Main Bearing Clearance - Production Valu e............................................................................................................................................................ 0.039-0.070 mm (0.0015-0.0028 in.) Crankshaft Main Journal Diameter - Service Limit..................... .............................................................................................................................................................. ......79.89 mm (3.1453 in.) Crankshaft Main Journal Diameter - Production Value.............................. ..........................................................................................................................79.905-79.925 mm (3.1459-3.1466 in.) Crankshaft Runout - Service Limit........................................................................ ...................................................................................................................0.44 mm (0.0173 in.) Crankshaft Runout - Production Value................................................................................................. ....................................................................................0.05 mm (0.0020 in.) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Technical Service Bulletins > Customer Interest for Engine Block Heater: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps Engine Block Heater: Customer Interest Engine - MIL ON P0116/P1400 Set In Very Cold Temps TECHNICAL Bulletin No.: 10-06-04-008A Date: January 24, 2011 Subject: Malfunction Indicator Lamp (MIL) Illuminated at Very Cold Ambient Temperatures When Using Engine Coolant Heater, DTC P0116 and/or P1400 Set (Relocate Engine Coolant Temperature (ECT) Sensor and Engine Coolant Heater Cord) Models: 2006-2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2006-2010 Cadillac Escalade 2006-2007 Chevrolet Monte Carlo 2006-2009 Chevrolet Impala SS, TrailBlazer 2006-2010 Chevrolet Avalanche, Express, Silverado Tahoe 2006-2009 GMC Envoy 2006-2010 GMC Savana, Sierra, Yukon 2006-2008 Pontiac Grand Prix 2006-2009 Saab 9-7X Equipped with V8 Engine RPO LC9, LH6, LH8, LH9, L76, LS2, LS4, LFA, LZ1, L92, L94, L9H or L20, L96, LMF, LMG, LY2, LY5, LY6 Please Refer to GMVIS Attention: To properly correct this condition, you must follow both of the procedures to relocate the ECT sensor and the engine coolant heater cord. Supercede: This bulletin is being revised to add cast iron block engine RPOs and to update the Warranty Information coverage period. Please discard Corporate Bulletin Number 10-06-04-008 (Section 06 - Engine/Propulsion System). Condition Some customers may comment that the malfunction indicator lamp (MIL) illuminates after starting the vehicle when they were using the engine coolant heater in very cold ambient temperatures. This usually occurs in a range of -23 to -40°C (-10 to -40°F) or colder. The technician may observe on a scan tool DTC P0116 and/or P1400 set as Current or in History. Cause This condition may be caused by the engine control module (ECM) determining that the ignition OFF time requirement has been met at start-up and interpreting the temperature difference between the engine coolant temperature (ECT) sensor and the intake air temperature (IAT) sensor as being outside of a calibrated range. Correction Important DO NOT replace the ECM for this condition. Relocating the ECT Sensor 1. Turn ON the ignition with the engine OFF. 2. Perform the diagnostic system check - vehicle. Refer to Diagnostic System Check - Vehicle in SI. ‹› If DTC P0116 and/or P1400 are set and the customer WAS using the engine coolant heater, proceed to Step 3. ‹› If DTC P0116 and/or P1400 are set and the customer WAS NOT using the engine coolant heater, refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. 3. Turn OFF the ignition. Warning To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Technical Service Bulletins > Customer Interest for Engine Block Heater: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 2744 under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator are still hot. 4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle. Refer to Cooling System Draining and Filling in SI. 7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor. 10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J 38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle. 13. Disconnect the wiring harness connector from the ECT sensor (2). 14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT sensor in the hole of the cylinder head where the plug was removed. Tighten Tighten to 20 Nm (15 lb ft). 18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was removed Tighten Tighten to 20 Nm (15 lb ft). Important Leave enough wire attached to the ECT sensor harness connector in order to create manageable splices that are at least 40 mm (1.5 in) away from the other splice. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Technical Service Bulletins > Customer Interest for Engine Block Heater: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 2745 20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit. Cut off the ECT sensor harness connector and wiring. 21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured TO or WITHIN an existing protective conduit. Note This step is to set up and verify the length of wiring that is required before cutting. 22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the appropriate length. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. 26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit using tie straps. Important You MUST run the engine at the specified RPM and until it reaches normal operating temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool down in order to top off the coolant level as needed. 28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI. 29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan tool to clear any DTCs. Relocating the Engine Coolant Heater Cord Important For reference, the procedure and graphics that are shown are from a Chevrolet Silverado, but are similar for the other vehicles listed above. 1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit from the engine compartment in order to determine the required extension cord length. 3. Obtain an extension cord with the following features: - 120 volt - 14/3 gauge - 15A capacity - Three prong - Polarized plug and receptacle - Chemical resistant - Grounded terminals - Designed for use in a cold outdoor environment - Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight - Maximum length of 2.5-3 m (8-10 ft) 4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N 12345579 (in Canada, use P/N 10953481) or an equivalent. 6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Technical Service Bulletins > Customer Interest for Engine Block Heater: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 2746 7. Wrap electrical tape around the connection as shown. 8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to the engine coolant crossover pipe as shown. 9. Continue to route the extension cord to the exit location desired by the customer as shown. 10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the engine coolant heater cord to the vehicle that were released to provide length. Part Information The extension cord may be obtained at any of the following outlets: - Lowes* - Home Depot* - Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number: CWRSJTOW3C14-10 USA: Cords should bear the UL symbol. Canada: Cords should bear the ULc symbol or CSA approval. *We believe these sources and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from these firms or for any such items that may be available from other sources. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Technical Service Bulletins > Customer Interest for Engine Block Heater: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 2747 Warranty Information (excluding Saab Models) For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Block Heater: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps Engine Block Heater: All Technical Service Bulletins Engine - MIL ON P0116/P1400 Set In Very Cold Temps TECHNICAL Bulletin No.: 10-06-04-008A Date: January 24, 2011 Subject: Malfunction Indicator Lamp (MIL) Illuminated at Very Cold Ambient Temperatures When Using Engine Coolant Heater, DTC P0116 and/or P1400 Set (Relocate Engine Coolant Temperature (ECT) Sensor and Engine Coolant Heater Cord) Models: 2006-2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2006-2010 Cadillac Escalade 2006-2007 Chevrolet Monte Carlo 2006-2009 Chevrolet Impala SS, TrailBlazer 2006-2010 Chevrolet Avalanche, Express, Silverado Tahoe 2006-2009 GMC Envoy 2006-2010 GMC Savana, Sierra, Yukon 2006-2008 Pontiac Grand Prix 2006-2009 Saab 9-7X Equipped with V8 Engine RPO LC9, LH6, LH8, LH9, L76, LS2, LS4, LFA, LZ1, L92, L94, L9H or L20, L96, LMF, LMG, LY2, LY5, LY6 Please Refer to GMVIS Attention: To properly correct this condition, you must follow both of the procedures to relocate the ECT sensor and the engine coolant heater cord. Supercede: This bulletin is being revised to add cast iron block engine RPOs and to update the Warranty Information coverage period. Please discard Corporate Bulletin Number 10-06-04-008 (Section 06 - Engine/Propulsion System). Condition Some customers may comment that the malfunction indicator lamp (MIL) illuminates after starting the vehicle when they were using the engine coolant heater in very cold ambient temperatures. This usually occurs in a range of -23 to -40°C (-10 to -40°F) or colder. The technician may observe on a scan tool DTC P0116 and/or P1400 set as Current or in History. Cause This condition may be caused by the engine control module (ECM) determining that the ignition OFF time requirement has been met at start-up and interpreting the temperature difference between the engine coolant temperature (ECT) sensor and the intake air temperature (IAT) sensor as being outside of a calibrated range. Correction Important DO NOT replace the ECM for this condition. Relocating the ECT Sensor 1. Turn ON the ignition with the engine OFF. 2. Perform the diagnostic system check - vehicle. Refer to Diagnostic System Check - Vehicle in SI. ‹› If DTC P0116 and/or P1400 are set and the customer WAS using the engine coolant heater, proceed to Step 3. ‹› If DTC P0116 and/or P1400 are set and the customer WAS NOT using the engine coolant heater, refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. 3. Turn OFF the ignition. Warning To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Block Heater: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 2753 under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator are still hot. 4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle. Refer to Cooling System Draining and Filling in SI. 7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor. 10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J 38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle. 13. Disconnect the wiring harness connector from the ECT sensor (2). 14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT sensor in the hole of the cylinder head where the plug was removed. Tighten Tighten to 20 Nm (15 lb ft). 18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was removed Tighten Tighten to 20 Nm (15 lb ft). Important Leave enough wire attached to the ECT sensor harness connector in order to create manageable splices that are at least 40 mm (1.5 in) away from the other splice. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Block Heater: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 2754 20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit. Cut off the ECT sensor harness connector and wiring. 21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured TO or WITHIN an existing protective conduit. Note This step is to set up and verify the length of wiring that is required before cutting. 22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the appropriate length. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. 26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit using tie straps. Important You MUST run the engine at the specified RPM and until it reaches normal operating temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool down in order to top off the coolant level as needed. 28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI. 29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan tool to clear any DTCs. Relocating the Engine Coolant Heater Cord Important For reference, the procedure and graphics that are shown are from a Chevrolet Silverado, but are similar for the other vehicles listed above. 1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit from the engine compartment in order to determine the required extension cord length. 3. Obtain an extension cord with the following features: - 120 volt - 14/3 gauge - 15A capacity - Three prong - Polarized plug and receptacle - Chemical resistant - Grounded terminals - Designed for use in a cold outdoor environment - Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight - Maximum length of 2.5-3 m (8-10 ft) 4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N 12345579 (in Canada, use P/N 10953481) or an equivalent. 6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Block Heater: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 2755 7. Wrap electrical tape around the connection as shown. 8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to the engine coolant crossover pipe as shown. 9. Continue to route the extension cord to the exit location desired by the customer as shown. 10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the engine coolant heater cord to the vehicle that were released to provide length. Part Information The extension cord may be obtained at any of the following outlets: - Lowes* - Home Depot* - Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number: CWRSJTOW3C14-10 USA: Cords should bear the UL symbol. Canada: Cords should bear the ULc symbol or CSA approval. *We believe these sources and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from these firms or for any such items that may be available from other sources. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Block Heater: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 2756 Warranty Information (excluding Saab Models) For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Service and Repair > Coolant Heater Replacement Engine Block Heater: Service and Repair Coolant Heater Replacement Coolant Heater Replacement (LMM) Removal Procedure 1. Drain the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Cooling System/Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Cooling System/Service and Repair). 2. Remove the right front tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 3. Remove the right engine mount. Refer to Engine Mount Replacement - Right Side (See: Drive Belts, Mounts, Brackets and Accessories/Engine Mount/Service and Repair). 4. Disconnect the engine coolant heater cord. 5. Loosen the coolant heater bolt. 6. Remove the engine coolant heater from the engine block. 7. Do not score the machined surface of the hole. 8. Grasp the plug with pliers. 9. Pull the plug from the engine block. 10. Clean the core plug hole in order to remove the following substances: * Burrs * Compound * Paint * Rough spots Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Service and Repair > Coolant Heater Replacement > Page 2759 1. Coat the O-ring seal and the cleaned surface of the plug opening with water resistant high-temperature grease lubricant GM P/N 1052196 (Canadian P/N 5264008), or the equivalent. Note: Avoid element contact with the inside walls of the engine block. 2. Align the coolant heater element to point towards the top of the engine. 3. Tightly push the coolant heater into the engine block. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Tighten the bolt on the engine coolant heater until both of the locking wings draw tightly against the inner wall of the engine block. Tighten the bolt to 2 Nm (18 lb in). Caution: The heater cord must not touch the engine, hot pipes, manifold, or any moving parts. Route the cord to the left front of the engine compartment securing with tie straps as necessary to prevent damage. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Service and Repair > Coolant Heater Replacement > Page 2760 5. Connect the heater cord to the coolant heater. 6. Remove the right engine mount. Refer to Engine Mount Replacement - Right Side (See: Drive Belts, Mounts, Brackets and Accessories/Engine Mount/Service and Repair). 7. Install the right front tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 8. Fill the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Cooling System/Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Cooling System/Service and Repair). 9. Inspect for coolant leaks. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Service and Repair > Coolant Heater Replacement > Page 2761 Engine Block Heater: Service and Repair Coolant Heater Cord Replacement Coolant Heater Cord Replacement (LMM) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications Harmonic Balancer - Crankshaft Pulley: Specifications Crankshaft Balancer Bolt 1st Step........................................................................................................ .................................................................................................100 Nm (74 lb ft.) 2nd Step................. .............................................................................................................................................................. ..................................105 degrees Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 2765 Harmonic Balancer - Crankshaft Pulley: Service and Repair Crankshaft Balancer Replacement Special Tools J 44643 Flywheel Holding Tool Removal Procedure 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 2. Remove the right wheelhouse panel. Refer to Front Wheelhouse Liner Replacement - Right Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side)Front Wheelhouse Liner Replacement - Right Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side). 3. Remove the starter motor bolts. Reposition the starter aside. The wiring to the starter does not require removal. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 2766 4. Install J 44643 in order to hold the flywheel. 5. Remove the lower fan shroud. Refer to Engine Coolant Fan Lower Shroud Replacement (Mechanical) (See: Cooling System/Fan Shroud/Service and Repair). 6. Remove the crankshaft balancer bolt. 7. Remove the crankshaft balancer. 8. If required, clean and inspect the crankshaft balancer. Refer to Crankshaft Balancer Cleaning and Inspection (See: Service and Repair/Overhaul/19. Crankshaft Balancer Cleaning and Inspection). Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 2767 1. Lubricate the crankshaft balancer internal hub with clean engine oil. 2. Install the crankshaft balancer on the crankshaft. 3. Lubricate the crankshaft balancer bolt with clean engine oil. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the crankshaft balancer bolt and washer. 1. Tighten the bolt a first pass to 100 Nm (74 lb ft). 2. Tighten the bolt a second pass an additional 105 degrees. 5. Remove J 44643 . Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 2768 6. Position the starter motor. 7. Install the starter motor bolts and tighten to 78 Nm (58 lb ft). 8. Install the right wheelhouse panel. Refer to Front Wheelhouse Liner Replacement - Right Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side)Front Wheelhouse Liner Replacement - Right Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side). 9. Install the lower fan shroud. Refer to Engine Coolant Fan Lower Shroud Replacement (Mechanical) (See: Cooling System/Fan Shroud/Service and Repair). 10. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications Piston: Specifications Pistons and Pins Piston-Piston Diameter............................................................................................. ..............................................102.948-102.960 mm (4.0531-4.0535 in.) Piston-Piston Pin Bore Diam eter................................................................................................................................34.504-34.512 mm (1.3584-1.3587 in.) Pin-Piston Pin Clearance to Piston Pin Bore - Service Limit.......................... .............................................................................................................................................................. .0.017 mm (0.0007 in.) Pin-Piston Pin Clearance to Piston Pin Bore - Production Value.................... ........................................................................................................................................0.004-0.017 mm (0.0002-0.0007 in.) Pin-Piston Pin Diameter - Service Limit......................................................... ................................................................................................................................34.45 mm (1.3563 in.) Pin-Piston Pin Diameter - Production Value................................................................................... .........................................................................34.495-34.5 mm (1.3581-1.3583 in.) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications Piston Ring: Specifications Piston Rings Piston Ring End Gap-First Compression Ring - Service Limit........................................ ...................................................................................................................................................1.37 mm (0.0539 in.) Piston Ring End Gap-First Compression Ring - Production Value............................ ......................................................................................................................................0.3-0.45 mm (0.0118-0.0177 in.) Piston Ring End Gap-Second Compression Ring - Service Limit......................... .............................................................................................................................................................. ....1.35 mm (0.0531 in.) Piston Ring End Gap-Second Compression Ring - Production Value........... .....................................................................................................................................................0.500.65 mm (0.0197-0.0256 in.) Piston Ring End Gap-Oil Control Ring - Service Limit........................... .............................................................................................................................................................. ..1.20 mm (0.0472 in.) Piston Ring End Gap-Oil Control Ring - Production Value............................... .................................................................................................................................0.15-0.35 mm (0.0059-0.0138 in.) Piston Ring to Groove Clearance-First Compression Ring - Service Limit........... .............................................................................................................................................................. ..................0.26 mm (0.0102 in.) Piston Ring to Groove Clearance-First Compression Ring Production Value.................................................................................................................................. ..............................0.08-0.17 mm (0.0030-0.0067 in.) Piston Ring to Groove Clearance-Second Compression Ring - Service Limit........................................................................................................ ...................................................................................0.10 mm (0.0039 in.) Piston Ring to Groove Clearance-Second Compression Ring - Production Value................................................................... .............................................................................................0.01-0.03 mm (0.0004-0.0012 in.) Piston Ring to Groove Clearance-Oil Control Ring - Service Limit.................................................................. .........................................................................................................................0.12 mm (0.0047 in.) Piston Ring to Groove Clearance-Oil Control Ring - Production Value................................................ ................................................................................................................0.01-0.03 mm (0.0004-0.0012 in.) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Specifications Valve Clearance: Specifications Valve Clearance Adjustment Specifications Valve Lash ........................................................................................................................................... ...................................................... 0.3 mm (0.012 in) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Adjustments > On Vehicle Valve Clearance: Adjustments On Vehicle Valve Clearance Adjustment 1. Remove the fan clutch. Refer to Fan Clutch Replacement (Diesel) (See: Cooling System/Radiator Cooling Fan/Fan Clutch/Service and Repair). 2. Remove the upper valve rocker arm covers. Refer to Valve Rocker Arm Upper Cover Replacement - Left Side (See: Valve Cover/Service and Repair/Valve Rocker Arm Upper Cover Replacement - Left Side) and Valve Rocker Arm Upper Cover Replacement - Right Side (See: Valve Cover/Service and Repair/Valve Rocker Arm Upper Cover Replacement - Right Side). 3. Rotate the crankshaft in order to bring the number 1 cylinder to top dead center (TDC) of the compression stroke. The number 1 cylinder is the front cylinder on the right bank. The mark on the crankshaft balancer should be aligned with the mark on the engine. 4. Loosen the valve adjusting screws. 5. Insert a feeler gauge between the tip of the rocker arm and the valve bridge. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Adjustments > On Vehicle > Page 2781 6. Adjust the valve lash to 0.3 mm (0.012 in). Refer to Valve Clearance Adjustment Specifications (See: ) to determine which valves can be adjusted when the engine is at TDC. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 7. Tighten the lock nut. Tighten nut to 22 Nm (16 lb ft). 8. Rotate the crankshaft one revolution in order to bring the number 1 cylinder to TDC of the exhaust stroke. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Adjustments > On Vehicle > Page 2782 9. Loosen the valve adjusting screws. 10. Insert a feeler gauge between the tip of the rocker arm and the valve bridge. 11. Adjust the valve clearance to 0.3 mm (0.012 in). Refer to Valve Clearance Adjustment Specifications (See: ) to determine which valves can be adjusted when the engine is at TDC. 12. Tighten the lock nut. Tighten nut to 22 Nm (16 lb ft). 13. Install the upper valve rocker arm covers. Refer to Valve Rocker Arm Upper Cover Replacement - Left Side (See: Valve Cover/Service and Repair/Valve Rocker Arm Upper Cover Replacement - Left Side) and Valve Rocker Arm Upper Cover Replacement - Right Side (See: Valve Cover/Service and Repair/Valve Rocker Arm Upper Cover Replacement - Right Side). 14. Install the fan clutch. Refer to Fan Clutch Replacement (Diesel) (See: Cooling System/Radiator Cooling Fan/Fan Clutch/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Adjustments > On Vehicle > Page 2783 Valve Clearance: Adjustments Off Vehicle Valve Clearance Adjustment 1. Rotate the crankshaft to bring the number 1 cylinder at the top dead center of the compression stroke. The number 1 cylinder is the front cylinder on the right bank. The mark on the crankshaft balancer should be aligned with the mark on the engine. 2. Loosen the valve adjusting screws. 3. Insert a feeler gauge between the tip of the rocker arm and the valve bridge. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Adjustments > On Vehicle > Page 2784 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Adjust the valve lash to 0.3 mm (0.012 in). Refer to Valve Clearance Adjustment Specifications (See: ) to determine which valves that can be adjusted when the engine is at Top Dead Center. Tighten the valve lash lock nut to 22 Nm (16 lb ft). 5. Rotate the crankshaft one revolution to bring the number 1 cylinder at Top Dead Center of the exhaust stroke. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Adjustments > On Vehicle > Page 2785 6. Adjust the valve lash to 0.3 mm (0.012 in). Refer to Valve Clearance Adjustment Specifications (See: ) to determine which valves that can be adjusted when the engine is at Top Dead Center. Tighten the valve lash lock nut to 22 Nm (16 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair Fuel Pressure Relief Valve Replacement Removal Procedure 1. Remove the glow plug module and bracket. Refer to Glow Plug Control Module Replacement (See: Powertrain Management/Glow Plug System/Glow Plug Control Module/Service and Repair). 2. Remove the fuel pressure relief valve from the left fuel rail. Installation Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the fuel pressure relief valve to the left fuel rail. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service and Repair > Page 2789 Tighten the valve to 100 Nm (74 lb ft). 2. Install the glow plug module and bracket. Refer to Glow Plug Control Module Replacement (See: Powertrain Management/Glow Plug System/Glow Plug Control Module/Service and Repair). 3. Prime the fuel system. Refer to Fuel System Priming (See: Powertrain Management/Fuel Delivery and Air Induction/Service and Repair/Fuel System Priming). 4. Start the engine. If the engine stalls, repeat the above step. 5. Once the engine starts, inspect for fuel leaks. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair Rocker Arm Assembly: Service and Repair Valve Rocker Arm, Shaft, and Push Rod Replacement Removal Procedure 1. Remove the lower valve rocker arm covers. Refer to Valve Rocker Arm Lower Cover Replacement - Left Side (See: Valve Cover/Service and Repair/Valve Rocker Arm Lower Cover Replacement - Left Side) or Valve Rocker Arm Lower Cover Replacement - Right Side (See: Valve Cover/Service and Repair/Valve Rocker Arm Lower Cover Replacement - Right Side). 2. Loosen the valve clearance lock nuts on each rocker arm. 3. Loosen the valve clearance adjusting screw on each rocker arm in order to relieve tension on the valvetrain. 4. Remove the rocker arm shaft assembly bolts in the sequence shown. Leave the bolts in the rocker arm shaft brackets. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair > Page 2793 5. Remove the rocker arm shaft assembly from the cylinder head. 6. Remove the valve bridge pins. 7. Remove the valve bridges. 8. Remove the pushrods. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair > Page 2794 9. Remove the rocker arm shaft bracket bolts (1), if necessary. 10. Remove the bracket (12), rocker arm (11), and spring (10), if necessary. 11. Remove the remaining rocker arms, springs, and brackets, if necessary. 12. If required, clean and inspect the valve rocker arm and shaft. Refer to Valve Rocker Arm and Shaft Cleaning and Inspection (See: Service and Repair/Overhaul/84. Valve Rocker Arm and Shaft Cleaning and Inspection). Installation Procedure 1. Lubricate the rocker arm shaft (7) and the inside of the rocker arms with clean engine oil, if necessary. 2. Install the rocker arm bracket (12) and bolt (1) on one end of the rocker arm shaft, if necessary. 3. Install the intake rocker arm (9), spring (10), exhaust rocker arm (11), and bracket (12) with bolt (1). Continue in the same sequence to the last bracket, if necessary. 4. Push the bracket (12) to compress the springs and then install the bolt (1), if necessary. 5. Lubricate the top of the valves, the valve bridge stem, the valve lifter bridge, and the valve spring caps with clean engine oil. 6. Install the valve bridge. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair > Page 2795 7. Install the valve bridge pins. 8. Lubricate the valve lifter end of the pushrod with clean engine oil. 9. Install the pushrods. To ensure the pushrod is properly installed, gently pull up on the pushrod. Resistance should be felt from the pushrod trying to lift the valve lifter. Caution: The pushrods must be correctly seated in the valve lifter and valve rocker arms before the rocker arm shaft assembly is torqued into place. Improper seating of the pushrods can cause damage to the pushrods or the valve rocker arm shaft assembly components. 10. Install the rocker arm shaft assembly. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 11. Tighten the rocker arm shaft bolts in the sequence shown. Tighten the bolts to 41 Nm (30 lb ft). 12. Adjust the valve clearance. Refer to Valve Clearance Adjustment (See: Valve Clearance/Adjustments). 13. Install the lower valve rocker arm covers. Refer to Valve Rocker Arm Lower Cover Replacement - Left Side (See: Valve Cover/Service and Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair > Page 2796 Repair/Valve Rocker Arm Lower Cover Replacement - Left Side) or Valve Rocker Arm Lower Cover Replacement - Right Side (See: Valve Cover/Service and Repair/Valve Rocker Arm Lower Cover Replacement - Right Side). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Rocker Arm Upper Cover Replacement - Left Side Valve Cover: Service and Repair Valve Rocker Arm Upper Cover Replacement - Left Side Valve Rocker Arm Upper Cover Replacement - Left Side Removal Procedure 1. Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement (See: Intake Manifold/Service and Repair/Intake Manifold Cover Replacement). 2. Drain the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Cooling System/Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Cooling System/Service and Repair). 3. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). Note: After removing the charged air cooler duct, cover the turbocharger opening with tape in order to prevent entry of objects. 4. Remove the charged air cooler inlet duct. Refer to Charge Air Cooler Inlet Pipe Replacement (See: Powertrain Management/Fuel Delivery and Air Induction/Turbocharger/Intercooler/Intercooler Duct/Service and Repair/Charge Air Cooler Inlet Pipe Replacement). 5. Remove the battery cable to generator nut. 6. If equipped, remove the battery cable to the auxiliary generator. 7. Remove the battery cable harness clip from the bracket. 8. Remove the battery cable junction block bolt (1) from the power steering pump. 9. Move and secure the battery cables out of the way. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Rocker Arm Upper Cover Replacement - Left Side > Page 2801 10. Disconnect the fuel lines. Refer to Metal Collar Quick Connect Fitting Service (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Metal Collar Quick Connect Fitting Service). 11. Remove the fuel hose bracket nut. 12. Disconnect the main engine electrical harness connectors. Lift up on the latches (1) in order to disconnect the connectors. 13. Open the harness clip (2). 14. Remove the main engine electrical harness connectors. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Rocker Arm Upper Cover Replacement - Left Side > Page 2802 15. Disconnect the turbocharger vane position sensor electrical connector (1). 16. Unclip the main engine electrical harness connectors from the main electrical connector harness bracket. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Rocker Arm Upper Cover Replacement - Left Side > Page 2803 17. Remove the main electrical connector harness bracket bolts (1). 18. Remove the main electrical connector harness bracket (2). 19. Remove the water outlet tube. Refer to Water Outlet Tube Replacement (LU3) (See: Cooling System/Coolant Outlet/Service and Repair)Water Outlet Tube Replacement (LMM) (See: Cooling System/Coolant Outlet/Service and Repair). 20. Remove the auxiliary generator, if equipped. Refer to Auxiliary Generator Replacement (6.6L) (See: Starting and Charging/Charging System/Alternator/Service and Repair/Auxiliary Generator Replacement (6.6L)). 21. Remove the positive crankcase ventilation (PCV) hose/pipe. Refer to Positive Crankcase Ventilation Hose/Pipe/Tube Replacement (See: Powertrain Management/Emission Control Systems/Positive Crankcase Ventilation/PCV Valve Hose/Service and Repair). 22. Prior to removing the fuel injector pipes, use compressed air to blow any debris from between the injector line and fittings. Wipe the fittings clean of debris. 23. Spray lithium grease between the fuel injector line and fittings to assist in containing any debris during removal. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Specifications/Adhesives, Fluids, Lubricants, and Sealers) for the correct part number. Caution: DO NOT use compressed air to clean debris from the fuel injector inlet after the fuel line is removed. Using compressed air can allow debris to enter the fuel injector inlet and damage the fuel injector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Rocker Arm Upper Cover Replacement - Left Side > Page 2804 24. Remove the left fuel injector pipes. 25. Remove the upper valve rocker arm cover bolts. 26. Remove the upper valve rocker arm cover. 27. Remove the upper valve rocker arm cover gasket. 28. Inspect the upper valve rocker arm cover gasket for damage, replace if necessary. Otherwise reuse the old gasket. 29. If required, clean and inspect the upper valve rocker arm cover. Refer to Valve Rocker Arm Cover Cleaning and Inspection - Upper (See: Service and Repair/Overhaul/88. Valve Rocker Arm Cover Cleaning and Inspection - Upper). Installation Procedure 1. Install the valve rocker arm cover gasket. 2. Install the upper valve rocker arm cover. 3. Install the upper valve rocker arm cover bolts. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Rocker Arm Upper Cover Replacement - Left Side > Page 2805 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Tighten the upper valve rocker arm cover bolts in the sequence shown. Tighten the bolts to 8 Nm (71 lb in). Caution: Ensure proper torquing of the fuel injector line. An under-torqued fuel injector line will not seal properly and an over-torqued fuel injector line may damage the fuel injector fitting. An improperly sealed or damaged fuel injector line or fuel injector fitting will cause a fuel leak. 5. Install the left fuel injector pipes. Tighten the pipes to 41 Nm (30 lb ft). 6. Install the water outlet tube. Refer to Water Outlet Tube Replacement (LU3) (See: Cooling System/Coolant Outlet/Service and Repair)Water Outlet Tube Replacement (LMM) (See: Cooling System/Coolant Outlet/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Rocker Arm Upper Cover Replacement - Left Side > Page 2806 7. Install the auxiliary generator, if equipped. Refer to Auxiliary Generator Replacement (6.6L) (See: Starting and Charging/Charging System/Alternator/Service and Repair/Auxiliary Generator Replacement (6.6L)). 8. Install the PCV hose/pipe. Refer to Positive Crankcase Ventilation Hose/Pipe/Tube Replacement (See: Powertrain Management/Emission Control Systems/Positive Crankcase Ventilation/PCV Valve Hose/Service and Repair). 9. Install the main electrical connector harness bracket (2). 10. Install the main electrical connector harness bracket bolts (1). Tighten the bolts to 21 Nm (15 lb ft). 11. Clip the main engine electrical harness connectors to the main electrical connector harness bracket. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Rocker Arm Upper Cover Replacement - Left Side > Page 2807 12. Connect the turbocharger vane position sensor electrical connector (1). 13. Connect the main engine electrical harness connectors. 14. Push down on the latches (1) in order to connect the connectors. 15. Close the harness clip (2). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Rocker Arm Upper Cover Replacement - Left Side > Page 2808 16. Connect the fuel lines. Refer to Metal Collar Quick Connect Fitting Service (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Metal Collar Quick Connect Fitting Service). 17. Install the fuel hose bracket nut. Tighten the nut to 21 Nm (15 lb ft). 18. Position the generator positive cable. 19. Install the generator positive cable in the clip on the engine front cover. 20. Install the generator positive cable and nut. Tighten the nut to 9 Nm (80 lb in). 21. Install the positive battery cable junction block bracket and bolt (1) to the power steering pump. Tighten the bolt to 9 Nm (80 lb in). 22. Remove the tape from the turbocharger openings. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Rocker Arm Upper Cover Replacement - Left Side > Page 2809 23. Install the charged air cooler inlet duct. Refer to Charge Air Cooler Inlet Pipe Replacement (See: Powertrain Management/Fuel Delivery and Air Induction/Turbocharger/Intercooler/Intercooler Duct/Service and Repair/Charge Air Cooler Inlet Pipe Replacement). 24. Fill the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Cooling System/Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Cooling System/Service and Repair). 25. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 26. Install the intake manifold cover. Refer to Intake Manifold Cover Replacement (See: Intake Manifold/Service and Repair/Intake Manifold Cover Replacement). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Rocker Arm Upper Cover Replacement - Left Side > Page 2810 Valve Cover: Service and Repair Valve Rocker Arm Upper Cover Replacement - Right Side Valve Rocker Arm Upper Cover Replacement - Right Side Removal Procedure 1. Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement (See: Intake Manifold/Service and Repair/Intake Manifold Cover Replacement). 2. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (See: Tune-up and Engine Performance Checks/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair/Air Cleaner Outlet Duct Replacement). 3. Remove the charged air cooler outlet duct. Refer to Charge Air Cooler Outlet Pipe Replacement (See: Powertrain Management/Fuel Delivery and Air Induction/Turbocharger/Intercooler/Intercooler Duct/Service and Repair/Charge Air Cooler Outlet Pipe Replacement). 4. Remove the exhaust gas recirculation (EGR) cooler tube. Refer to Exhaust Gas Recirculation Valve Cooler Replacement (See: Powertrain Management/Emission Control Systems/Exhaust Gas Recirculation/EGR Cooler/Service and Repair/Exhaust Gas Recirculation Valve Cooler Replacement). 5. Remove the heater outlet hose bolt from the bracket. 6. Position the heater outlet hose out of the way. 7. Remove the wiring harness retainer from the bracket. 8. Remove the oil level indicator tube bolt (1). 9. Remove the oil level indicator tube bracket bolts (2). 10. Remove the bracket. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Rocker Arm Upper Cover Replacement - Left Side > Page 2811 11. Remove the fuel filter bracket bolts. 12. Reposition the fuel filter with bracket. 13. Remove the positive crankcase ventilation (PCV) hose/pipe. Refer to Positive Crankcase Ventilation Hose/Pipe/Tube Replacement (See: Powertrain Management/Emission Control Systems/Positive Crankcase Ventilation/PCV Valve Hose/Service and Repair). 14. Remove the engine harness bracket bolt. 15. Position engine harness brackets aside. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Rocker Arm Upper Cover Replacement - Left Side > Page 2812 16. Prior to removing the fuel injector pipes, use compressed air to blow any debris from between the injector line and fittings. Wipe the fittings clean of debris. 17. Spray lithium grease between the fuel injector line and fittings to assist in containing any debris during removal. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Specifications/Adhesives, Fluids, Lubricants, and Sealers) for the correct part number. Caution: DO NOT use compressed air to clean debris from the fuel injector inlet after the fuel line is removed. Using compressed air can allow debris to enter the fuel injector inlet and damage the fuel injector. 18. Remove the right fuel injector pipes. 19. Remove the upper valve rocker arm cover bolts. 20. Remove the upper valve rocker arm cover. 21. Remove the upper valve rocker arm cover gasket. 22. Inspect the upper valve rocker arm cover gasket for damage, replace if necessary. Otherwise reuse the old gasket. 23. If required, clean and inspect the upper valve rocker arm cover. Refer to Valve Rocker Arm Cover Cleaning and Inspection - Upper (See: Service and Repair/Overhaul/88. Valve Rocker Arm Cover Cleaning and Inspection - Upper). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Rocker Arm Upper Cover Replacement - Left Side > Page 2813 Installation Procedure 1. Install the upper valve rocker arm cover gasket. 2. Install the upper valve rocker arm cover. 3. Install the upper valve rocker arm cover bolts. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Tighten the upper valve rocker arm cover bolts in the sequence shown. Tighten the bolts to 8 Nm (71 lb in). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Rocker Arm Upper Cover Replacement - Left Side > Page 2814 Caution: Ensure proper torquing of the fuel injector line. An under-torqued fuel injector line will not seal properly and an over-torqued fuel injector line may damage the fuel injector fitting. An improperly sealed or damaged fuel injector line or fuel injector fitting will cause a fuel leak. 5. Install the fuel injector pipes. Tighten the pipes to 41 Nm (30 lb ft). 6. Position engine harness brackets. 7. Install the engine harness bracket bolt. Tighten the bolt to 21 Nm (15 lb ft). 8. Install the PCV hose/pipe. Refer to Positive Crankcase Ventilation Hose/Pipe/Tube Replacement (See: Powertrain Management/Emission Control Systems/Positive Crankcase Ventilation/PCV Valve Hose/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Rocker Arm Upper Cover Replacement - Left Side > Page 2815 9. Position the fuel filter with bracket to the rocker cover. 10. Install the fuel filter bracket bolts. Tighten the bolts to 21 Nm (15 lb ft). 11. Position the heater outlet hose. 12. Install the heater hose bracket bolt to the bracket. Tighten the bolt to 21 Nm (15 lb ft). 13. Install the EGR cooler tube. Refer to Exhaust Gas Recirculation Valve Cooler Replacement (See: Powertrain Management/Emission Control Systems/Exhaust Gas Recirculation/EGR Cooler/Service and Repair/Exhaust Gas Recirculation Valve Cooler Replacement). 14. Install the bracket. 15. Install the oil level indicator tube bracket bolts (2). Tighten the bolts to 21 Nm (15 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Rocker Arm Upper Cover Replacement - Left Side > Page 2816 16. Install the oil level indicator tube bolt (1). Tighten the bolt to 21 Nm (15 lb ft). 17. Install the wiring harness retainer to the bracket. 18. Install the charged air cooler outlet duct. Refer to Charge Air Cooler Outlet Pipe Replacement (See: Powertrain Management/Fuel Delivery and Air Induction/Turbocharger/Intercooler/Intercooler Duct/Service and Repair/Charge Air Cooler Outlet Pipe Replacement). 19. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (See: Tune-up and Engine Performance Checks/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair/Air Cleaner Outlet Duct Replacement). 20. Install the intake manifold cover. Refer to Intake Manifold Cover Replacement (See: Intake Manifold/Service and Repair/Intake Manifold Cover Replacement). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Rocker Arm Upper Cover Replacement - Left Side > Page 2817 Valve Cover: Service and Repair Valve Rocker Arm Lower Cover Replacement - Left Side Valve Rocker Arm Lower Cover Replacement - Left Side Removal Procedure 1. Remove the upper left valve rocker arm cover. Refer to Valve Rocker Arm Upper Cover Replacement - Left Side (See: Valve Rocker Arm Upper Cover Replacement - Left Side). 2. Remove the fuel injectors. Refer to Fuel Injector Replacement (Right) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Injector/Service and Repair/Removal and Replacement/Fuel Injector Replacement (Right))Fuel Injector Replacement (Left) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Injector/Service and Repair/Removal and Replacement/Fuel Injector Replacement (Left)). 3. Remove the lower valve rocker arm cover bolts. 4. Remove the lower valve rocker arm cover. 5. Remove the gasket from the lower valve rocker arm cover. 6. Inspect the lower valve rocker arm cover gasket for damage, replace if necessary. Otherwise reuse the old gasket. 7. If required, clean and inspect the lower valve rocker arm cover. Refer to Valve Rocker Arm Cover Cleaning and Inspection - Lower (See: Service and Repair/Overhaul/87. Valve Rocker Arm Cover Cleaning and Inspection - Lower). Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Rocker Arm Upper Cover Replacement - Left Side > Page 2818 1. Install the lower valve rocker arm cover gasket. 2. Install the lower valve rocker arm cover. 3. Install the lower valve rocker arm cover bolts. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Tighten the lower valve rocker arm cover bolts in the sequence shown. Tighten the bolts to 10 Nm (89 lb in). 5. Install the fuel injectors. Refer to Fuel Injector Replacement (Right) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Injector/Service and Repair/Removal and Replacement/Fuel Injector Replacement (Right))Fuel Injector Replacement (Left) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Injector/Service and Repair/Removal and Replacement/Fuel Injector Replacement (Left)). 6. Install the upper left valve rocker arm cover. Refer to Valve Rocker Arm Upper Cover Replacement - Left Side (See: Valve Rocker Arm Upper Cover Replacement - Left Side). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Rocker Arm Upper Cover Replacement - Left Side > Page 2819 Valve Cover: Service and Repair Valve Rocker Arm Lower Cover Replacement - Right Side Valve Rocker Arm Lower Cover Replacement - Right Side Removal Procedure 1. Remove the upper right valve rocker arm cover. Refer to Valve Rocker Arm Upper Cover Replacement - Right Side (See: Valve Rocker Arm Upper Cover Replacement - Right Side). 2. Remove the fuel injectors. Refer to Fuel Injector Replacement (Right) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Injector/Service and Repair/Removal and Replacement/Fuel Injector Replacement (Right))Fuel Injector Replacement (Left) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Injector/Service and Repair/Removal and Replacement/Fuel Injector Replacement (Left)). 3. Remove the lower valve rocker arm cover bolts. 4. Remove the lower valve rocker arm cover. 5. Remove the gasket from the lower valve rocker arm cover. 6. Inspect the lower valve rocker arm cover gasket for damage, replace if necessary. Otherwise reuse the old gasket. 7. If required, clean and inspect the lower valve rocker arm cover. Refer to Valve Rocker Arm Cover Cleaning and Inspection - Lower (See: Service and Repair/Overhaul/87. Valve Rocker Arm Cover Cleaning and Inspection - Lower). Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Rocker Arm Upper Cover Replacement - Left Side > Page 2820 1. Install the lower valve rocker arm cover gasket. 2. Install the lower valve rocker arm cover. 3. Install the lower valve rocker arm cover bolts. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Tighten the bolts in the sequence shown. Tighten the bolts to 10 Nm (89 lb in). 5. Install the fuel injectors. Refer to Fuel Injector Replacement (Right) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Injector/Service and Repair/Removal and Replacement/Fuel Injector Replacement (Right))Fuel Injector Replacement (Left) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Injector/Service and Repair/Removal and Replacement/Fuel Injector Replacement (Left)). 6. Install the right upper valve rocker arm cover. Refer to Valve Rocker Arm Upper Cover Replacement - Right Side (See: Valve Rocker Arm Upper Cover Replacement - Right Side). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component Information > Technical Service Bulletins > Engine - Duramax(R) Valve Guide/Stem Oil Seal Change Valve Guide: Technical Service Bulletins Engine - Duramax(R) Valve Guide/Stem Oil Seal Change INFORMATION Bulletin No.: 10-06-01-009 Date: October 06, 2010 Subject: Information on Duramax Valve Guide and Valve Stem Oil Seal Change Models: 2006-2010 Chevrolet Express Vans, Kodiak C4500/C5500 Series, Silverado 2006-2010 GMC Savana Vans, Sierra, TopKick C4500/C5500 Series Equipped with Duramax(TM) Diesel Engine (RPOs LLY, LBZ or LMM) A technician may notice a change in the valve guides and valve stem oil seals on replacement cylinder heads or engines for 2006-2010 model year vehicles. This change may also be noticed on 2006-2010 vehicles that have received a replacement cylinder head or engine during a previous repair. Beginning in 2010, production LGH and LML engines were made with a new design valve guide and pressed fit valve stem oil seal. Replacement cylinder heads and remanufactured engines for 2006-2010 vehicles will also be made with the new design valve guide and pressed fit valve stem oil seal. The new design requires special tool EN-49761 to install the valve stem oil seal to the correct height. Identify the valve guide design before servicing the valve stem oil seals on a 2006-2010 model year vehicle. The first design valve guide can be identified by the presence of a valve stem oil seal locating groove (1). This design used GM P/N 97212994. The second design valve guide does not have this groove, as the valve stem oil seal is a pressed fit to the guide (1). This design used GM P/N 12624396. When servicing an engine with the second design valve guides, be sure to use EN-49761 to install the valve stem oil seal to the correct height. The EN-49761 is tapped down until it bottoms on the lower valve spring seat. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component Information > Technical Service Bulletins > Engine - Duramax(R) Valve Guide/Stem Oil Seal Change > Page 2825 Parts Information Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service Precautions Valve Spring: Service Precautions Valve Springs Can Be Tightly Compressed Warning Warning Valve springs can be tightly compressed. Use care when removing retainers and plugs. Personal injury could result. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service Precautions > Page 2829 Valve Spring: Service and Repair Valve Stem Oil Seal and Valve Spring Replacement Special Tools * J 26999 Compression Gauge * J 26999-20 Compression Gauge Adapter * J 44646 Valve Spring Compressor * J 44640 Valve Stem Seal Installer Removal Procedure 1. Remove the upper and lower fan shroud. Refer to Engine Coolant Fan Lower Shroud Replacement (Mechanical) (See: Cooling System/Fan Shroud/Service and Repair) and Engine Coolant Fan Upper Shroud Replacement (LMM Diesel) (See: Cooling System/Fan Shroud/Service and Repair)Engine Coolant Fan Upper Shroud Replacement (Mechanical) (See: Cooling System/Fan Shroud/Service and Repair). 2. Remove the valve rocker arm shaft, valve bridges, and pushrods for the cylinder head being serviced. Refer to Valve Rocker Arm, Shaft, and Push Rod Replacement (See: Rocker Arm Assembly/Service and Repair). 3. Remove the glow plug for the cylinder requiring service. Refer to Glow Plug Replacement - Bank 1 (See: Powertrain Management/Glow Plug System/Glow Plug/Service and Repair/Glow Plug Replacement - Bank 1) or Glow Plug Replacement - Bank 2 (See: Powertrain Management/Glow Plug System/Glow Plug/Service and Repair/Glow Plug Replacement - Bank 2). 4. In order to apply shop air to the cylinders use the following procedures to modify J 26999-20 (1) and J 26999 (2): 1. Remove the valve core from J 26999-20 to allow air to flow. 2. Remove the quick connect fitting from J 26999 . 3. Adapt the quick connect fitting in order to use for shop air. 4. Connect the quick connect fitting to J 26999-20 . Note: Rotate the cylinder to be serviced to the bottom of the stroke. This is to ensure that the engine does not rotate when the compressed air is applied to the cylinder being serviced. 5. Install J 26999-20 into the glow plug hole for the cylinder being serviced. 6. Apply compressed air to hold the valves in place. If the compressed air is released, the valves can drop into the cylinder. Warning Compressed valve springs have high tension against the valve spring compressor. Valve springs that are not properly compressed by or released from the valve spring compressor can be ejected from the valve spring compressor with intense force. Use care when compressing or releasing the valve spring with the valve spring compressor and when removing or installing the valve stem keys. Failing to use care may cause personal injury. 7. Install J 44646 to the rocker arm bosses on the cylinder head. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service Precautions > Page 2830 J 44646 should be installed in the rocker arm boss next to the cylinder being serviced. The pivot pin can be removed from the stand to allow the stand to be installed. The lever has different locating holes for the pivot pin depending on available clearance. The lever is also notched for different locations of the compressor. 8. Using J 44646 compress the valve spring. 9. Remove the valve keys (1) from the valve stem. 10. Carefully release the valve spring tension. 11. Remove the valve spring upper seat (2) and the valve spring (3). 12. Remove the valve stem oil seal (4). 13. Remove the valve spring lower seat (5). 14. Continue removing the remaining valve stem seals for the cylinder using the above procedure. Installation Procedure Caution: Air pressure should remain applied to the cylinder for installation. 1. Install the valve spring lower seat. 2. Install the valve stem seal using J 44640 . Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service Precautions > Page 2831 3. Install the valve spring (3), the painted end of the valve spring goes toward the cylinder head. 4. Install the valve spring upper seat (2). Warning Compressed valve springs have high tension against the valve spring compressor. Valve springs that are not properly compressed by or released from the valve spring compressor can be ejected from the valve spring compressor with intense force. Use care when compressing or releasing the valve spring with the valve spring compressor and when removing or installing the valve stem keys. Failing to use care may cause personal injury. 5. Using J 44646 compress the valve spring. 6. Install the valve keys to the valve stem. Caution: The valve stem keys must correctly seat in the valve spring cap. Engine damage may occur by not installing properly. 7. Carefully release the valve spring pressure. Make sure the valve keys stay in place. 8. Continue to install the 3 remaining valve stem seals for the cylinder. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service Precautions > Page 2832 9. Release the compressed air holding the valves in place. 10. Remove J 26999-20 (1) from the glow plug hole. 11. Continue to replace the valve stem seals on the remaining cylinders using the above procedures. 12. Install the glow plug. Refer to Glow Plug Replacement - Bank 1 (See: Powertrain Management/Glow Plug System/Glow Plug/Service and Repair/Glow Plug Replacement - Bank 1) or Glow Plug Replacement - Bank 2 (See: Powertrain Management/Glow Plug System/Glow Plug/Service and Repair/Glow Plug Replacement - Bank 2). 13. Install the valve rocker arm shaft, the valve bridges, and the push rods. Refer to Valve Rocker Arm, Shaft, and Push Rod Replacement (See: Rocker Arm Assembly/Service and Repair). 14. Install the upper and lower fan shroud. Refer to Engine Coolant Fan Lower Shroud Replacement (Mechanical) (See: Cooling System/Fan Shroud/Service and Repair) and Engine Coolant Fan Upper Shroud Replacement (LMM Diesel) (See: Cooling System/Fan Shroud/Service and Repair)Engine Coolant Fan Upper Shroud Replacement (Mechanical) (See: Cooling System/Fan Shroud/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Customer Interest: > 05-06-01-018B > Feb > 11 > Diesel Engine - Drive Belt Chirp/Squeal at Cold Idle Drive Belt: Customer Interest Diesel Engine - Drive Belt Chirp/Squeal at Cold Idle TECHNICAL Bulletin No.: 05-06-01-018B Date: February 09, 2011 Subject: Accessory Drive Belt Chirp, Squeal or Squeak Type Noise at Cold Idle (Replace A/C Compressor/Power Steering Pump Mounting Bracket or Enlarge Bracket Bolt Holes) Models: 2004-2010 Chevrolet Silverado 2006-2010 Chevrolet Express 2004-2010 GMC Sierra 2006-2010 GMC Savana Equipped with 6.6L Duramax(R) Diesel Engine (VINs D, 2 - RPOs LBZ, LLY, LMM) Supercede: This bulletin is being revised to add model years and RPOs. Please discard Corporate Bulletin Number 05-06-01-018A (Section 06 - Engine/Propulsion System). Condition Important It should be noted that a chirp type noise on engine shutdown is normal for a diesel engine due to higher engine compression and the rapid stopping of the crankshaft. No repairs should be attempted for this condition. Some customers may comment on an accessory drive belt chirp, squeal, or squeak type noise at idle, especially on a cold start. The noise may be reduced or go away after the engine warms up. Cause Some 2004/2005 Silverado or Sierra trucks, with a 6.6L LLY engine produced before June, 2004, may have an A/C compressor/power steering pump mounting bracket and power steering rear mounting bracket that are machined slightly out of specification, causing a misaligned power steering pump. If the power steering pump is misaligned, it will force the accessory drive belt to run farther inboard on the fan pulley. When the belt leaves the fan pulley, the belt will not align properly to the crankshaft pulley grooves and create a chirp or squeak type noise at the point of interference. Vehicles built after June 2004 will already have the new A/C compressor/power steering pump mounting bracket installed, but still may exhibit belt noise caused by the power steering pump rear mounting bracket. Correction Vehicles built prior to June 2004, replace the A/C compressor/power steering pump mounting bracket. Vehicles built after June 2004, enlarge the rear power steering pump bracket bolt holes. 1. Follow the published service information (SI) diagnostics for drive belt chirping. The diagnostic chart for the drive belt chirping will ask to inspect for a misaligned accessory drive pulley. Important Remove the top section of the radiator shroud and TCM/cover to gain access to check alignment and measure the power steering pulley on the power steering pump shaft. 2. Verify that the power steering pulley is properly pressed onto the power steering pump shaft. Refer to SI for the power steering pulley replacement. If the pulley needs to be realigned on the power steering pump shaft, follow the published SI procedures for the power steering pulley replacement. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Customer Interest: > 05-06-01-018B > Feb > 11 > Diesel Engine - Drive Belt Chirp/Squeal at Cold Idle > Page 2842 3. If the noise was not fully eliminated by the procedure in step 2, the power steering pulley may be adjusted with an allowable maximum variance of 1.0 mm (0.039 in) to the front from the flush position on the shaft to assist in eliminating any remaining belt noise. Refer to graphic illustration number 1 and number 2. Ensure that the power steering pump pulley illustration number 1 is flush against the power steering pump shaft illustration number 2, with an allowable variance of 1.0 mm (0.039 in). 4. If the noise was not fully eliminated by the procedure in step 3, and there are no other concerns found, follow the published SI diagnostics for drive belt chirping. Then, if the vehicle was built prior to June 2004 go to step 5. If the vehicle was built after June 2004, go to step 6. 5. Vehicles Built Prior to June 2004: 1. Replace the A/C compressor/power steering pump mounting bracket with P/N 97362175. Refer to graphic illustration number 1. Follow the published SI procedures for the Air Conditioning (A/C) Compressor and Power Steering Pump Mounting Bracket Replacement. 2. With the new A/C compressor/power steering pump mounting bracket installed, reposition the power steering pump to gain access to drill larger holes into the rear mounting bracket using a 14 mm (1/2") drill bit. Drilling the bolt holes larger will ensure proper alignment of the bracket when installing the bolts. Refer to graphic illustration number 2. 3. Install the power steering pump to the A/C compressor/power steering pump bracket. Refer to graphic illustration numbers 4, 2, and 1. Important Power steering pump front mounting bolts must always be tightened first to ensure correct pulley alignment. 4. Refer to graphic illustration number 4 and tighten the front power steering pump mounting bolts. Tighten Tighten the bolts to 50 Nm (37 lb ft). 5. Refer to graphic illustration number 2 and tighten the rear power steering bracket bolts. Tighten Tighten the bolts to 50 Nm (37 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Customer Interest: > 05-06-01-018B > Feb > 11 > Diesel Engine - Drive Belt Chirp/Squeal at Cold Idle > Page 2843 6. Vehicles Built After June 2004: 1. Remove the front and rear power steering bracket bolts from the A/C compressor/power steering pump bracket. Refer to graphic illustration numbers 4, 2, and 1. 2. Reposition the power steering pump to gain access to drill larger holes into the rear mounting bracket using a 14 mm (1/2 in) drill bit. Drilling the bolt holes larger will ensure proper alignment of the bracket when installing the bolts. Refer to graphic illustration number 2. 3. Install the power steering pump to A/C compressor/power steering pump bracket. Refer to graphic illustration numbers 4, 2, and 1. Important Power steering pump front mounting bolts must always be tightened first to ensure correct pulley alignment. 4. Refer to graphic illustration number 4 and tighten the front power steering pump mounting bolts. Tighten Tighten the bolts to 50 Nm (37 lb ft). 5. Refer to graphic illustration number 2 and tighten the rear bracket bolts. Tighten Tighten the bolts to 50 Nm (37 lb ft). Dual Generator System New belts are not available for dual generator systems. If a belt chirp noise is occurring on a dual generator system, please complete a Field Product Report (FPR). The instructions for completing a FPR can be found in Service Bulletin Number 02-00-89-002G. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Customer Interest: > 05-06-01-018B > Feb > 11 > Diesel Engine - Drive Belt Chirp/Squeal at Cold Idle > Page 2844 Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-06-01-018B > Feb > 11 > Diesel Engine - Drive Belt Chirp/Squeal at Cold Idle Drive Belt: All Technical Service Bulletins Diesel Engine - Drive Belt Chirp/Squeal at Cold Idle TECHNICAL Bulletin No.: 05-06-01-018B Date: February 09, 2011 Subject: Accessory Drive Belt Chirp, Squeal or Squeak Type Noise at Cold Idle (Replace A/C Compressor/Power Steering Pump Mounting Bracket or Enlarge Bracket Bolt Holes) Models: 2004-2010 Chevrolet Silverado 2006-2010 Chevrolet Express 2004-2010 GMC Sierra 2006-2010 GMC Savana Equipped with 6.6L Duramax(R) Diesel Engine (VINs D, 2 - RPOs LBZ, LLY, LMM) Supercede: This bulletin is being revised to add model years and RPOs. Please discard Corporate Bulletin Number 05-06-01-018A (Section 06 - Engine/Propulsion System). Condition Important It should be noted that a chirp type noise on engine shutdown is normal for a diesel engine due to higher engine compression and the rapid stopping of the crankshaft. No repairs should be attempted for this condition. Some customers may comment on an accessory drive belt chirp, squeal, or squeak type noise at idle, especially on a cold start. The noise may be reduced or go away after the engine warms up. Cause Some 2004/2005 Silverado or Sierra trucks, with a 6.6L LLY engine produced before June, 2004, may have an A/C compressor/power steering pump mounting bracket and power steering rear mounting bracket that are machined slightly out of specification, causing a misaligned power steering pump. If the power steering pump is misaligned, it will force the accessory drive belt to run farther inboard on the fan pulley. When the belt leaves the fan pulley, the belt will not align properly to the crankshaft pulley grooves and create a chirp or squeak type noise at the point of interference. Vehicles built after June 2004 will already have the new A/C compressor/power steering pump mounting bracket installed, but still may exhibit belt noise caused by the power steering pump rear mounting bracket. Correction Vehicles built prior to June 2004, replace the A/C compressor/power steering pump mounting bracket. Vehicles built after June 2004, enlarge the rear power steering pump bracket bolt holes. 1. Follow the published service information (SI) diagnostics for drive belt chirping. The diagnostic chart for the drive belt chirping will ask to inspect for a misaligned accessory drive pulley. Important Remove the top section of the radiator shroud and TCM/cover to gain access to check alignment and measure the power steering pulley on the power steering pump shaft. 2. Verify that the power steering pulley is properly pressed onto the power steering pump shaft. Refer to SI for the power steering pulley replacement. If the pulley needs to be realigned on the power steering pump shaft, follow the published SI procedures for the power steering pulley replacement. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-06-01-018B > Feb > 11 > Diesel Engine - Drive Belt Chirp/Squeal at Cold Idle > Page 2850 3. If the noise was not fully eliminated by the procedure in step 2, the power steering pulley may be adjusted with an allowable maximum variance of 1.0 mm (0.039 in) to the front from the flush position on the shaft to assist in eliminating any remaining belt noise. Refer to graphic illustration number 1 and number 2. Ensure that the power steering pump pulley illustration number 1 is flush against the power steering pump shaft illustration number 2, with an allowable variance of 1.0 mm (0.039 in). 4. If the noise was not fully eliminated by the procedure in step 3, and there are no other concerns found, follow the published SI diagnostics for drive belt chirping. Then, if the vehicle was built prior to June 2004 go to step 5. If the vehicle was built after June 2004, go to step 6. 5. Vehicles Built Prior to June 2004: 1. Replace the A/C compressor/power steering pump mounting bracket with P/N 97362175. Refer to graphic illustration number 1. Follow the published SI procedures for the Air Conditioning (A/C) Compressor and Power Steering Pump Mounting Bracket Replacement. 2. With the new A/C compressor/power steering pump mounting bracket installed, reposition the power steering pump to gain access to drill larger holes into the rear mounting bracket using a 14 mm (1/2") drill bit. Drilling the bolt holes larger will ensure proper alignment of the bracket when installing the bolts. Refer to graphic illustration number 2. 3. Install the power steering pump to the A/C compressor/power steering pump bracket. Refer to graphic illustration numbers 4, 2, and 1. Important Power steering pump front mounting bolts must always be tightened first to ensure correct pulley alignment. 4. Refer to graphic illustration number 4 and tighten the front power steering pump mounting bolts. Tighten Tighten the bolts to 50 Nm (37 lb ft). 5. Refer to graphic illustration number 2 and tighten the rear power steering bracket bolts. Tighten Tighten the bolts to 50 Nm (37 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-06-01-018B > Feb > 11 > Diesel Engine - Drive Belt Chirp/Squeal at Cold Idle > Page 2851 6. Vehicles Built After June 2004: 1. Remove the front and rear power steering bracket bolts from the A/C compressor/power steering pump bracket. Refer to graphic illustration numbers 4, 2, and 1. 2. Reposition the power steering pump to gain access to drill larger holes into the rear mounting bracket using a 14 mm (1/2 in) drill bit. Drilling the bolt holes larger will ensure proper alignment of the bracket when installing the bolts. Refer to graphic illustration number 2. 3. Install the power steering pump to A/C compressor/power steering pump bracket. Refer to graphic illustration numbers 4, 2, and 1. Important Power steering pump front mounting bolts must always be tightened first to ensure correct pulley alignment. 4. Refer to graphic illustration number 4 and tighten the front power steering pump mounting bolts. Tighten Tighten the bolts to 50 Nm (37 lb ft). 5. Refer to graphic illustration number 2 and tighten the rear bracket bolts. Tighten Tighten the bolts to 50 Nm (37 lb ft). Dual Generator System New belts are not available for dual generator systems. If a belt chirp noise is occurring on a dual generator system, please complete a Field Product Report (FPR). The instructions for completing a FPR can be found in Service Bulletin Number 02-00-89-002G. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-06-01-018B > Feb > 11 > Diesel Engine - Drive Belt Chirp/Squeal at Cold Idle > Page 2852 Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-06-01-008A > Jul > 09 > Engine - Drive Belt Misalignment Diagnostics Drive Belt: All Technical Service Bulletins Engine - Drive Belt Misalignment Diagnostics INFORMATION Bulletin No.: 08-06-01-008A Date: July 27, 2009 Subject: Diagnosing Accessory Drive Belt / Serpentine Belt Noise and Availability and Use of Kent-Moore EN-49228 Laser Alignment Tool - Drive Belt Models: 2010 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add a model year and update the Tool Information. Please discard Corporate Bulletin Number 08-06-01-008 (Section 06 - Engine). Background Several aftermarket companies offer laser alignment tools for accessory drive systems that can be very helpful in eliminating drive belt noise as a result of misaligned pulleys. Typically pricing ranges from $160 - $200. EN-49228 Laser Alignment Tool - Drive Belt The GM Tool program has now made available a competitive, simple to use and time-saving laser tool to assist in achieving precise alignment of the drive belt pulleys. This optional tool removes the guesswork from proper pulley alignment and may serve to reduce comebacks from: - Drive Belt Noise - Accelerated Drive Belt Wear - Drive Belt Slippage Instructions The instructions below are specific only to the truck Gen IV V-8 family of engines. These instructions are only for illustrative purposes to show how the tool may be used. Universal instructions are included in the box with the Laser Alignment Tool - Drive Belt. Caution - Do not look directly into the beam projected from the laser. - Use caution when shining the laser on highly polished or reflective surfaces. Laser safety glasses help reduce laser beam glare in many circumstances. - Always use laser safety glasses when using the laser. Laser safety glasses are not designed to protect eyes from direct laser exposure. 1. Observe and mark the serpentine belt orientation. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-06-01-008A > Jul > 09 > Engine - Drive Belt Misalignment Diagnostics > Page 2857 2. Remove the serpentine belt from the accessory drive system. 3. Install the tool onto the power steering pulley. Position the legs of the tool into the outer grooves of the pulley, farthest from the front of the engine. 4. Install the retaining cord around the pulley and to the legs of the tool. 5. Put on the laser safety glasses provided with the tool. 6. Depress the switch on the rear of the tool to activate the light beam. 7. Rotate the power steering pulley as required to project the light beam onto the crankshaft balancer pulley grooves. 8. Inspect for proper power steering pulley alignment. - If the laser beam projects onto the second rib or raised area (1), the pulleys are aligned properly. - If the laser beam projects more than one-quarter rib 0.9 mm (0.035 in) mis-alignment, adjust the position of the power steering pulley as required. - Refer to SI for Power Steering Pulley Removal and Installation procedures. 9. Install the serpentine belt to the accessory drive system in the original orientation. 10. Operate the vehicle and verify that the belt noise concern is no longer present. Tool Information Please visit the GM service tool website for pricing information or to place your order for this tool. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-06-01-008A > Jul > 09 > Engine - Drive Belt Misalignment Diagnostics > Page 2858 Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Drive Belt: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps Coolant Temperature Sensor/Switch (For Computer): All Technical Service Bulletins Engine - MIL ON P0116/P1400 Set In Very Cold Temps TECHNICAL Bulletin No.: 10-06-04-008A Date: January 24, 2011 Subject: Malfunction Indicator Lamp (MIL) Illuminated at Very Cold Ambient Temperatures When Using Engine Coolant Heater, DTC P0116 and/or P1400 Set (Relocate Engine Coolant Temperature (ECT) Sensor and Engine Coolant Heater Cord) Models: 2006-2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2006-2010 Cadillac Escalade 2006-2007 Chevrolet Monte Carlo 2006-2009 Chevrolet Impala SS, TrailBlazer 2006-2010 Chevrolet Avalanche, Express, Silverado Tahoe 2006-2009 GMC Envoy 2006-2010 GMC Savana, Sierra, Yukon 2006-2008 Pontiac Grand Prix 2006-2009 Saab 9-7X Equipped with V8 Engine RPO LC9, LH6, LH8, LH9, L76, LS2, LS4, LFA, LZ1, L92, L94, L9H or L20, L96, LMF, LMG, LY2, LY5, LY6 Please Refer to GMVIS Attention: To properly correct this condition, you must follow both of the procedures to relocate the ECT sensor and the engine coolant heater cord. Supercede: This bulletin is being revised to add cast iron block engine RPOs and to update the Warranty Information coverage period. Please discard Corporate Bulletin Number 10-06-04-008 (Section 06 - Engine/Propulsion System). Condition Some customers may comment that the malfunction indicator lamp (MIL) illuminates after starting the vehicle when they were using the engine coolant heater in very cold ambient temperatures. This usually occurs in a range of -23 to -40°C (-10 to -40°F) or colder. The technician may observe on a scan tool DTC P0116 and/or P1400 set as Current or in History. Cause This condition may be caused by the engine control module (ECM) determining that the ignition OFF time requirement has been met at start-up and interpreting the temperature difference between the engine coolant temperature (ECT) sensor and the intake air temperature (IAT) sensor as being outside of a calibrated range. Correction Important DO NOT replace the ECM for this condition. Relocating the ECT Sensor 1. Turn ON the ignition with the engine OFF. 2. Perform the diagnostic system check - vehicle. Refer to Diagnostic System Check - Vehicle in SI. ‹› If DTC P0116 and/or P1400 are set and the customer WAS using the engine coolant heater, proceed to Step 3. ‹› If DTC P0116 and/or P1400 are set and the customer WAS NOT using the engine coolant heater, refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. 3. Turn OFF the ignition. Warning To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Drive Belt: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 2864 under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator are still hot. 4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle. Refer to Cooling System Draining and Filling in SI. 7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor. 10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J 38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle. 13. Disconnect the wiring harness connector from the ECT sensor (2). 14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT sensor in the hole of the cylinder head where the plug was removed. Tighten Tighten to 20 Nm (15 lb ft). 18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was removed Tighten Tighten to 20 Nm (15 lb ft). Important Leave enough wire attached to the ECT sensor harness connector in order to create manageable splices that are at least 40 mm (1.5 in) away from the other splice. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Drive Belt: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 2865 20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit. Cut off the ECT sensor harness connector and wiring. 21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured TO or WITHIN an existing protective conduit. Note This step is to set up and verify the length of wiring that is required before cutting. 22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the appropriate length. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. 26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit using tie straps. Important You MUST run the engine at the specified RPM and until it reaches normal operating temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool down in order to top off the coolant level as needed. 28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI. 29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan tool to clear any DTCs. Relocating the Engine Coolant Heater Cord Important For reference, the procedure and graphics that are shown are from a Chevrolet Silverado, but are similar for the other vehicles listed above. 1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit from the engine compartment in order to determine the required extension cord length. 3. Obtain an extension cord with the following features: - 120 volt - 14/3 gauge - 15A capacity - Three prong - Polarized plug and receptacle - Chemical resistant - Grounded terminals - Designed for use in a cold outdoor environment - Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight - Maximum length of 2.5-3 m (8-10 ft) 4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N 12345579 (in Canada, use P/N 10953481) or an equivalent. 6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Drive Belt: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 2866 7. Wrap electrical tape around the connection as shown. 8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to the engine coolant crossover pipe as shown. 9. Continue to route the extension cord to the exit location desired by the customer as shown. 10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the engine coolant heater cord to the vehicle that were released to provide length. Part Information The extension cord may be obtained at any of the following outlets: - Lowes* - Home Depot* - Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number: CWRSJTOW3C14-10 USA: Cords should bear the UL symbol. Canada: Cords should bear the ULc symbol or CSA approval. *We believe these sources and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from these firms or for any such items that may be available from other sources. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Drive Belt: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 2867 Warranty Information (excluding Saab Models) For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Drive Belt: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 2873 under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator are still hot. 4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle. Refer to Cooling System Draining and Filling in SI. 7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor. 10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J 38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle. 13. Disconnect the wiring harness connector from the ECT sensor (2). 14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT sensor in the hole of the cylinder head where the plug was removed. Tighten Tighten to 20 Nm (15 lb ft). 18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was removed Tighten Tighten to 20 Nm (15 lb ft). Important Leave enough wire attached to the ECT sensor harness connector in order to create manageable splices that are at least 40 mm (1.5 in) away from the other splice. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Drive Belt: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 2874 20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit. Cut off the ECT sensor harness connector and wiring. 21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured TO or WITHIN an existing protective conduit. Note This step is to set up and verify the length of wiring that is required before cutting. 22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the appropriate length. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. 26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit using tie straps. Important You MUST run the engine at the specified RPM and until it reaches normal operating temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool down in order to top off the coolant level as needed. 28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI. 29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan tool to clear any DTCs. Relocating the Engine Coolant Heater Cord Important For reference, the procedure and graphics that are shown are from a Chevrolet Silverado, but are similar for the other vehicles listed above. 1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit from the engine compartment in order to determine the required extension cord length. 3. Obtain an extension cord with the following features: - 120 volt - 14/3 gauge - 15A capacity - Three prong - Polarized plug and receptacle - Chemical resistant - Grounded terminals - Designed for use in a cold outdoor environment - Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight - Maximum length of 2.5-3 m (8-10 ft) 4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N 12345579 (in Canada, use P/N 10953481) or an equivalent. 6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Drive Belt: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 2875 7. Wrap electrical tape around the connection as shown. 8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to the engine coolant crossover pipe as shown. 9. Continue to route the extension cord to the exit location desired by the customer as shown. 10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the engine coolant heater cord to the vehicle that were released to provide length. Part Information The extension cord may be obtained at any of the following outlets: - Lowes* - Home Depot* - Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number: CWRSJTOW3C14-10 USA: Cords should bear the UL symbol. Canada: Cords should bear the ULc symbol or CSA approval. *We believe these sources and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from these firms or for any such items that may be available from other sources. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Drive Belt: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 2876 Warranty Information (excluding Saab Models) For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Page 2877 Drive Belt: Diagrams Drive Belt Replacement Equipped with a single generator. Equipped with dual generators. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Page 2878 Drive Belt: Service Precautions Belt Dressing Caution Caution: Do not use belt dressing on the drive belt. Belt dressing causes the breakdown of the composition of the drive belt. Failure to follow this recommendation will damage the drive belt. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Page 2879 Drive Belt: Description and Operation Drive Belt System Description The drive belt system consists of the following components: * The drive belt * The drive belt tensioner * The drive belt idler pulley * The crankshaft balancer pulley * The accessory drive component mounting brackets * The accessory drive components - The power steering pump, if belt driven - The generator - The A/C compressor, if equipped - The engine cooling fan, if belt driven - The water pump, if belt driven - The vacuum pump, if equipped - The air compressor, if equipped The drive belt system may use 1 belt or 2 belts. The drive belt is thin so that it can bend backwards and has several ribs to match the grooves in the pulleys. The drive belts are made of different types of rubbers, chloroprene or EPDM, and have different layers or plys containing either fiber cloth or cords for reinforcement. Both sides of the drive belt may be used to drive the different accessory drive components. When the back side of the drive belt is used to drive a pulley, the pulley is smooth. The drive belt is pulled by the crankshaft balancer pulley across the accessory drive component pulleys. The spring loaded drive belt tensioner keeps constant tension on the drive belt to prevent the drive belt from slipping. The drive belt tensioner arm will move when loads are applied to the drive belt by the accessory drive components and the crankshaft. The drive belt system may have an idler pulley, which is used to add wrap to the adjacent pulleys. Some systems use an idler pulley in place of an accessory drive component when the vehicle is not equipped with the accessory. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping, Squeal, and Whine Diagnosis Drive Belt: Testing and Inspection Drive Belt Chirping, Squeal, and Whine Diagnosis Drive Belt Chirping, Squeal, and Whine Diagnosis Diagnostic Aids * A chirping or squeal noise may be intermittent due to moisture on the drive belts or the pulleys. It may be necessary to spray a small amount of water on the drive belts in order to duplicate the customers concern. If spraying water on the drive belt duplicates the symptom, cleaning the belt pulleys may be the probable solution. * If the noise is intermittent, verify the accessory drive components by varying their loads making sure they are operated to their maximum capacity. An overcharged A/C system, power steering system with a pinched hose or wrong fluid, or a generator failing are suggested items to inspect. * A chirping, squeal or whine noise may be caused by a loose or improper installation of a body or suspension component. Other items of the vehicle may also cause the noise. * The drive belts will not cause a whine noise. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. The noise may not be engine related. This step is to verify that the engine is making the noise. If the engine is not making the noise do not proceed further with this table. 3. The noise may be an internal engine noise. Removing the drive belts one at a time and operating the engine for a brief period will verify the noise is related to the drive belt. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belts removed. 4. Inspect all drive belt pulleys for pilling. Pilling is the small balls or pills or it can be strings in the drive belt grooves from the accumulation of rubber dust. 6. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found refer to that accessory drive component for the proper installation procedure for that pulley. 10. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed. 12. Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating properly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley. 14. This test is to verify that the drive belt tensioner operates properly. If the drive belt tensioner is not operating properly, proper belt tension may not be achieved to keep the drive belt from slipping which could cause a squeal noise. 15. This test is to verify that the drive belt is not too long, which would prevent the drive belt tensioner from working properly. Also if an incorrect length drive belt was installed, it may not be routed properly and may be turning an accessory drive component in the wrong direction. 16. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found refer to that accessory drive component for the proper installation procedure for that pulley. 17. This test is to verify that the pulleys are the correct diameter or width. Using a known good vehicle compare the pulley sizes. 19. Replacing the drive belt when it is not damaged or there is not excessive pilling will only be a temporary repair. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping, Squeal, and Whine Diagnosis > Page 2882 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping, Squeal, and Whine Diagnosis > Page 2883 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping, Squeal, and Whine Diagnosis > Page 2884 Drive Belt: Testing and Inspection Drive Belt Rumbling and Vibration Diagnosis Drive Belt Rumbling and Vibration Diagnosis Diagnostic Aids The accessory drive components can have an affect on engine vibration. Vibration from the engine operating may cause a body component or another part of the vehicle to make rumbling noise. Vibration can be caused by, but not limited to the air conditioning (A/C) system over charged, the power steering system restricted or the incorrect fluid, or an extra load on the generator. To help identify an intermittent or an improper condition, vary the loads on the accessory drive components. The drive belt may have a rumbling condition that can not be seen or felt. Sometimes replacing the drive belt may be the only repair for the symptom. If replacing the drive belt, completing the diagnostic table, and the noise is only heard when the drive belts are installed, there might be an accessory drive component with a failure. Varying the load on the different accessory drive components may aid in identifying which component is causing the rumbling noise. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This test is to verify that the symptom is present during diagnosing. Other vehicle components may cause a similar symptom. 3. This test is to verify that one of the drive belts is causing the rumbling noise or vibration. Rumbling noise may be confused with an internal engine noise due to the similarity in the description. Remove only one drive belt at a time if the vehicle has multiple drive belts. When removing the drive belts the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belts removed. 4. Inspecting the drive belts is to ensure that they are not causing the noise. Small cracks across the ribs of the drive belt will not cause the noise. Belt separation is identified by the plys of the belt separating and may be seen at the edge of the belt our felt as a lump in the belt. 5. Small amounts of pilling is normal condition and acceptable. When the pilling is severe the drive belt does not have a smooth surface for proper operation. 9. Inspecting of the fasteners can eliminate the possibility that the wrong bolt, nut, spacer, or washer was installed. 11. This step should only be performed if the water pump is driven by the drive belt. Inspect the water pump shaft for being bent. Also inspect the water pump bearings for smooth operation and excessive play. Compare the water pump with a known good water pump. 12. Accessory drive component brackets that are bent, cracked, or loose may put extra strain on that accessory component causing it to vibrate. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping, Squeal, and Whine Diagnosis > Page 2885 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping, Squeal, and Whine Diagnosis > Page 2886 Drive Belt: Testing and Inspection Drive Belt Falls Off and Excessive Wear Diagnosis Drive Belt Falls Off and Excessive Wear Diagnosis Diagnostic Aids If the drive belt repeatedly falls off the drive belt pulleys, this is because of pulley misalignment. An extra load that is quickly applied on released by an accessory drive component may cause the drive belt to fall off the pulleys. Verify the accessory drive components operate properly. If the drive belt is the incorrect length, the drive belt tensioner may not keep the proper tension on the drive belt. Excessive wear on a drive belt is usually caused by an incorrect installation or the wrong drive belt for the application. Minor misalignment of the drive belt pulleys will not cause excessive wear, but will probably cause the drive belt to make a noise or to fall off. Excessive misalignment of the drive belt pulleys will cause excessive wear but may also make the drive belt fall off. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This inspection is to verify the condition of the drive belt. Damage may of occurred to the drive belt when the drive belt fell off. The drive belt may of been damaged, which caused the drive belt to fall off. Inspect the belt for cuts, tears, sections of ribs missing, or damaged belt plys. 4. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found refer to that accessory drive component for the proper installation procedure of that pulley. 5. Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating properly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley. 6. Accessory drive component brackets that are bent or cracked will let the drive belt fall off. 7. Inspection of the fasteners can eliminate the possibility that a wrong bolt, nut , spacer, or washer was installed. Missing, loose, or the wrong fasteners may cause pulley misalignment from the bracket moving under load. Over tightening of the fasteners may cause misalignment of the accessory component bracket. 13. The inspection is to verify the drive belt is correctly installed on all of the drive belt pulleys. Wear on the drive belt may be caused by mis-positioning the drive belt by one groove on a pulley. 14. The installation of a drive belt that is too wide or too narrow will cause wear on the drive belt. The drive belt ribs should match all of the grooves on all of the pulleys. 15. This inspection is to verify the drive belt is not contacting any parts of the engine or body while the engine is operating. There should be sufficient clearance when the drive belt accessory drive components load varies. The drive belt should not come in contact with an engine or a body component when snapping the throttle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping, Squeal, and Whine Diagnosis > Page 2887 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Page 2888 Drive Belt: Service and Repair Drive Belt Replacement Removal Procedure 1. Remove the upper fan shroud. Refer to Engine Coolant Fan Upper Shroud Replacement (LMM Diesel) (See: Cooling System/Fan Shroud/Service and Repair)Engine Coolant Fan Upper Shroud Replacement (Mechanical) (See: Cooling System/Fan Shroud/Service and Repair ). 2. Remove the 3 engine cooling fan shroud bolts (1). 3. Position the engine cooling fan shroud (1) forward to the radiator. 4. Install a 1/2 inch breaker bar into the tensioner opening and rotate the tensioner counterclockwise. 5. Remove the belt from the tensioner. 6. Slowly release the tension on the tensioner arm. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Page 2889 7. Remove the drive belt from the drive pulleys , if equipped with a single generator. 8. Remove the drive belt from the drive pulleys, if equipped with dual generators. 9. Inspect the drive belt for excessive cracking or any visible damage and replace if necessary. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Page 2890 1. Install the drive belt, if equipped with dual generators. 2. Route the drive belt over and/or around all the drive pulleys except for the tensioner. 3. Install the drive belt, if equipped with a single generator. 4. Route the drive belt over and/or around all the drive pulleys except for the tensioner. 5. Install a 1/2 inch breaker bar into the tensioner opening and rotate the tensioner counterclockwise. 6. Install the belt over and/or around the tensioner. 7. Slowly release the tension on the tensioner arm. 8. Inspect the drive belt for proper installation on and/or around all pulleys. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Page 2891 9. Position the engine cooling fan shroud on the 3 mounting brackets (1). 10. Install the bolts. Loosely tighten the top mounting bolt at the oil filler neck. 11. Center the engine cooling fan shroud to the fan blade in 3 places (1). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Note: Maintain a 6 mm (0.25 in) minimum clearance at all 3 places. 12. Fully tighten the 3 engine cooling fan shroud bolts (1). Tighten the bolts to 8 Nm (71 lb in). 13. Install the upper fan shroud. Refer to Engine Coolant Fan Upper Shroud Replacement (LMM Diesel) (See: Cooling System/Fan Shroud/Service and Repair)Engine Coolant Fan Upper Shroud Replacement (Mechanical) (See: Cooling System/Fan Shroud/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Testing and Inspection Drive Belt Tensioner: Testing and Inspection Drive Belt Tensioner Diagnosis Caution: Allowing the drive belt tensioner to snap into the free position may result in damage to the tensioner. Note: When the engine is operating the drive belt tensioner arm will move. Do not replace the drive belt tensioner because of movement in the drive belt tensioner arm. 1. Remove the drive belt. Refer to Drive Belt Replacement (See: Drive Belt/Service and Repair). 2. Position a 3/8-inch drive breaker bar into the drive belt tensioner opening and rotate the tensioner counterclockwise. 3. Move the drive belt tensioner through its full travel. * The movement should feel smooth * There should be no binding * The tensioner should return freely 4. If any binding is observed, replace the drive belt tensioner. Refer to Drive Belt Tensioner Replacement (See: Service and Repair). 5. Install the drive belt. Refer to Drive Belt Replacement (See: Drive Belt/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Testing and Inspection > Page 2895 Drive Belt Tensioner: Service and Repair Drive Belt Tensioner Replacement Removal Procedure 1. Remove the drive belt. Refer to Drive Belt Replacement (See: Drive Belt/Service and Repair). 2. Remove the drive belt tensioner bolt. 3. Remove the drive belt tensioner. Installation Procedure 1. Install the drive belt tensioner. Align the pin with the hole in the generator bracket. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the drive belt tensioner bolt. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Testing and Inspection > Page 2896 Tighten bolt to 50 Nm (37 lb ft). 3. Install the drive belt. Refer to Drive Belt Replacement (See: Drive Belt/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Accessory Bracket > Component Information > Technical Service Bulletins > Customer Interest for Engine Accessory Bracket: > 05-06-01-018B > Feb > 11 > Diesel Engine - Drive Belt Chirp/Squeal at Cold Idle Engine Accessory Bracket: Customer Interest Diesel Engine - Drive Belt Chirp/Squeal at Cold Idle TECHNICAL Bulletin No.: 05-06-01-018B Date: February 09, 2011 Subject: Accessory Drive Belt Chirp, Squeal or Squeak Type Noise at Cold Idle (Replace A/C Compressor/Power Steering Pump Mounting Bracket or Enlarge Bracket Bolt Holes) Models: 2004-2010 Chevrolet Silverado 2006-2010 Chevrolet Express 2004-2010 GMC Sierra 2006-2010 GMC Savana Equipped with 6.6L Duramax(R) Diesel Engine (VINs D, 2 - RPOs LBZ, LLY, LMM) Supercede: This bulletin is being revised to add model years and RPOs. Please discard Corporate Bulletin Number 05-06-01-018A (Section 06 - Engine/Propulsion System). Condition Important It should be noted that a chirp type noise on engine shutdown is normal for a diesel engine due to higher engine compression and the rapid stopping of the crankshaft. No repairs should be attempted for this condition. Some customers may comment on an accessory drive belt chirp, squeal, or squeak type noise at idle, especially on a cold start. The noise may be reduced or go away after the engine warms up. Cause Some 2004/2005 Silverado or Sierra trucks, with a 6.6L LLY engine produced before June, 2004, may have an A/C compressor/power steering pump mounting bracket and power steering rear mounting bracket that are machined slightly out of specification, causing a misaligned power steering pump. If the power steering pump is misaligned, it will force the accessory drive belt to run farther inboard on the fan pulley. When the belt leaves the fan pulley, the belt will not align properly to the crankshaft pulley grooves and create a chirp or squeak type noise at the point of interference. Vehicles built after June 2004 will already have the new A/C compressor/power steering pump mounting bracket installed, but still may exhibit belt noise caused by the power steering pump rear mounting bracket. Correction Vehicles built prior to June 2004, replace the A/C compressor/power steering pump mounting bracket. Vehicles built after June 2004, enlarge the rear power steering pump bracket bolt holes. 1. Follow the published service information (SI) diagnostics for drive belt chirping. The diagnostic chart for the drive belt chirping will ask to inspect for a misaligned accessory drive pulley. Important Remove the top section of the radiator shroud and TCM/cover to gain access to check alignment and measure the power steering pulley on the power steering pump shaft. 2. Verify that the power steering pulley is properly pressed onto the power steering pump shaft. Refer to SI for the power steering pulley replacement. If the pulley needs to be realigned on the power steering pump shaft, follow the published SI procedures for the power steering pulley replacement. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Accessory Bracket > Component Information > Technical Service Bulletins > Customer Interest for Engine Accessory Bracket: > 05-06-01-018B > Feb > 11 > Diesel Engine - Drive Belt Chirp/Squeal at Cold Idle > Page 2905 3. If the noise was not fully eliminated by the procedure in step 2, the power steering pulley may be adjusted with an allowable maximum variance of 1.0 mm (0.039 in) to the front from the flush position on the shaft to assist in eliminating any remaining belt noise. Refer to graphic illustration number 1 and number 2. Ensure that the power steering pump pulley illustration number 1 is flush against the power steering pump shaft illustration number 2, with an allowable variance of 1.0 mm (0.039 in). 4. If the noise was not fully eliminated by the procedure in step 3, and there are no other concerns found, follow the published SI diagnostics for drive belt chirping. Then, if the vehicle was built prior to June 2004 go to step 5. If the vehicle was built after June 2004, go to step 6. 5. Vehicles Built Prior to June 2004: 1. Replace the A/C compressor/power steering pump mounting bracket with P/N 97362175. Refer to graphic illustration number 1. Follow the published SI procedures for the Air Conditioning (A/C) Compressor and Power Steering Pump Mounting Bracket Replacement. 2. With the new A/C compressor/power steering pump mounting bracket installed, reposition the power steering pump to gain access to drill larger holes into the rear mounting bracket using a 14 mm (1/2") drill bit. Drilling the bolt holes larger will ensure proper alignment of the bracket when installing the bolts. Refer to graphic illustration number 2. 3. Install the power steering pump to the A/C compressor/power steering pump bracket. Refer to graphic illustration numbers 4, 2, and 1. Important Power steering pump front mounting bolts must always be tightened first to ensure correct pulley alignment. 4. Refer to graphic illustration number 4 and tighten the front power steering pump mounting bolts. Tighten Tighten the bolts to 50 Nm (37 lb ft). 5. Refer to graphic illustration number 2 and tighten the rear power steering bracket bolts. Tighten Tighten the bolts to 50 Nm (37 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Accessory Bracket > Component Information > Technical Service Bulletins > Customer Interest for Engine Accessory Bracket: > 05-06-01-018B > Feb > 11 > Diesel Engine - Drive Belt Chirp/Squeal at Cold Idle > Page 2906 6. Vehicles Built After June 2004: 1. Remove the front and rear power steering bracket bolts from the A/C compressor/power steering pump bracket. Refer to graphic illustration numbers 4, 2, and 1. 2. Reposition the power steering pump to gain access to drill larger holes into the rear mounting bracket using a 14 mm (1/2 in) drill bit. Drilling the bolt holes larger will ensure proper alignment of the bracket when installing the bolts. Refer to graphic illustration number 2. 3. Install the power steering pump to A/C compressor/power steering pump bracket. Refer to graphic illustration numbers 4, 2, and 1. Important Power steering pump front mounting bolts must always be tightened first to ensure correct pulley alignment. 4. Refer to graphic illustration number 4 and tighten the front power steering pump mounting bolts. Tighten Tighten the bolts to 50 Nm (37 lb ft). 5. Refer to graphic illustration number 2 and tighten the rear bracket bolts. Tighten Tighten the bolts to 50 Nm (37 lb ft). Dual Generator System New belts are not available for dual generator systems. If a belt chirp noise is occurring on a dual generator system, please complete a Field Product Report (FPR). The instructions for completing a FPR can be found in Service Bulletin Number 02-00-89-002G. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Accessory Bracket > Component Information > Technical Service Bulletins > Customer Interest for Engine Accessory Bracket: > 05-06-01-018B > Feb > 11 > Diesel Engine - Drive Belt Chirp/Squeal at Cold Idle > Page 2907 Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Accessory Bracket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Accessory Bracket: > 05-06-01-018B > Feb > 11 > Diesel Engine - Drive Belt Chirp/Squeal at Cold Idle Engine Accessory Bracket: All Technical Service Bulletins Diesel Engine - Drive Belt Chirp/Squeal at Cold Idle TECHNICAL Bulletin No.: 05-06-01-018B Date: February 09, 2011 Subject: Accessory Drive Belt Chirp, Squeal or Squeak Type Noise at Cold Idle (Replace A/C Compressor/Power Steering Pump Mounting Bracket or Enlarge Bracket Bolt Holes) Models: 2004-2010 Chevrolet Silverado 2006-2010 Chevrolet Express 2004-2010 GMC Sierra 2006-2010 GMC Savana Equipped with 6.6L Duramax(R) Diesel Engine (VINs D, 2 - RPOs LBZ, LLY, LMM) Supercede: This bulletin is being revised to add model years and RPOs. Please discard Corporate Bulletin Number 05-06-01-018A (Section 06 - Engine/Propulsion System). Condition Important It should be noted that a chirp type noise on engine shutdown is normal for a diesel engine due to higher engine compression and the rapid stopping of the crankshaft. No repairs should be attempted for this condition. Some customers may comment on an accessory drive belt chirp, squeal, or squeak type noise at idle, especially on a cold start. The noise may be reduced or go away after the engine warms up. Cause Some 2004/2005 Silverado or Sierra trucks, with a 6.6L LLY engine produced before June, 2004, may have an A/C compressor/power steering pump mounting bracket and power steering rear mounting bracket that are machined slightly out of specification, causing a misaligned power steering pump. If the power steering pump is misaligned, it will force the accessory drive belt to run farther inboard on the fan pulley. When the belt leaves the fan pulley, the belt will not align properly to the crankshaft pulley grooves and create a chirp or squeak type noise at the point of interference. Vehicles built after June 2004 will already have the new A/C compressor/power steering pump mounting bracket installed, but still may exhibit belt noise caused by the power steering pump rear mounting bracket. Correction Vehicles built prior to June 2004, replace the A/C compressor/power steering pump mounting bracket. Vehicles built after June 2004, enlarge the rear power steering pump bracket bolt holes. 1. Follow the published service information (SI) diagnostics for drive belt chirping. The diagnostic chart for the drive belt chirping will ask to inspect for a misaligned accessory drive pulley. Important Remove the top section of the radiator shroud and TCM/cover to gain access to check alignment and measure the power steering pulley on the power steering pump shaft. 2. Verify that the power steering pulley is properly pressed onto the power steering pump shaft. Refer to SI for the power steering pulley replacement. If the pulley needs to be realigned on the power steering pump shaft, follow the published SI procedures for the power steering pulley replacement. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Accessory Bracket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Accessory Bracket: > 05-06-01-018B > Feb > 11 > Diesel Engine - Drive Belt Chirp/Squeal at Cold Idle > Page 2913 3. If the noise was not fully eliminated by the procedure in step 2, the power steering pulley may be adjusted with an allowable maximum variance of 1.0 mm (0.039 in) to the front from the flush position on the shaft to assist in eliminating any remaining belt noise. Refer to graphic illustration number 1 and number 2. Ensure that the power steering pump pulley illustration number 1 is flush against the power steering pump shaft illustration number 2, with an allowable variance of 1.0 mm (0.039 in). 4. If the noise was not fully eliminated by the procedure in step 3, and there are no other concerns found, follow the published SI diagnostics for drive belt chirping. Then, if the vehicle was built prior to June 2004 go to step 5. If the vehicle was built after June 2004, go to step 6. 5. Vehicles Built Prior to June 2004: 1. Replace the A/C compressor/power steering pump mounting bracket with P/N 97362175. Refer to graphic illustration number 1. Follow the published SI procedures for the Air Conditioning (A/C) Compressor and Power Steering Pump Mounting Bracket Replacement. 2. With the new A/C compressor/power steering pump mounting bracket installed, reposition the power steering pump to gain access to drill larger holes into the rear mounting bracket using a 14 mm (1/2") drill bit. Drilling the bolt holes larger will ensure proper alignment of the bracket when installing the bolts. Refer to graphic illustration number 2. 3. Install the power steering pump to the A/C compressor/power steering pump bracket. Refer to graphic illustration numbers 4, 2, and 1. Important Power steering pump front mounting bolts must always be tightened first to ensure correct pulley alignment. 4. Refer to graphic illustration number 4 and tighten the front power steering pump mounting bolts. Tighten Tighten the bolts to 50 Nm (37 lb ft). 5. Refer to graphic illustration number 2 and tighten the rear power steering bracket bolts. Tighten Tighten the bolts to 50 Nm (37 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Accessory Bracket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Accessory Bracket: > 05-06-01-018B > Feb > 11 > Diesel Engine - Drive Belt Chirp/Squeal at Cold Idle > Page 2914 6. Vehicles Built After June 2004: 1. Remove the front and rear power steering bracket bolts from the A/C compressor/power steering pump bracket. Refer to graphic illustration numbers 4, 2, and 1. 2. Reposition the power steering pump to gain access to drill larger holes into the rear mounting bracket using a 14 mm (1/2 in) drill bit. Drilling the bolt holes larger will ensure proper alignment of the bracket when installing the bolts. Refer to graphic illustration number 2. 3. Install the power steering pump to A/C compressor/power steering pump bracket. Refer to graphic illustration numbers 4, 2, and 1. Important Power steering pump front mounting bolts must always be tightened first to ensure correct pulley alignment. 4. Refer to graphic illustration number 4 and tighten the front power steering pump mounting bolts. Tighten Tighten the bolts to 50 Nm (37 lb ft). 5. Refer to graphic illustration number 2 and tighten the rear bracket bolts. Tighten Tighten the bolts to 50 Nm (37 lb ft). Dual Generator System New belts are not available for dual generator systems. If a belt chirp noise is occurring on a dual generator system, please complete a Field Product Report (FPR). The instructions for completing a FPR can be found in Service Bulletin Number 02-00-89-002G. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Accessory Bracket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Accessory Bracket: > 05-06-01-018B > Feb > 11 > Diesel Engine - Drive Belt Chirp/Squeal at Cold Idle > Page 2915 Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Accessory Bracket > Component Information > Technical Service Bulletins > Page 2916 Engine Accessory Bracket: Service and Repair Air Conditioning (A/C) Compressor and Power Steering Pump Bracket Replacement Removal Procedure 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 2. Remove the cooling fan and shroud. Refer to Cooling Fan and Shroud Replacement (Non-HP2) (See: Cooling System/Radiator Cooling Fan/Service and Repair). 3. Remove the drive belt. Refer to Drive Belt Replacement (See: Drive Belt/Service and Repair). 4. If equipped, remove the auxiliary generator. Refer to Auxiliary Generator Replacement (6.6L) (See: Starting and Charging/Charging System/Alternator/Service and Repair/Auxiliary Generator Replacement (6.6L)). 5. If equipped with dual generators, remove the bolt from the left side idler pulley (smooth pulley). 6. Remove the idler pulley. 7. Disconnect the air conditioning (A/C) compressor clutch electrical connector. 8. Disconnect the A/C cut out switch electrical connector. 9. Remove the A/C compressor bolts. 10. Move the A/C compressor with the hoses attached to the right side of the engine compartment. 11. Remove the rear power steering pump bracket bolts (1). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Accessory Bracket > Component Information > Technical Service Bulletins > Page 2917 12. Remove the power steering pump front bracket bolts. 13. Move and secure the power steering pump out of the way. The hoses and battery cables can remain attach to pump. 14. Remove the A/C compressor and power steering pump bracket bolts and nuts. 15. Remove the A/C compressor and power steering pump bracket. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Accessory Bracket > Component Information > Technical Service Bulletins > Page 2918 1. Position the A/C compressor and power steering pump bracket. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the A/C compressor and power steering pump bracket bolts and nuts. Tighten the bolts to 46 Nm (34 lb ft). 3. Install the power steering pump and loosely install the front bracket bolts. Note: Tighten the front bracket bolts before the rear bracket bolts to ensure pulley alignment. 4. Loosely install the rear power steering pump bracket bolts (1). 1. Tighten the front bracket bolts to 50 Nm (37 lb ft). 2. Tighten the rear bracket bolts to 50 Nm (37 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Accessory Bracket > Component Information > Technical Service Bulletins > Page 2919 5. If equipped with dual generators, install the left side idler pulley and bolt. Tighten the bolt to 43 Nm (32 lb ft) 6. Install the auxiliary generator. Refer to Auxiliary Generator Replacement (6.6L) (See: Starting and Charging/Charging System/Alternator/Service and Repair/Auxiliary Generator Replacement (6.6L)). 7. Position the A/C compressor. 8. Install the A/C compressor bolts. Tighten the bolts to 50 Nm (37 lb ft). 9. Connect the A/C cut out switch electrical connector. 10. Connect the A/C clutch electrical connector. 11. Install the drive belt. Refer to Drive Belt Replacement (See: Drive Belt/Service and Repair). 12. Install the cooling fan and shroud. Refer to Cooling Fan and Shroud Replacement (Non-HP2) (See: Cooling System/Radiator Cooling Fan/Service and Repair). 13. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Testing and Inspection Engine Mount: Testing and Inspection Engine Mount Inspection 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the oil pan skid plate. 3. Remove the engine protection shield. Caution: Refer to Engine Mounting Caution (See: Service Precautions/Engine Mounting Caution). 4. Inspect for loose or missing bolts at the following locations: * Engine mount bracket to engine * Engine mount frame bracket to frame * Engine mount to engine mount bracket * Engine mount to engine mount frame bracket 5. Replace missing or loose bolts. Refer to Engine Mechanical Specifications (See: Specifications/Service Limits & General Specifications). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Testing and Inspection > Page 2923 Caution: Refer to Engine Lifting Caution (See: Service Precautions/Engine Lifting Caution). 6. If the vehicle is 4-wheel drive (4WD), you will not be able to access the lifting points on the engine. In order to raise the engine, attach a chain to the front of the engine. Then follow the inspection steps. 7. If the vehicle is rear-wheel drive (RWD), in order to raise the engine to inspect the left engine mount, use a suitable jack on the ground wire bolt bosses on the left side of the engine 8. If equipped with an automatic transmission, remove the bolt retaining the transmission oil cooler line bracket. 9. Move the transmission oil cooler lines aside. 10. In order to raise the engine to inspect the right engine mount, use a suitable jack on the ground wire bolt bosses on the right side of the engine 11. Perform the following in order to inspect the engine mounts: 1. Raise the engine to remove weight from the engine mount. 2. Place a slight tension on the rubber cushion. 3. Observe the engine mount for the following while raising the engine: * Heat check cracks covering the hard rubber surface * The rubber cushion is separated from the metal plate of the engine mount. * There is a split through the rubber cushion. 12. Replace the engine mount if any of the above conditions exist. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 13. Install the engine protection shield and bolts. Tighten the engine protection shield bolts to 20 Nm (15 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Testing and Inspection > Page 2924 14. Install the oil pan skid plate and bolts. Tighten the oil pan skid plate bolts to 20 Nm (15 lb ft). 15. Lower the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Replacement - Left Side Engine Mount: Service and Repair Engine Mount Replacement - Left Side Engine Mount Replacement - Left Side Removal Procedure 1. If RWD vehicle, raise the vehicle to a height to work through the front wheelhouse opening. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. If 4-wheel drive (4WD) vehicle, raise the vehicle in order to remove the front tires and wheels and support with jackstands. 3. Remove the wheelhouse inner panel. Refer to Front Wheelhouse Liner Replacement - Left Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Left Side)Front Wheelhouse Liner Replacement - Left Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Left Side). Caution: Broken engine mountings can cause misalignment of certain drive-train components. Misalignment of drive-train components causes eventual destruction of the drive-train components. If one engine mount breaks, the rest of the engine mounts will have increased stress put on them. This could cause the rest of the engine mounts to break. 4. Working through the wheelhouse opening remove the 3 bolts retaining the engine mount to the engine mount frame bracket. 5. Remove the oil pan skid plate, if equipped. 6. Remove the engine protection shield from the vehicle, if equipped. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Replacement - Left Side > Page 2927 Caution: When raising or supporting the engine for any reason, do not use a jack under the oil pan, any sheet metal, or the crankshaft pulley. Lifting the engine in an unapproved manner may cause component damage. Note: When raising the engine only raise enough to separate the engine mount from the engine mount bracket. Raising any further will require removal of the fan shroud or the exhaust pipe. 7. If RWD vehicle, using a suitable jack on the ground wire bolt bosses, raise the engine. Only raise the engine enough to separate the engine mount to engine mount bracket. 8. If 4WD vehicle, attach a chain to the front of the engine. Use accessible mounting bolts for the generator mounting bracket and the power steering pump mounting bracket. 9. Raise the engine with a suitable lifting device to remove the engine mount. Only raise the engine enough to separate the engine mount to engine mount bracket. 10. Remove the bolts holding the engine mount to the engine. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Replacement - Left Side > Page 2928 11. Remove the 2 through-bolts for the engine mount frame bracket. 12. Remove the engine mount frame bracket. 13. Remove the engine mount. Installation Procedure 1. Position the engine mount frame bracket on the frame. Do not install the bolts. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Replacement - Left Side > Page 2929 2. Install the engine mount. 3. Perform the following procedure prior to installing the engine mount bracket bolts. 1. Remove all traces of the original adhesive patch. 2. Clean the threads of the bolt with denatured alcohol or equivalent and allow to dry. 3. Apply threadlocker GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the bolts. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the 2 through-bolts. Tighten the through-bolts to 75 Nm (55 lb ft). 5. Install the bolts holding the engine mount to the engine. Tighten the engine mount bolts to 58 Nm (43 lb ft). 6. Lower the engine. 7. If 4WD vehicle remove the chain from the front of the engine. 8. If 4WD vehicle, install the generator mounting bracket and the power steering mount bracket bolt. Tighten the mounting bracket bolts to 50 Nm (37 lb ft). 9. Install the 3 bolts holding the engine mount to the engine mount frame bracket. Tighten the engine mount to engine mount frame bracket bolts to 65 Nm (48 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Replacement - Left Side > Page 2930 10. Install the engine protection shield and bolts. Tighten the engine protection shield bolts to 20 Nm (15 lb ft). 11. Install the oil pan skid plate. Tighten the bolts to 20 Nm (15 lb ft). 12. Remove the wheelhouse inner panel. Refer to Front Wheelhouse Liner Replacement - Left Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Left Side)Front Wheelhouse Liner Replacement - Left Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Left Side). 13. Lower the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Replacement - Left Side > Page 2931 Engine Mount: Service and Repair Engine Mount Replacement - Right Side Engine Mount Replacement - Right Side Removal Procedure 1. Remove the starter motor. Refer to Starter Replacement (V8) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair )Starter Replacement (V6) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair)Starter Replacement (6.6L) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair). 2. If RWD vehicle, raise the vehicle to a height to work through the front wheelhouse opening. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 3. If 4-wheel drive (4WD) vehicle, raise the vehicle in order to remove the front tires and wheels and support with jackstands. 4. Remove the right front tire and wheel, if necessary. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 5. Remove the pushpins holding the right front fender wheelhouse inner panel (1). 6. Remove the wheelhouse inner panel. Caution: Broken engine mountings can cause misalignment of certain drive-train components. Misalignment of drive-train components causes eventual destruction of the drive-train components. If one engine mount breaks, the rest of the engine mounts will have increased stress put on them. This could cause the rest of the engine mounts to break. 7. Working through the wheelhouse opening remove the 3 bolts retaining the engine mount to the engine mount frame bracket. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Replacement - Left Side > Page 2932 8. Remove the oil pan skid plate, if equipped. 9. Remove the engine protection shield from the vehicle, if equipped. 10. If RWD vehicle and equipped with an automatic transmission, remove the bracket bolt for the transmission oil cooler lines to the engine. 11. Move the transmission oil cooler lines aside. Caution: When raising or supporting the engine for any reason, do not use a jack under the oil pan, any sheet metal, or the crankshaft pulley. Lifting the engine in an unapproved manner may cause component damage. Note: When raising the engine only raise enough to separate the engine mount from the engine mount bracket. Raising any further the fan shroud or the exhaust pipe will require removal. 12. If RWD vehicle, using a suitable jack on the ground wire bolt bosses, raise the engine. Only raise the engine enough to separate the engine mount to engine mount bracket. 13. If 4WD vehicle, attach a chain to the front of the engine. Use accessible mounting bolts for the generator mounting bracket and the power steering pump mounting bracket. 14. Raise the engine with a suitable lifting device to remove the engine mount. Only raise the engine enough to separate the engine mount to engine mount bracket. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Replacement - Left Side > Page 2933 15. Remove the bolts holding the engine mount to the engine. 16. Remove the 2 through-bolts for the engine mount frame bracket. 17. Remove the engine mount frame bracket. 18. Remove the engine mount. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Replacement - Left Side > Page 2934 1. Position the engine mount frame bracket on the frame. Do not install the bolts. 2. Install the engine mount. 3. Perform the following procedure prior to installing the engine mount bracket bolts. 1. Remove all traces of the original adhesive patch. 2. Clean the threads of the bolt with denatured alcohol or equivalent and allow to dry. 3. Apply threadlocker GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the bolts. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the 2 through-bolts. Tighten the through-bolts to 75 Nm (55 lb ft). 5. Install the bolts holding the engine mount to the engine. Tighten the engine mount bolts to 58 Nm (43 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Replacement - Left Side > Page 2935 6. Lower the engine. 7. If 4WD vehicle, remove the chain from the front of the engine. 8. If 4WD vehicle, install the generator mounting bracket and the power steering mount bracket bolt. Tighten the mounting bracket bolts to 50 Nm (37 lb ft). 9. Install the 3 bolts holding the engine mount to the engine mount frame bracket. Tighten the engine mount to engine mount frame bracket bolts to 65 Nm (48 lb ft). 10. If RWD vehicle with an automatic transmission, install the bolt for the transmission oil cooler line bracket. Tighten the transmission oil cooler line bracket bolt to 9 Nm (80 lb in). 11. Install the engine protection shield and bolts. Tighten the engine protection shield bolts to 20 Nm (15 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Replacement - Left Side > Page 2936 12. Install the oil pan skid plate. Tighten the bolts to 20 Nm (15 lb ft). 13. Install the right front tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 14. Install the front fender wheelhouse inner panel. 15. Install the starter motor. Refer to Starter Replacement (V8) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair)Starter Replacement (V6) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair)Starter Replacement (6.6L) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair). 16. Lower the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Service and Repair Idler Pulley: Service and Repair Drive Belt Idler Pulley Replacement Removal Procedure 1. Remove the drive belt. Refer to Drive Belt Replacement (See: Drive Belt/Service and Repair). 2. Remove the bolt (1) from the right side idler pulley. 3. Remove the idler pulley. 4. Remove the bolt (2) for the center idler pulley. 5. Remove the idler pulley. 6. If equipped with dual generators, remove the bolt from the left side idler pulley. 7. If equipped with dual generators, remove the idler pulley. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Service and Repair > Page 2940 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the right side idler pulley and bolt (1). Tighten the bolt to 50 Nm (37 lb ft). 2. Install the center idler pulley and bolt (2). Tighten the bolt to 50 Nm (37 lb ft). 3. If equipped with dual generators, install the left side idler pulley and bolt. Tighten the bolt to 50 Nm (37 lb ft). 4. Install the drive belt. Refer to Drive Belt Replacement (See: Drive Belt/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications Oil Pressure - Minimum- Hot - at idle................................................................................................... .............................................................48 KPa (7 psi) Oil Pressure - Minimum - Hot - 1800 RPM...... .............................................................................................................................................193 KPa (28 psi) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications > Page 2945 Engine Oil Pressure: Testing and Inspection Oil Pressure Diagnosis and Testing Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick Tube > Component Information > Service and Repair > Oil Level Indicator Tube Replacement Engine Oil Dip Stick - Dip Stick Tube: Service and Repair Oil Level Indicator Tube Replacement Oil Level Indicator Tube Replacement Removal Procedure 1. Remove the oil level indicator. 2. Remove the exhaust manifold. Refer to Exhaust Manifold Replacement - Right Side (V8) (See: Exhaust System/Exhaust Manifold/Service and Repair)Exhaust Manifold Replacement - Right Side (6.6L) (See: Exhaust System/Exhaust Manifold/Service and Repair)Exhaust Manifold Replacement - Right Side (V6) (See: Exhaust System/Exhaust Manifold/Service and Repair). 3. Remove the starter motor. Refer to Starter Replacement (V8) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair )Starter Replacement (V6) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair)Starter Replacement (6.6L) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair). 4. Remove the oil level indicator tube bolt at the indicator tube bracket. 5. Remove the oil level indicator tube and O-ring seals. 6. Remove and discard the O-ring seals. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick Tube > Component Information > Service and Repair > Oil Level Indicator Tube Replacement > Page 2950 1. Install NEW O-ring seals onto the oil level indicator tube. 2. Lightly lubricate the O-ring seals with engine oil. 3. Install the oil level indicator tube. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the oil level indicator tube bolt at the indicator tube bracket. Tighten the bolt to 21 Nm (15 lb ft). 5. Install the starter motor. Refer to Starter Replacement (V8) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair)Starter Replacement (V6) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair)Starter Replacement (6.6L) (See: Starting and Charging/Starting System/Starter Motor/Service and Repair). 6. Install the exhaust manifold. Refer to Exhaust Manifold Replacement - Right Side (V8) (See: Exhaust System/Exhaust Manifold/Service and Repair)Exhaust Manifold Replacement - Right Side (6.6L) (See: Exhaust System/Exhaust Manifold/Service and Repair)Exhaust Manifold Replacement - Right Side (V6) (See: Exhaust System/Exhaust Manifold/Service and Repair). 7. Install the oil level indicator. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick Tube > Component Information > Service and Repair > Oil Level Indicator Tube Replacement > Page 2951 Engine Oil Dip Stick - Dip Stick Tube: Service and Repair Oil Filler Tube Replacement Oil Filler Tube Replacement Removal Procedure 1. Remove the fan and clutch assembly. Refer to Cooling Fan and Shroud Replacement (Non-HP2) (See: Cooling System/Radiator Cooling Fan/Service and Repair). 2. Remove the drive belt. Refer to Drive Belt Replacement (See: Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair). 3. Remove the upper oil fill tube bolt (1). 4. Remove the oil filler tube bracket bolts. 5. Remove the oil fill tube bracket. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick Tube > Component Information > Service and Repair > Oil Level Indicator Tube Replacement > Page 2952 6. Remove the lower oil fill tube bolt (1). 7. Remove the oil fill tube. 8. Remove and discard the oil fill tube O-ring seal. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick Tube > Component Information > Service and Repair > Oil Level Indicator Tube Replacement > Page 2953 1. Install a NEW O-ring seal onto the oil fill tube. 2. Install the oil fill tube. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the lower oil fill tube bolt (1). Tighten the bolts to 21 Nm (15 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick Tube > Component Information > Service and Repair > Oil Level Indicator Tube Replacement > Page 2954 4. Install the oil fill tube bracket. 5. Install the oil filler tube bracket bolts. Tighten the bolts to 21 Nm (15 lb ft). 6. Install the upper oil fill tube bolt (1). Tighten the bolts to 21 Nm (15 lb ft). 7. Install the drive belt. Refer to Drive Belt Replacement (See: Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair). 8. Install the fan and clutch assembly. Refer to Cooling Fan and Shroud Replacement (Non-HP2) (See: Cooling System/Radiator Cooling Fan/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil With Filter ........................................................................................................................... ............................................. 10.0 quarts (9.5 liters) NOTE: All capacities are approximate. When adding, be sure to fill to the approximate level. Recheck fluid level after filling. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 2959 Engine Oil: Fluid Type Specifications WHAT KIND OF ENGINE OIL TO USE LOOK FOR THESE THINGS: Oils designated as API CJ-4 are required for your vehicle. The CJ-4 designation can appear either alone or in combination with other American Petroleum Institute (API) designations, such as API CJ-4/SL. These letters show API levels of quality. SAE 15W-40 is best for your vehicle. When it is very cold, below 0°F (-18°C), you should use SAE 5W-40 to improve cold starting. These numbers on the oil container show its viscosity, or thickness. Do not use other viscosity oils such as SAE 10W-30, SAE 10W-40, or SAE 20W-50. NOTICE: Use only engine oils that have the designation CJ-4 for the diesel engine. Failure to use the recommended oil can result in engine damage not covered by your warranty. ENGINE OIL ADDITIVES ENGINE OIL FLUSHES Do not add anything to the oil. The recommended oils with the API service symbol are all you need for good performance and engine protection. Engine oil flushes are not recommended and could cause engine damage not covered by the vehicle warranty. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Page 2960 Engine Oil: Service and Repair Engine Oil and Oil Filter Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Position a suitable drain pan under the oil pan drain plug. 3. Remove the oil drain plug. 4. Allow the oil to drain completely. 5. Clean and inspect the oil pan drain plug, replace if necessary. 6. Clean and inspect the oil pan drain plug sealing surface, replace the oil pan if necessary. 7. Wipe any remaining oil from the drain plug hole and reinstall the oil pan drain plug until snug. 8. Position a suitable drain pan under the oil filter 9. Remove the oil filter. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Page 2961 10. Ensure that the oil filter gasket is still on the old oil filter, if not remove the oil filter gasket from the adapter. Installation Procedure 1. Apply clean engine oil to the NEW oil filter gasket. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the NEW oil filter and tighten after contact plus 1 to 11/4 turn. 3. Tighten the oil pan drain plug to 84 Nm (62 lb ft). 4. Remove the oil drain pan from under the vehicle. 5. Lower the vehicle. 6. Fill the engine with new engine oil. Refer to Approximate Fluid Capacities (See: Maintenance/Specifications) and Fluid and Lubricant Recommendations (USA and Canada) (See: Maintenance). 7. Start the engine. 8. Inspect for oil leaks after engine start up. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Page 2962 9. Turn off the engine and allow the oil a few minutes to drain back into the oil pan. 10. Remove the oil level indicator from the oil level indicator tube. 11. Clean off the indicator end of the oil level indicator with a clean paper towel or cloth. 12. Install the oil level indicator into the oil level indicator tube until the oil level indicator handle contacts the top of the oil level indicator tube. 13. Again, remove the oil level indicator from the oil level indicator tube keeping the tip of the oil level indicator down. 14. Check the level of the engine oil on the oil level indicator. 15. If necessary, adjust the oil level be adding or draining oil. 16. Check for oil leaks. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Engine Oil Cooler Connector Replacement Oil Cooler: Service and Repair Engine Oil Cooler Connector Replacement Engine Oil Cooler Connector Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Engine Oil Cooler Connector Replacement > Page 2967 Oil Cooler: Service and Repair Engine Oil Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection Engine Oil Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection Special Tools * DT-47731 1/2 in Line Quick Release Tool * J 28585 Universal Snap Ring Remover for the 5/8 in Line Removal Procedure 1. Remove the plastic caps from the quick connect fittings by pulling the caps back along the pipe before installation. 2. Install the DT-47731 onto the engine oil cooler (EOC) pipe, or use the J 28585 3. Slide the DT-47731 toward the EOC pipe fitting, or use the J 28585 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Engine Oil Cooler Connector Replacement > Page 2968 Note: Rotate the DT-47731 to engage the EOC pipe fitting's retainer slots. The DT-47731 should be nearly flush with the fitting. 4. Connect the DT-47731 onto the EOC pipe fitting. 5. Rotate the DT-47731 or use the J 28585 until the retainer clip (1) rises above the fitting retainer seat. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Engine Oil Cooler Connector Replacement > Page 2969 6. Pull back on the EOC pipe to disengage the pipe from the EOC pipe fitting. 7. Remove the DT-47731 or the J 28585 from the EOC pipe. Installation Procedure Note: Discard the EOC retaining clip and install a new retaining clip. 1. Install the EOC pipe into the EOC pipe fitting. A distinct snap should be heard or felt when assembling the EOC pipe to the fitting. 2. To ensure the cooler line is properly installed, give the cooler pipe a gentle pull. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Engine Oil Cooler Connector Replacement > Page 2970 Oil Cooler: Service and Repair Engine Oil Cooler Hose/Pipe Replacement Engine Oil Cooler Hose/Pipe Replacement Removal Procedure The optional oil cooler is either an integral part of the radiator or a separate unit placed in front of the radiator. The cooler lines and hoses are serviceable. 1. Disconnect the engine oil cooler quick connect fittings. Refer to Engine Oil Cooler Pipe/Hose Quick Connect Fitting Replacement (See: Engine Oil Cooler Pipe/Hose Quick Connect Fitting Replacement). 2. If equipped with regular production option (RPO) L76 (6.0L) engine, perform the following. 1. Open the oil cooler hose clip located on the lower fan shroud. 2. Remove the oil cooler hoses from the clip. 3. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Engine Oil Cooler Connector Replacement > Page 2971 4. If equipped with RPO LY6 (6.0L) engine, remove the oil cooler hoses from the clip. 5. Place a jack or utility stands at the rear of the vehicle. 6. If equipped, remove the engine protection shield. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement). 7. For both 1500 and 2500 series, support the front differential carrier with a suitable adjustable jack. 8. For 1500 series vehicles, remove the differential carrier right side nuts. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Engine Oil Cooler Connector Replacement > Page 2972 9. Remove the differential carrier left side bolts. 10. Lower the differential carrier. 11. For 2500 series vehicles, remove the differential carrier right side nuts. 12. Remove the differential carrier upper mounting bolt and nut. 13. Remove the differential carrier lower mounting bolt and nut. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Engine Oil Cooler Connector Replacement > Page 2973 14. If equipped with RPO L76 (6.0L) engine, perform the following: 1. Lower the differential carrier. 2. Remove the oil cooler hose adapter bolts (2). 3. Remove the oil cooler hose assembly and gasket. Discard the gasket. 4. Inspect the fittings, connectors, and cooler hoses for damage or distortion. 15. If equipped with RPO LY6 (6.0L) engine, perform the following: 1. Remove the oil cooler hose bracket bolt. (1) 2. Remove the oil cooler hose adapter bolts. (2) 3. Remove the oil cooler hose assembly. Discard the gasket. 4. Inspect the fittings, connectors, and cooler hoses for damage or distortion. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Engine Oil Cooler Connector Replacement > Page 2974 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. If equipped with RPO LY6 (6.0L) engine, perform the following: 1. Install the oil cooler hose assembly and a NEW gasket. 2. Install the oil cooler hose adapter bolts (2). Tighten the bolts to 12 Nm (106 lb in). 3. Install the oil cooler hose bracket bolt. Tighten the bolt to 25 Nm (18 lb ft). 2. If equipped with a RPO L76 (6.0L) engine, perform the following. 1. Install the oil cooler hose assembly and a NEW gasket. 2. Install the oil cooler hose adapter bolts (2). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Engine Oil Cooler Connector Replacement > Page 2975 Tighten the bolts to 12 Nm (106 lb in). 3. Install the oil cooler hose bracket bolt (1). Tighten the bolt to 25 Nm (18 lb ft). 3. For 2500 series vehicles, raise the differential carrier into position. 4. Install the differential carrier left side upper bolt and nut until snug. 5. Install the differential carrier left side lower bolt and nut until snug. 6. Install the differential carrier right side nuts. Tighten the bolt to 100 Nm (74 lb ft). 7. For 1500 series vehicles, raise the differential carrier into position. 8. Install the differential carrier right side nuts. 9. Install the differential carrier left side bolts. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Engine Oil Cooler Connector Replacement > Page 2976 Tighten the bolts/nuts to 100 Nm (74 lb ft). 10. If equipped, install the engine protection shield. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement). 11. Remove the jack or utility stand from the rear of the vehicle. 12. Lower the vehicle. Note: * Ensure the oil cooler line being installed has a plastic cap on the end that connects to the quick connect fitting. If no plastic cap exists, or the plastic cap is damaged, obtain a new cap. Install the cap onto the cooler line prior cooler line installation. * Do not use the plastic cap in order to install the cooler line into the fitting. 13. If equipped with RPO LY6 (6.0L) engine, install the oil cooler hoses to the clip. Note: * Ensure the oil cooler line being installed has a plastic cap on the end that connects to the quick connect fitting. If no plastic cap exists, or the Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Engine Oil Cooler Connector Replacement > Page 2977 plastic cap is damaged, obtain a new cap. Install the cap onto the cooler line prior cooler line installation. * Do not use the plastic cap in order to install the cooler line into the fitting. 14. If equipped with RPO L76 (6.0L) engine, perform the following: 1. Install the oil cooler hoses to the hose clip on the fan shroud. 2. Snap the oil cooler hose clip shut. 15. Install the oil cooler lines to the radiator. Refer to Engine Oil Cooler Pipe/Hose Quick Connect Fitting Replacement (See: Engine Oil Cooler Pipe/Hose Quick Connect Fitting Replacement). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Engine Oil Cooler Connector Replacement > Page 2978 Oil Cooler: Service and Repair Engine Oil Cooler Pipe/Hose Quick Connect Fitting Replacement Engine Oil Cooler Pipe/Hose Quick Connect Fitting Replacement Removal Procedure 1. Disengage the plastic caps from the quick connect fittings. Pull the caps back along the pipe. 2. Using a bent-tip screwdriver or equivalent, pull on one of the open ends of the retaining ring in order to rotate the retaining ring. 3. Rotate the retaining ring around the quick connector until the retaining ring is out of position and can be completely removed. Discard the retaining rings. 4. Remove the engine oil cooler line from the quick connector fitting at the radiator. Refer to Engine Oil Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection (See: Engine Oil Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection). Pull the lines straight out from the connectors. 5. Clean all of the components in a suitable solvent, and dry them with compressed air. 6. Inspect the fittings, the connectors, the cooler lines, and the cooler for damage, distortion, or restriction. Replace parts as necessary. Installation Procedure Note: When performing the following procedure, do not reuse the old retaining rings. Replace the old retaining rings with new ones. Do not install the new retaining ring onto the fitting by pushing the retaining ring down over the fitting. 1. Install a new retaining ring into each quick connector fitting. 2. Hook one of the open ends of the retaining ring in one of the slots in the quick connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Engine Oil Cooler Connector Replacement > Page 2979 3. Rotate the retaining ring around the connector until the retaining ring is positioned with all 3 ears through the 3 slots. 4. Ensure the 3 retaining ring ears can be seen from the inside of the connector and the retaining ring can move freely in the slots. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Engine Oil Cooler Connector Replacement > Page 2980 5. Install the engine oil cooler line into the quick connector fitting until a click is heard or felt. Pull back on the engine oil cooler lines to ensure a proper connection. Note: Do not manually depress the retaining clip when installing the plastic cap. 6. Snap the plastic cap onto the quick connect fitting. 7. Ensure that the plastic cap is fully seated against the fitting. 8. Ensure that no gap is present between the cap and the fitting. 9. Inspect and fill the engine oil to the proper level. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Technical Service Bulletins > Engine - Noise/Damage Oil Filter Application Importance Oil Filter: Technical Service Bulletins Engine - Noise/Damage Oil Filter Application Importance INFORMATION Bulletin No.: 07-06-01-016B Date: July 27, 2009 Subject: Information on Internal Engine Noise or Damage After Oil Filter Replacement Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being updated to add model years. Please discard Corporate Bulletin Number 07-06-01-016A (Section 06 - Engine/Propulsion System). Important Engine damage that is the result of an incorrect or improperly installed engine oil filter is not a warrantable claim. The best way to avoid oil filter quality concerns is to purchase ACDelco(R) oil filters directly from GMSPO. Oil filter misapplication may cause abnormal engine noise or internal damage. Always utilize the most recent parts information to ensure the correct part number filter is installed when replacing oil filters. Do not rely on physical dimensions alone. Counterfeit copies of name brand parts have been discovered in some aftermarket parts systems. Always ensure the parts you install are from a trusted source. Improper oil filter installation may result in catastrophic engine damage. Refer to the appropriate Service Information (SI) installation instructions when replacing any oil filter and pay particular attention to procedures for proper cartridge filter element alignment. If the diagnostics in SI (Engine Mechanical) lead to the oil filter as the cause of the internal engine noise or damage, dealers should submit a field product report. Refer to Corporate Bulletin Number 02-00-89-002I (Information for Dealers on How to Submit a Field Product Report). Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Technical Service Bulletins > Page 2985 Oil Filter: Service and Repair Engine Oil and Oil Filter Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Position a suitable drain pan under the oil pan drain plug. 3. Remove the oil drain plug. 4. Allow the oil to drain completely. 5. Clean and inspect the oil pan drain plug, replace if necessary. 6. Clean and inspect the oil pan drain plug sealing surface, replace the oil pan if necessary. 7. Wipe any remaining oil from the drain plug hole and reinstall the oil pan drain plug until snug. 8. Position a suitable drain pan under the oil filter 9. Remove the oil filter. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Technical Service Bulletins > Page 2986 10. Ensure that the oil filter gasket is still on the old oil filter, if not remove the oil filter gasket from the adapter. Installation Procedure 1. Apply clean engine oil to the NEW oil filter gasket. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the NEW oil filter and tighten after contact plus 1 to 11/4 turn. 3. Tighten the oil pan drain plug to 84 Nm (62 lb ft). 4. Remove the oil drain pan from under the vehicle. 5. Lower the vehicle. 6. Fill the engine with new engine oil. Refer to Approximate Fluid Capacities (See: Maintenance/Specifications) and Fluid and Lubricant Recommendations (USA and Canada) (See: Maintenance). 7. Start the engine. 8. Inspect for oil leaks after engine start up. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Technical Service Bulletins > Page 2987 9. Turn off the engine and allow the oil a few minutes to drain back into the oil pan. 10. Remove the oil level indicator from the oil level indicator tube. 11. Clean off the indicator end of the oil level indicator with a clean paper towel or cloth. 12. Install the oil level indicator into the oil level indicator tube until the oil level indicator handle contacts the top of the oil level indicator tube. 13. Again, remove the oil level indicator from the oil level indicator tube keeping the tip of the oil level indicator down. 14. Check the level of the engine oil on the oil level indicator. 15. If necessary, adjust the oil level be adding or draining oil. 16. Check for oil leaks. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Service and Repair Oil Filter Adapter: Service and Repair Oil Filter Adapter and Oil Cooler Assembly Replacement Removal Procedure 1. Drain the engine coolant and the engine block. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Cooling System/Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Cooling System/Service and Repair). 2. Remove the charge air inlet pipe. Refer to Charge Air Cooler Inlet Pipe Replacement (See: Powertrain Management/Fuel Delivery and Air Induction/Turbocharger/Intercooler/Intercooler Duct/Service and Repair/Charge Air Cooler Inlet Pipe Replacement). 3. Remove the cooling fan shroud bracket bolts. 4. Remove the cooling fan shroud bracket. 5. Loosen the water pump outlet pipe nuts at the coolant pipe. 6. Remove the lower EGR cooler pipe. Refer to Exhaust Gas Recirculation Coolant Hoses/Pipes Replacement (See: Powertrain Management/Emission Control Systems/Exhaust Gas Recirculation/EGR Cooler/Service and Repair/Exhaust Gas Recirculation Coolant Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Service and Repair > Page 2991 Hoses/Pipes Replacement). 7. If equipped, remove the oil pan skid plate bolts and plate. 8. Remove the oil filter. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Service and Repair > Page 2992 9. Remove the oil cooler adapter nuts and studs from the flywheel housing. 10. Remove the oil cooler assembly bolts. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Service and Repair > Page 2993 11. Remove the oil cooler adapter bolts from the oil filter adapter/oil cooler. 12. Remove the oil cooler and adapter. 13. Remove the coolant pipe nuts. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Service and Repair > Page 2994 14. Remove the coolant pipe. 15. Remove and discard the oil filter adapter/oil cooler O-ring seals. 16. Remove and discard the coolant pipe O-ring and gasket. 17. If required, clean and inspect the oil filter adapter/oil cooler. Refer to Oil Filter Adapter and Oil Cooler Assembly Cleaning and Inspection (See: Service and Repair/Overhaul/89. Oil Filter Adapter and Oil Cooler Assembly Cleaning and Inspection). Installation Procedure 1. Install new coolant pipe O-ring and gasket. 2. Install new oil filter adapter/oil cooler O-ring seals. 3. Install the coolant pipe. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Service and Repair > Page 2995 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the coolant pipe nuts. Tighten the coolant pipe nuts to 25 Nm (18 lb ft). 5. Install the oil cooler and adapter. 6. Install the oil cooler adapter bolts to the oil filter adapter/oil cooler. Tighten the oil cooler adapter bolts to 25 Nm (18 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Service and Repair > Page 2996 7. Install the oil cooler assembly bolts. Tighten the oil cooler assembly bolts to 25 Nm (18 lb ft). 8. Install the oil cooler adapter nuts and studs to the flywheel housing. * Tighten the oil cooler adapter nuts to 25 Nm (18 lb ft). * Tighten the oil cooler adapter studs to 10 Nm (89 lb in). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Service and Repair > Page 2997 9. Install the oil filter. 10. If removed, install the oil pan skid plate bolts and plate. Tighten the bolts to 20 Nm (15 lb ft). 11. Install the lower EGR cooler pipe. Refer to Exhaust Gas Recirculation Coolant Hoses/Pipes Replacement (See: Powertrain Management/Emission Control Systems/Exhaust Gas Recirculation/EGR Cooler/Service and Repair/Exhaust Gas Recirculation Coolant Hoses/Pipes Replacement). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Service and Repair > Page 2998 12. Install the water pump outlet pipe nuts at the coolant pipe. Tighten the nuts to 25 Nm (18 lb ft). 13. Position the cooling fan shroud bracket (2). 14. Install the cooling fan shroud bracket bolts (1). Tighten the fan shroud bolt to 8 Nm (71 lb in). Tighten the fan shroud bracket to engine block bolts to 58Nm (63 lb ft). 15. Install the charge air inlet pipe. Refer to Charge Air Cooler Inlet Pipe Replacement (See: Powertrain Management/Fuel Delivery and Air Induction/Turbocharger/Intercooler/Intercooler Duct/Service and Repair/Charge Air Cooler Inlet Pipe Replacement). 16. Fill the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Cooling System/Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Cooling System/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions Oil Level Sensor: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Schematic Symbols Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3003 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3004 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3005 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3006 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3007 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3008 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3009 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3010 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3011 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3012 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3013 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3014 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3015 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3016 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3017 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3018 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3019 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3020 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3021 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3022 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3023 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3024 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3025 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3026 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3027 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3028 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3029 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3030 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3031 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3032 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3033 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3034 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3035 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3036 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3037 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3038 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3039 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3040 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3041 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3042 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3043 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3044 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3045 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3046 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3047 Oil Level Sensor: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed with Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3048 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3049 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Connector Test Adapters) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3050 Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Test Lamp) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Fused Jumper Wires) * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage Drop) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Frequency) * Testing Ground and Low Reference Circuits (See: Testing and Inspection/Component Tests and General Diagnostics/Testing Ground and Low Reference Circuits) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fuses) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Circuit Breakers) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fusible Links) Troubleshooting with a Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Testing for a Short to Voltage Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3051 Testing for a Short to Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure tests for a short to voltage in a circuit. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the Digital Multimeter (DMM) to the V (DC) position. 4. Connect the positive lead of the DMM to one end of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. Turn ON the ignition and operate all accessories. 7. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Special Tools J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure). Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents). Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3052 The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the frequency of a signal. Note: Connecting the Digital Multimeter (DMM) to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Set to Hz on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3053 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the Digital Multimeter (DMM). 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the difference in voltage potential between 2 points. 1. Set the Digital Multimeter (DMM) to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3054 Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Backprobe Note: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3055 (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for Continuity Testing for Continuity Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures verify good continuity in a circuit. With a Digital Multimeter (DMM) 1. Set the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Select the MIN MAX function on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3056 Testing for Electrical Intermittents Testing for Electrical Intermittents Special Tools J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. Note: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions). 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3057 visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing for Terminal Fretting Some intermittent conditions can be caused by wire terminal fretting corrosion. Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can pile up enough at the electrical contact spots that the electrical resistance across the connection increases. Movement between the contacting surfaces as small as 10 to 100 microns can cause fretting. To put this in perspective, a sheet of paper is about 100 microns thick, so fretting motion is small and hard to see. Vibration and thermal expansion/contraction are the main sources that create fretting motion. Since vehicles vibrate and can experience large temperature swings, they are a good source for fretting motion. Tin, copper, nickel, and iron surfaces are all susceptible to fretting corrosion. Fretting corrosion can be difficult to see but it looks like small, dark smudges on the terminals contact surface. To correct a fretting condition disconnect the suspect connector and add Nyogel lubricant 760G (dielectric grease) to both sides of the connector terminals. Then reconnect the connector and wipe away any excess lubricant. This will correct the additional terminal contact resistance due to the terminal fretting corrosion. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3058 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics). * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Ground Distribution Schematics). Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Checking Aftermarket Accessories). * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3059 Note: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures test for a short to ground in a circuit. With a Digital Multimeter (DMM) 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohms position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Danger: High voltage circuits should only be tested using a digital multimeter (DMM) and test leads with at least a CAT III rating, such as the J 39200-A Digital Multimeter. Failure to follow the procedures exactly as written may result in serious injury or death. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Digital Multimeter (DMM) Basic Requirements Service information is validated using digital multimeters that meet or exceed the following requirements. Using a multimeter that does not meet these basic requirements may give inaccurate readings which could lead to an incorrect diagnosis. Display and Settings 1. Four digits displayed 2. Voltage, amperage, resistance, frequency, diode test settings, and min-max function 3. Display positive and negative values Voltage 1. Have at least 10 M ohm input impedance Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3060 2. Test a DC voltage range of 0.1-1000 V. 3. Test an AC voltage range of 0.1-1000 V. Amperage 1. Test a DC amperage range of 0.1µA-10 A. 2. Test an AC amperage range of 0.1µA-10 A. Resistance Test a resistance range of 0.1 ohm-40 Mohm and displays infinite for a value greater than 40 M ohm (O.L. (Over-load)) Frequency Test for a frequency range of 0.5 HZ-199 K HZ Diode Test 1. Apply at least 1 mA when performing the diode bias test 2. Display the break over voltage drop (0-3 V) of a forward biased diode 3. Display infinite (O.L. (Over-load)) when a diode is reverse biased Min-Max Readings 1. Can update at a 1 ms sample rate 2. Saves and displays minimum and maximum values Note: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Probe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors). * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the EL-38125-580 GM Approved Terminal Release Tool Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the EL-38125-580 GM Approved Terminal Release Tool Kit , ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the EL-38125-580 GM Approved Terminal Release Tool Kit label on the inside of the EL-38125-580 GM Approved Terminal Release Tool Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3061 Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/EPC Connectors AFL/EPC Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3062 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 3. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3063 View showing depressing of the lever lock release tab. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3064 6. Release the rear lower half of the wiredress cover. 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3065 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3066 Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Bosch Connectors (ECM) Bosch Connectors (ECM) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3067 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. 2. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3068 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-bladed tool to release the locking tabs and remove the dress cover. 4. The terminal positive assurance (TPA) is located in the front of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3069 5. Use a small flat-blade tool to remove TPA from the connector. 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3070 Note: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3071 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3072 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Terminal Replacement Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3073 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3074 5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Position Assurance Locks) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Terminal Position Assurance Locks) * AFL/EPC Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/AFL/EPC Connectors) * Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (BSK))Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (0.64))Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (2.8 JPT))Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (ECM)) * Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Weather Pack))Delphi Connectors (Push To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Push to Seat))Delphi Connectors Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3075 (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Pull to Seat))Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro-Pack 100W))Delphi Connectors (Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro .64))Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (12-Way)) * FCI Connectors (Lever Lock) (See: General Electrical Diagnostic Procedures/Connector Repairs/FCI Connectors (Lever Lock)) * JST Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/JST Connectors) * Kostal Connectors (Glow Plug Control Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Glow Plug Control Module))Kostal Connectors (Transmission) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Transmission)) * Molex Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Molex Connectors) * Sumitomo Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Sumitomo Connectors) * Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (CM 42-Way))Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Sensor))Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (0.25 Cap))Tyco/AMP Connectors (43-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (43-Way))Tyco/AMP Connectors (Door Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Door Module))Tyco/AMP Connectors (102-Way Inline) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (102-Way Inline))Tyco/AMP Connectors (Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Seat))Tyco/AMP Connectors (SIR) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (SIR)) * Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (2-Way))Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (16-Way)) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3076 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3077 * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3078 * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3079 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3080 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3081 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Push to Seat) Delphi Connectors (Push To Seat) Special Tools J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3082 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs). 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Terminated Lead Repair 1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice sleeves depending on the gauge size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Delphi Connectors (Pull to Seat) Delphi Connectors (Pull To Seat) Special Tools Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3083 J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Note: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3084 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. View of a typical Micro 64 connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3085 Depress the lock and pull the lever over and past the lock. View of the connector when released from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3086 View of another type of Micro 64 connector. Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3087 View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3088 Note: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3089 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3090 Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Note: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3091 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3092 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3093 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3094 1. Cut the wire as close to the terminal as possible. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3095 Terminal Replacement Procedure After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Special Tools J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Note: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals). 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12-Way) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3096 Delphi Connectors (12-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3097 4. Release the lower wire dress cover locking tab. 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3098 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3099 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors (Lever Lock) FCI Connectors (Lever Lock) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3100 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. The release tab is located on the top of the wiredress cover. 3. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3101 6. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3102 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3103 1. While depressing the lock, remove the connector from the component. 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3104 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. 4. View of the TPA when removed from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3105 5. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Glow Plug Control Module) Kostal Connectors (Glow Plug Control Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3106 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3107 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3108 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. Note: The front TPA cannot be removed from the connector. Only move it to the preset position. 6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm). 7. Use a small flat-blade tool to completely remove the rear TPA from the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3109 8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Transmission) Kostal Connectors (Transmission) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3110 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3111 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Terminal Replacement Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3112 After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3113 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3114 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3115 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3116 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3117 3. To assemble the connector, reverse the connector disassembly procedure. Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3118 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3119 7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3120 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3121 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3122 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3123 Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3124 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3125 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3126 6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (102-Way Inline) Tyco/AMP Connectors (102-Way Inline) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3127 View of a typical connector in the assembled position. 1. Pull the locking lever to the 90 degree position from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3128 2. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal. 3. Slide the male connector body out away from the guide plates. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3129 Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 4. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. 5. Using terminal release tool J 38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3130 6. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 7. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3131 8. The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool J-38125-11A or equivalent to release the locking tab and slide the connector off the female body. 9. Move the locking lever 180 degrees from the connected position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3132 10. With the locking lever in the 180 degree position the guide plates can be removed from the connector body. Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 11. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3133 12. Using terminal release tool J 38125-216, lift the terminal plate past the terminals and out of the connector body cavity. 13. Terminal plate will bind slightly on each corner. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3134 14. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 15. Using terminal release tool J 38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3135 16. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 17. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3136 18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever. 19. Slide the male connector body back inward toward the guide plates. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3137 20. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly. 21. Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Seat) Tyco/AMP Connectors (Seat) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3138 Removal Procedure 1. Grasp the locking slide lever and pull outward from the end of the connector. 2. As the slide lever is pulled out the mating connector is lifted from the seated position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3139 Note: TPA is keyed and can only be inserted in one direction. 3. Using terminal release tool J 38125-11A or equivalent, push the TPA tabs into the connector body. 4. Pull the TPA from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3140 5. Using terminal release tool J 38125-11A or equivalent, release the connector wire dress cover locking tab. 6. With the lock tab released, lift the connector wire dress cover from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3141 7. Using terminal release tool J 38125-212, press the prongs into the holes each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 8. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3142 9. Using terminal release tool J 38125-556, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (SIR) Tyco/AMP Connectors (SIR) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3143 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3144 3. Using terminal tool J-38125-11A or equivalent, release the wire dress cover locking tabs. 4. Pivot connector wire dress cover while removing from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3145 5. Using terminal tool J-38125-11A or equivalent, remove the TPA by lifting straight off the connector body. 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals Repairing Connector Terminals Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3146 Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gauge size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3147 2. Disconnect the connector from the component. 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3148 4. Relieve the tension on the nose piece retainers by inserting J 38125-12A into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. 5. Once the nose piece retainers are relaxed, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3149 6. On the opposite side of the nose piece, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3150 8. Insert the J 38125-553 tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3151 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. If the TPA is removed, be sure to reinstall it before reconnecting the connector. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3152 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Special Tools Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3153 J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Note: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3154 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3155 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3156 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3157 1. While depressing the lock, pull the two connector halves apart. Note: The TPA is fragile and may break if not done carefully. 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. 3. View of the male half of the connector with female terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3158 4. View of the female half of the connector with male terminals. 5. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. View of the female half of the connector with male terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3159 7. View of the male half of the connector with female terminals. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3160 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are a one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine if the element in the fuse is broken (2). If not broken (1), also check for continuity using a Digital Multimeter (DMM) or a continuity tester. If the element is broken or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a Digital Multimeter (DMM) at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gauge size. Repairing a Fusible Link Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3161 Flat Wire Repairs The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Special Tools J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool * J 38125-5 Ultra Torch Special Tool The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Note: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation). GMLAN Connector Terminal Repair Note: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) for the appropriate connector repair procedure. GMLAN Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3162 Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3163 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Special Tools J-38125 Terminal Repair Kit Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3164 repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs High Temperature Wiring Repairs Special Tools J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gauge size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3165 splice. Note: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3166 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3167 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the wire insulation has been chafed, or broken, enough to show the conductive portion of the wire, and the wire is not damaged, determine the length of insulation that needs to be repaired. If the repair is less than 280 mm (11 in), cut the wire within the damaged area. Then slide the appropriate heat shrink tubing (listed below) over the wire, and repair the wire by splicing the wires together. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Once the wire is spliced together slide heat shrink tubing over the damaged area and apply heat to seal the repaired wire. If the wire is damaged, or the damaged area is larger than 280 mm (11 in), then replace the damaged wire by splicing in a new section of wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3168 SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Special Tools J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3169 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3170 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3171 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Special Tools J-38125 Terminal Repair Kit Note: Use only DuraSeal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use DuraSeal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use DuraSeal splice sleeves where there are special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3172 * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3173 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3174 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the instructions for Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Staggering the splices by 65 mm (2.5 in) is recommended. Note: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product AL-36FR to replace the damaged mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Flat Wire Repairs) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/GMLAN Wiring Repairs) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Heated Oxygen Sensor Wiring Repairs) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves) * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Twisted or Shielded Cable) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Inline Harness Diodes) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/SIR/SRS Wiring Repairs) US English/Metric Conversion US English/Metric Conversion Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3175 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3176 Testing Ground and Low Reference Circuits Testing Ground and Low Reference Circuits Because a test lamp can light with up to 200 ohm in a ground or low reference circuit they are not recommended to be used for this type of test. A low impedance test lamp can light and indicate the circuit is good when there is as much as 20-30 ohm present, while a high impedance test lamp can light with up to 200 ohm present in the circuit. This is why the Digital Multi-Meter (DMM) is used when validating a ground or low reference circuit continuity. When using the DMM there are many vehicle conditions that can affect the ground and low reference continuity testing. If these conditions are not met, a ground or low reference circuit test can fail on a good circuit. This may cause longer diagnosis time and incorrect component replacement. Any current flow through a ground or low reference circuit, while being tested, will skew the DMM continuity reading, or display a reading higher than when there is no current flowing. Performing a ground or low reference circuit continuity test, in reference to the vehicles battery negative terminal, will have the highest risk of failing a good ground or low reference circuit test than any other ground reference point. The best ground test points would be a control module housing (if the control modules housing is metal and grounded), door jamb striker (if attached to metal), under dash metal frame work, engine block, or body ground studs (other than where the negative battery cable is attached). A typical DMM ground or low reference circuit continuity reading can be as high as 100 ohm with the ignition ON, and drop to 15-25 ohm after the ignition is turned OFF. The reading will drop below 10 ohm after 30-40 seconds, then below 5 ohm after 60 seconds. Once the vehicle completely goes to sleep (generally 3-10 minutes) the reading will drop below 0.3 ohm. The following list of conditions may need to be met to ensure a valid continuity reading on a ground or low reference circuit: * Ignition OFF * Key out of the ignition switch (when not equipped with keyless entry and remote start) * Retained Accessory Power (RAP) OFF (open and close the driver door after ignition OFF) * Battery charger set at a 2 A or less charge rate * Scan tool not communicating with any vehicle control module (in some cases it may need to be disconnected from the DLC) * All entry doors closed * Headlamps OFF (auto headlamps disabled) * Any delay lighting OFF * HVAC after blow OFF * Any accessory that can work when the ignition is OFF * Wait up to 60 seconds (after all other listed conditions are met) Activating the DOOR LOCK function with a key fob can greatly reduce the time to achieve a valid ground or low reference continuity test result. Terminal Removal Terminal Removal Special Tools * EL-38125-580 - Terminal Release Tool Kit * EL-35616 - Connector Test Adapter Kit For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repair procedures. 1. Find the appropriate connector end view within the connector end view section. The connector end view has the following information: Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3177 * Diagnostic probe tool * Terminal release tool * Terminal/terminated lead part numbers Note: Not using the proper test kit probe may cause damage to the terminal(s) that are probed. 2. Determine if a terminal is damaged. * Locate the diagnostic probe tool from the connector end view. The connector end view describes the color and part number to help the technician find and use the correct tool. * Connect the probe tool to the Digital Multimeter. * Insert the probe tool into the cavity and follow the procedures from the Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter). 3. Disconnect the connector body to perform the repair. 4. Use the following procedure to remove the terminal from the connector body. Note: Several procedures for specific connector bodies are called out in the Wiring Repairs section. * The terminal position assurance (TPA) and connector position assurance (CPA) should be removed before releasing the terminal for the connector body. * Look at the connector end view to locate the cavity of the damaged terminal and find the proper terminal release tool from the terminal release tool kit. Note: Using the incorrect terminal release tool can damage the connector body. * Insert the terminal release tool into the cavity. Note: Some terminals have a lever that must be disengaged before the terminal can be released. 5. Gently pull the wire out of the back of the connector. 6. Repair the terminal by following the Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) procedure. 7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminated Lead Repair Terminated Lead Repair Special Tools * J-38125-8 - Splice Sleeve Crimp Tool Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3178 * J-38125-5 - Ultra Torch For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) procedures. Terminated leads are terminals that are crimped onto wires. The terminated lead can be used throughout the vehicle since it is designed for temperatures up to 150°C. The length of the wire is 450 mm. The DuraSeal splice sleeve has the following 2 critical features: * A special heat shrink tubing that environmentally seals the splice. The shrink tubing contains a sealing adhesive inside the shrink tubing. * A cross hatched (knurled) core crimp that provides the necessary contact integrity for sensitive low energy circuits. 1. Use the connector end view to identify the correct terminated lead. 2. The terminated lead package should include a DuraSeal splice sleeve. If not, use the chart to identify the correct part. 3. Open the harness by removing any tape: Use a sewing seam ripper, or a comparable tool, to cut open the harness, to avoid wire insulation damage. 4. Depending on how many terminals need repairs, cut the terminal and wire back at least 40 mm. Try to keep the harness wire length the same. If more than one terminated lead is required, stagger the lengths by 40 mm. This helps reduce the bundle size of the wire harness. 5. Use the EL-38125-10 - tool in order to position the DuraSeal splice sleeve in the proper color nest of the splice sleeve crimp tool. The crimp tool has four nests, one for each color. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3179 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the J-38125-5 - ultra torch , apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3180 Oil Level Sensor: Connector Views Component Connector End Views Engine Oil Level (EOL) Switch (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3181 Oil Level Sensor: Electrical Diagrams Engine Mechanical Schematics Engine Oil Level Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Page 3182 Oil Level Sensor: Testing and Inspection Engine Oil Level Sensor Diagnosis Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Diagnostic Fault Information Typical Scan Tool Data Circuit/System Description The engine oil level sensor/switch is normally-closed with proper engine oil level. The switch opens when the engine oil level drops below a calibrated level. The engine control module (ECM) monitors the engine oil level signal circuit when the ignition is ON, and the engine is OFF. With the switch in the closed position, the ECM detects a low voltage on the signal circuit. With the switch in the open position, the ECM detects a high voltage on the signal circuit. When high voltage is detected on the signal circuit, the ECM will send a serial data message to the instrument panel cluster (IPC). The IPC will then display a message on the driver information center (DIC) or illuminate a low engine oil level lamp. The following information determines the message sent from the ECM to the IPC: * The Low Engine Oil Level message lamp is displayed only after the ECM detects a high voltage on the signal circuit for three consecutive ignition cycles, followed by an ignition OFF event from 15 minutes to greater than 50 minutes, depending on engine oil temperatures. * The Low Engine Oil Level message is turned OFF when the ECM detects a low voltage on the signal circuit after an ignition OFF event for greater than 90 seconds, followed by an ignition ON event for less than 1 second. Reference Information Schematic Reference * Engine Mechanical Schematics (See: Diagrams/Electrical Diagrams) * Instrument Cluster Schematics (See: Diagrams/Electrical Diagrams/Instrument Panel, Gauges and Warning Indicators/System Diagram/Instrument Cluster Schematics) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views) Description and Operation * Instrument Cluster Description and Operation (See: Instrument Panel, Gauges and Warning Indicators/Description and Operation/Instrument Cluster) * Indicator/Warning Message Description and Operation (See: Instrument Panel, Gauges and Warning Indicators/Description and Operation/Indicator/Warning Message) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Page 3183 Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning) for scan tool information. Circuit/System Verification 1. Verify proper engine oil level. Add oil as necessary. 2. Ignition ON, observe the scan tool Engine Oil Level parameter. The reading should be OK and change to low when the oil level sensor/switch harness connector is disconnected. Circuit/System Testing Note: Verify proper engine oil level before continuing with diagnosis. 1. Ignition OFF, disconnect the harness connector at the engine oil level sensor and/or switch. 2. Ignition OFF, test for less than 2 ohm between the ground circuit terminal B and ground. ‹› If greater than the specified range, test the ground circuit for an open/high resistance. 3. Ignition ON, verify the scan tool Engine Oil Level Switch parameter reads Low. ‹› If the Engine Oil Level Switch parameter reads OK, test the signal circuit terminal A for a short to ground. If the circuit tests normal, replace the ECM. Note: If a short to voltage is found on the signal circuit, the fuse in the 3A jumper wire will open. 4. Ignition ON, install a 3A fused jumper wire between the signal circuit terminal A and the ground circuit terminal B. Verify the scan tool Engine Oil Level Switch parameter reads OK. ‹› If the Engine Oil Level Switch parameter reads Low, test the signal circuit terminal A for an open/high resistance. If the circuit tests normal, replace the ECM. 5. If all circuits test normal, test or replace the engine oil level sensor and/or switch. Repair Instructions Perform the Diagnostic Repair Verification (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. * Engine Oil Level Sensor and/or Switch Replacement (See: Service and Repair) * Control Module References (See: Testing and Inspection/Programming and Relearning) for the ECM replacement, setup, and programming Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Page 3184 Oil Level Sensor: Service and Repair Engine Oil Level Sensor and/or Switch Replacement Removal Procedure 1. Remove the lower oil pan. Refer to Lower Oil Pan Replacement (See: Oil Pan/Service and Repair/Lower Oil Pan Replacement). 2. Remove the oil level sensor clip (3). 3. Remove the oil level sensor bolt (2) and sensor (1). Installation Procedure Note: When routing the oil level sensor wire, ensure that the wire is routed along the side of the oil pan. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the oil level sensor (1) and bolt (2) and tighten to 9 Nm (80 lb in). 2. Install the oil level sensor clip (3). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Diagrams > Page 3185 3. Install the lower oil pan. Refer to Lower Oil Pan Replacement (See: Oil Pan/Service and Repair/Lower Oil Pan Replacement). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Line, Turbocharger > Component Information > Service and Repair Oil Line: Service and Repair Turbocharger Oil Feed Pipe Replacement Removal Procedure 1. Remove the turbocharger. Refer to Turbocharger Replacement (See: Powertrain Management/Fuel Delivery and Air Induction/Turbocharger/Service and Repair/Turbocharger Replacement). 2. Remove the turbocharger oil feed pipe bolt. 3. Remove the oil feed pipe and washer. Installation Procedure Caution: Do not twist the turbocharger oil feed pipe. Twisting of the feed pipe will result in the collapse and deformation of the plastic pipe, restricting oil flow and causing turbocharger damage. During turbocharger replacement, gently push the oil feed pipe towards the front of the engine to clear the turbocharger. Assistance may be required to keep the pipes clear of the turbocharger during removal or installation. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Line, Turbocharger > Component Information > Service and Repair > Page 3189 Note: Lubricate the NEW washer with diesel fuel before installing. 1. Position the oil feed pipe and a NEW washer into place. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the oil feed pipe bolt. Tighten the bolt to 34 Nm (25 lb ft). 3. Install the turbocharger. Refer to Turbocharger Replacement (See: Powertrain Management/Fuel Delivery and Air Induction/Turbocharger/Service and Repair/Turbocharger Replacement). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications Oil Pan: Specifications Oil Pan Bolts/Nuts - Lower................................................................................................................... ........................................................10 Nm (89 lb in.) Oil Pan Bolt - Upper.............................................................................................................................. ........................................................20 Nm (15 lb ft.) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Oil Pan Replacement Oil Pan: Service and Repair Oil Pan Replacement Oil Pan Replacement (4WD) Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. For 1500 series vehicles, remove the oil pan skid plate bolts and skid plate, if equipped. 3. For 2500 series vehicles, loosen the 2 rear oil pan skid plate bolts, remove the 2 front oil pan skid plate bolts and skid plate, if equipped. 4. Remove the front differential carrier. Refer to Differential Carrier Assembly Replacement (1500 FWD) (See: Transmission and Drivetrain/Differential Assembly/Service and Repair)Differential Carrier Assembly Replacement (2500 4WD) (See: Transmission and Drivetrain/Differential Assembly/Service and Repair). 5. Unbolt the steering rack and hang downward. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Oil Pan Replacement > Page 3195 6. Place a suitable drain pan under the oil pan drain plug. 7. Remove the oil pan drain plug (430). 8. Allow the oil pan to drain completely. 9. Re-install the oil pan drain plug until snug. 10. Place the drain pan under the oil filter. 11. Remove the oil filter (437). 12. Allow the oil to drain completely. 13. Re-install the oil filter until snug. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Oil Pan Replacement > Page 3196 14. Remove the right side transmission cover bolt. 15. Remove the left side transmission cover bolt and cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Oil Pan Replacement > Page 3197 16. For 1500 series vehicles, remove the crossbar bolts/nuts and crossbar. 17. For 2500 series vehicles, remove the crossbar bolts/nuts and crossbar. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Oil Pan Replacement > Page 3198 18. For vehicles with a 4L60-E/4L70-E automatic transmission, remove the 2 lower transmission bolts. 19. For vehicles with a 4L80-E automatic transmission, remove the 2 lower transmission bolts. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Oil Pan Replacement > Page 3199 20. For vehicles with a 6L80-E automatic transmission, remove the lower left transmission bolt. 21. For vehicles with a 6L80-E automatic transmission, remove the lower right transmission stud. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Oil Pan Replacement > Page 3200 22. Disconnect the engine harness electrical connector (4) from the oil level sensor. 23. Remove the engine harness clip (3) from the transmission oil cooler line bracket. 24. Remove the battery cable channel bolt (2). 25. Slide the channel pin (3) out of the oil pan tab. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Oil Pan Replacement > Page 3201 26. For vehicles with a 4L60-E/4L70-E automatic transmission, remove the oil cooler lines from the clip (1), if equipped. 27. For vehicles with a 4L80-E automatic transmission, remove the oil cooler lines from the clip (1), if equipped. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Oil Pan Replacement > Page 3202 28. For vehicles with a 6L80-E automatic transmission, remove the oil cooler lines from the clip (1). 29. Remove the transmission oil cooler line clip bolt and clip from the oil pan. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Oil Pan Replacement > Page 3203 30. Remove the oil pan bolts. 31. Remove the oil pan. 32. If reusing the oil pan perform the following steps, otherwise proceed to step 3 of the installation procedure. Note: DO NOT allow foreign material to enter the oil passages of the oil pan, cap or cover the openings as required. 33. Drill out the oil pan gasket rivets (2), if necessary. 34. Remove the oil pan gasket (1) from the pan. 35. Discard the oil pan gasket. 36. Discard the rivets, if necessary. Installation Procedure Note: * The alignment of the structural oil pan is critical. The rear bolt hole locations of the oil pan provide mounting points for the transmission bellhousing. To ensure the rigidity of the powertrain and correct transmission alignment, it is important that the rear of the block and the rear of the oil pan must NEVER protrude beyond the engine block and transmission bellhousing plane. * Do not reuse the oil pan gasket. * It is not necessary to rivet the NEW gasket to the oil pan. 1. If reusing the oil pan perform the following step, otherwise proceed to step 3. Note: Be sure to align the oil gallery passages in the oil pan and engine block properly with the oil pan gasket. 2. Place a NEW oil pan gasket onto the oil pan. 3. Apply a 5 mm (0.20 in) bead of sealant, 20 mm (0.80 in) long to the engine block. Apply the sealant directly onto the tabs of the front cover gasket that protrudes into the oil pan surface. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Specifications/Adhesives, Fluids, Lubricants, and Sealers). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Oil Pan Replacement > Page 3204 4. Apply a 5 mm (0.20 in) bead of sealant, 20 mm (0.8 in) long to the engine block. Apply the sealant directly onto the tabs of the rear cover gasket that protrudes into the oil pan surface. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Specifications/Adhesives, Fluids, Lubricants, and Sealers). 5. Install 1 oil pan bolt into a oil pan bolt hole and up through the gasket. 6. Position and install the oil pan and the rest of the oil pan bolts. 7. Tighten the oil pan bolts until snug. 8. For vehicles with a 6L80-E automatic transmission, position the oil cooler bracket and install the lower right transmission stud until snug. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Oil Pan Replacement > Page 3205 9. For vehicles with a 6L80-E automatic transmission, install the lower left transmission bolt until snug. 10. For vehicles with a 4L80-E automatic transmission, install the 2 lower transmission bolts until snug. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Oil Pan Replacement > Page 3206 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 11. For vehicles with a 4L60-E/4L70-E automatic transmission, install the 2 lower transmission bolts until snug. 1. Tighten the oil pan and oil pan-to-oil pan front cover bolts to 25 Nm (18 lb ft). 2. Tighten the oil pan-to-rear cover bolts to 12 Nm (106 lb in). 3. Tighten the transmission bolts/stud to 50 Nm (37 lb ft). 12. Position the transmission oil cooler line clip and install the bolt to the oil pan. Tighten the bolt to 9 Nm (80 lb in). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Oil Pan Replacement > Page 3207 13. For vehicles with a 6L80-E automatic transmission, install the oil cooler lines to the clip (1). 14. For vehicles with a 4L80-E automatic transmission, install the oil cooler lines to the clip (1), if equipped. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Oil Pan Replacement > Page 3208 15. For vehicles with a 4L60-E/4L70-E automatic transmission, install the oil cooler lines to the clip (1), if equipped. 16. Position the channel and slide the channel pin (3) into the oil pan tab. 17. Install the battery cable channel bolt (2). Tighten the bolt to 12 Nm (106 lb in). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Oil Pan Replacement > Page 3209 18. Connect the engine harness electrical connector (4) to the oil level sensor. 19. Install the engine harness clip (3) to the transmission oil cooler line bracket. 20. For both the 1500 and 2500 series, perform the following steps prior to installing the crossbar bolts. 1. Remove all traces of the original adhesive patch. 2. Clean the threads of the bolts with denatured alcohol or equivalent and allow to dry. 3. Apply threadlock GM P/N 12345493 (Canadian P/N 10953488) or equivalent to the bolt threads. 21. For 2500 series vehicles, install the crossbar and crossbar bolts/nuts. Tighten the nuts to 120 Nm (89 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Oil Pan Replacement > Page 3210 22. For 1500 series vehicles, install the crossbar and crossbar bolts/nuts. Tighten the nuts to 100 Nm (74 lb ft). 23. Position the left side transmission cover and install the cover bolt. Tighten the bolt to 12 Nm (106 lb in). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Oil Pan Replacement > Page 3211 24. Install the right side transmission cover bolt. Tighten the bolt to 12 Nm (106 lb in). 25. If reusing the old oil pan remove the old oil filter and install a NEW oil filter. 26. Lubricate the NEW oil filter seal with clean engine oil. 27. Install the NEW oil filter (437). Tighten the oil filter to 30 Nm (22 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Oil Pan Replacement > Page 3212 28. Ensure that the oil pan drain plug (430) is tight. Tighten the drain plug to 25 Nm (18 lb ft). 29. Install the front differential carrier. Refer to Differential Carrier Assembly Replacement (1500 FWD) (See: Transmission and Drivetrain/Differential Assembly/Service and Repair)Differential Carrier Assembly Replacement (2500 4WD) (See: Transmission and Drivetrain/Differential Assembly/Service and Repair). 30. Raise the steering rack in place and install the steering rack bolts. * Tighten the left side steering rack bolts to 200 Nm (148 lb ft). * Tighten the right side steering rack bolts to 100 Nm (74 lb ft). 31. For 2500 series vehicles, position the oil pan skid plate and tighten until snug the 2 rear oil pan skid plate bolts, install the 2 front oil pan skid plate bolts, if equipped. Tighten the bolts to 28 Nm (21 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Oil Pan Replacement > Page 3213 32. For 1500 series vehicles, position the oil pan skid plate and install the oil pan skid plate bolts, if equipped. Tighten the bolts to 28 Nm (21 lb ft). 33. Lower the vehicle. 34. Fill the engine with NEW engine oil. Refer to Fluid and Lubricant Recommendations (USA and Canada) (See: Maintenance) and Approximate Fluid Capacities (See: Maintenance/Specifications). 35. Start the engine and inspect for leaks. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Oil Pan Replacement > Page 3214 Oil Pan: Service and Repair Lower Oil Pan Replacement Lower Oil Pan Replacement Special Tools J 37228 Seal Cutter Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Place a suitable container under the engine in order to drain the oil. 3. Remove the oil drain plug. 4. Drain the engine oil. 5. Remove the oil pan skid plate bolts and plate, if equipped. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Oil Pan Replacement > Page 3215 6. If equipped with a 2-wheel drive (2WD) vehicle, remove the crossmember bolts and crossmember. 7. If equipped with a 4-wheel drive (4WD) vehicle, remove the crossmember bolts and crossmember. 8. Disconnect the oil level sensor electrical connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Oil Pan Replacement > Page 3216 9. Remove the lower oil pan bolts/nuts. Note: DO NOT damage the sealing surfaces when separating the lower oil pan from the upper oil pan. 10. Separate the lower oil pan from the upper oil pan using J 37228 . 11. Remove the lower oil pan. 12. If necessary, clean and inspect the lower oil pan. Refer to Lower Oil Pan Cleaning and Inspection (See: Service and Repair/Overhaul/86. Lower Oil Pan Cleaning and Inspection). Installation Procedure 1. Apply a 2-3 mm (0.79-0.118 in) by 0.5-1.5 mm (0.02-0.06 in ) wide bead of sealant to the lower oil pan mating surface. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Specifications/Adhesives, Fluids, Lubricants, and Sealers) for the correct part number. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Oil Pan Replacement > Page 3217 2. Install the lower oil pan. 3. Install the lower oil pan bolts/nuts. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Tighten the oil pan bolts/nuts in the sequence shown. Tighten the bolts/nuts to 10 Nm (89 lb in). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Oil Pan Replacement > Page 3218 5. Connect the oil level sensor electrical connector. 6. If equipped with a 2WD, install the crossmember and bolts. Tighten the bolts to 100 Nm (74 lb ft). 7. If equipped with a 4WD, install the crossmember and bolts. Tighten the bolts to 100 Nm (74 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Oil Pan Replacement > Page 3219 8. Install the oil pan skid plate and bolts, if equipped. Tighten the bolts to 20 Nm (15 lb ft). 9. Install NEW engine oil and a oil filter. Refer to Engine Oil and Oil Filter Replacement (See: Engine Oil/Service and Repair). 10. Lower the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Oil Pan Replacement > Page 3220 Oil Pan: Service and Repair Upper Oil Pan Replacement Upper Oil Pan Replacement Special Tools J 37228 Seal Cutter Removal Procedure 1. Remove the oil level indicator. 2. Remove the oil level indicator tube bolt from the indicator tube bracket. 3. If vehicle is a 4-wheel drive (4WD), remove the front differential carrier. Refer to Differential Carrier Assembly Replacement (1500 FWD) (See: Transmission and Drivetrain/Differential Assembly/Service and Repair)Differential Carrier Assembly Replacement (2500 4WD) (See: Transmission and Drivetrain/Differential Assembly/Service and Repair). 4. If vehicle is a 2-wheel drive (2WD), disconnect the relay rod from the pitman arm and idler arm. Refer to Relay Rod Replacement (See: Steering and Suspension/Steering/Center Link/Service and Repair). 5. Remove the lower oil pan. Refer to Lower Oil Pan Replacement (See: Lower Oil Pan Replacement). 6. Remove the engine flywheel. Refer to Engine Flywheel Replacement (See: Transmission and Drivetrain/Flex Plate/Service and Repair/Engine Flywheel Replacement). 7. Remove the battery cable bracket bolts. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Oil Pan Replacement > Page 3221 8. Remove the battery cable bracket nut. 9. Remove the two flywheel housing to upper oil pan bolts. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Oil Pan Replacement > Page 3222 10. Remove the upper oil pan bolts and any brackets. Mark the bolt location of the bracket. 11. Separate the upper oil pan from the engine block using J 37228 . 12. Remove the upper oil pan. The oil level indicator tube needs to be removed while lowering the upper oil pan. 13. If required, clean and inspect the upper oil pan. Refer to Upper Oil Pan Cleaning and Inspection (See: Service and Repair/Overhaul/81. Upper Oil Pan Cleaning and Inspection). Installation Procedure 1. Apply a 2-3 mm (0.79-0.118 in) wide by 0.5-1.5 mm (0.02-0.06 in) bead of sealant to the upper oil pan mating surfaces. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Specifications/Adhesives, Fluids, Lubricants, and Sealers) for the correct part number. 2. Apply a 2-3 mm (0.79-0.118 in) wide by 0.5-1.5 mm (0.02-0.06 in) bead of sealant to the flywheel housing sealing surface. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Specifications/Adhesives, Fluids, Lubricants, and Sealers) for the correct part number. 3. Install the upper oil pan to the engine block. Ensure the oil level indicator tube is installed into the upper oil pan. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Oil Pan Replacement > Page 3223 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install any brackets and the upper oil pan bolts in the sequence shown. Tighten the bolts to 20 Nm (15 lb ft). 5. Install the two flywheel housing to upper oil pan bolts. Tighten the bolts to 50 Nm (37 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Oil Pan Replacement > Page 3224 6. Install the battery cable bracket bolts. Tighten the bolts to 12 Nm (106 lb in). 7. Install the battery cable bracket nut. Tighten the nut to 8 Nm (71 lb in). 8. Install the engine flywheel. Refer to Engine Flywheel Replacement (See: Transmission and Drivetrain/Flex Plate/Service and Repair/Engine Flywheel Replacement). 9. Install the lower oil pan. Refer to Lower Oil Pan Replacement (See: Lower Oil Pan Replacement). 10. If vehicle is a 4WD, install the front differential carrier. Refer to Differential Carrier Assembly Replacement (1500 FWD) (See: Transmission and Drivetrain/Differential Assembly/Service and Repair)Differential Carrier Assembly Replacement (2500 4WD) (See: Transmission and Drivetrain/Differential Assembly/Service and Repair). 11. If vehicle is a 2WD, Connect the relay rod to the pitman arm and idler arm. Refer to Relay Rod Replacement (See: Steering and Suspension/Steering/Center Link/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Oil Pan Replacement > Page 3225 12. Lower the vehicle. 13. Install the oil level indicator tube bolt to the indicator tube bracket. Tighten the bolt to 21 Nm (15 lb ft). 14. Install the oil level indicator. 15. Fill the engine with oil. Refer to Engine Oil and Oil Filter Replacement (See: Engine Oil/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Diagrams Oil Pressure Sensor: Diagrams Component Connector End Views Engine Oil Pressure (EOP) Sensor (Diesel) Engine Oil Pressure (EOP) Sensor (Gas except LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Diagrams > Page 3229 Engine Oil Pressure (EOP) Sensor (LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Diagrams > Page 3230 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Diagrams > Page 3231 Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement Special Tools DT-48827 Skip Shift Socket Removal Procedure 1. Remove the left wheelhouse inner panel. Refer to Front Wheelhouse Liner Replacement - Left Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Left Side)Front Wheelhouse Liner Replacement - Left Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Left Side). Note: Clean the area around the sensor. Do not allow debris to enter the engine. 2. Disconnect the oil pressure sensor electrical connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Diagrams > Page 3232 3. Using DT-48827 , remove the oil pressure sensor (1). Installation Procedure 1. Apply sealant to the threads of the oil pressure sensor. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Engine, Cooling and Exhaust/Engine/Specifications/Adhesives, Fluids, Lubricants, and Sealers) for the correct part number. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Using DT-48827 , install the oil pressure sensor (1). Tighten the sensor to 49 Nm (36 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Diagrams > Page 3233 3. Connect the oil pressure sensor electrical connector. 4. Install the left wheelhouse inner panel. Refer to Front Wheelhouse Liner Replacement - Left Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Left Side)Front Wheelhouse Liner Replacement - Left Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Left Side). 5. Check and add engine oil if necessary. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications Oil Pressure - Minimum- Hot - at idle................................................................................................... .............................................................48 KPa (7 psi) Oil Pressure - Minimum - Hot - 1800 RPM...... .............................................................................................................................................193 KPa (28 psi) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications > Page 3238 Engine Oil Pressure: Testing and Inspection Oil Pressure Diagnosis and Testing Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Engine - Intake Manifold Inspection/Replacement Intake Manifold: Technical Service Bulletins Engine - Intake Manifold Inspection/Replacement INFORMATION Bulletin No.: 00-06-01-026C Date: February 03, 2010 Subject: Intake Manifold Inspection/Replacement After Severe Internal Engine Damage Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to include additional model years. Please discard Corporate Bulletin Number 00-06-01-026B (Section 06 - Engine). When replacing an engine due to internal damage, extreme care should be taken when transferring the intake manifold to the new Goodwrench service engine long block. Internal damage may result in the potential discharge of internal engine component debris in the intake manifold via broken pistons and/or bent, broken, or missing intake valves. After removing the intake manifold from the engine, the technician should carefully inspect all of the cylinder head intake ports to see if the valve heads are still present and not bent. Usually when the valve heads are missing or sufficiently bent, internal engine component debris will be present to varying degrees in the intake port of the cylinder head. If this debris is present in any of the cylinder head intake ports, the intake manifold should be replaced. This replacement is required due to the complex inlet runner and plenum configuration of most of the intake manifolds, making thorough and complete component cleaning difficult and nearly impossible to verify complete removal of debris. Re-installation of an intake manifold removed from an engine with deposits of internal engine component debris may result in the ingestion of any remaining debris into the new Goodwrench service engine. This may cause damage or potential failure of the new service engine. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Page 3243 Intake Manifold: Specifications Left Right Intake Manifold Bolts/Nuts.................................................................................................................... ........................................................25 Nm (18 lb ft.) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Replacement Intake Manifold: Service and Repair Intake Manifold Replacement Intake Manifold Replacement - Left SIDE Intake Manifold Replacement - Left Side Removal Procedure 1. Remove the center intake manifold. Refer to Center Intake Manifold Replacement (See: ). 2. Remove the glow plug module and bracket. Refer to Glow Plug Control Module Replacement (See: Powertrain Management/Glow Plug System/Glow Plug Control Module/Service and Repair). 3. Remove the left fuel rail. Refer to Fuel Injection Fuel Rail Assembly Replacement - Bank 1 (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Rail/Service and Repair/Fuel Injection Fuel Rail Assembly Replacement - Bank 1). 4. Remove the intake manifold bolts/nuts. Note: The intake manifold uses sealer. Pry at the area by the fuel rail bolt holes in order to avoid damage to the sealing surfaces. 5. Remove the intake manifold. 6. To prevent entry of debris in the cylinder head tape the openings. 7. If required, clean and inspect the intake manifold. Refer to Intake Manifold Cleaning and Inspection (See: Service and Repair/Overhaul/26. Intake Manifold Cleaning and Inspection). Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Replacement > Page 3246 1. Apply a 2-3 mm (1/8 in) wide, by 0.5-1.5 mm (1/16 in) high bead of sealant to the intake manifold. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Specifications/Adhesives, Fluids, Lubricants, and Sealers) for the correct part number. 2. Install the intake manifold. 3. Install the intake manifold bolts/nuts. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Replacement > Page 3247 Right Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Tighten the intake manifold bolts/nuts in the sequence shown. Tighten the bolts/nuts to 21 Nm (15 lb ft). 5. Install the left fuel rail. Refer to Fuel Injection Fuel Rail Assembly Replacement - Bank 1 (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Rail/Service and Repair/Fuel Injection Fuel Rail Assembly Replacement - Bank 1). 6. Install the glow plug module and bracket. Refer to Glow Plug Control Module Replacement (See: Powertrain Management/Glow Plug System/Glow Plug Control Module/Service and Repair). 7. Install the center intake manifold. Refer to Center Intake Manifold Replacement (See: ). Intake Manifold Replacement - Right SIDE Intake Manifold Replacement - Right Side Removal Procedure 1. Remove the center intake manifold. Refer to Center Intake Manifold Replacement (See: ). 2. Remove the right fuel rail. Refer to Fuel Injection Fuel Feed Front Pipe Replacement - Right Side (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Supply Line/Service and Repair/Fuel Injection Fuel Feed/Fuel Injection Fuel Feed Front Pipe Replacement - Right Side). 3. Remove the intake manifold bolts/nuts. 4. Remove the fuel return junction block. Refer to Fuel Injection Fuel Feed Manifold Replacement (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Supply Line/Service and Repair/Fuel Injection Fuel Feed/Fuel Injection Fuel Feed Manifold Replacement). Note: The intake manifold uses sealer. Pry at the area by the fuel rail bolt holes in order to avoid damage to the sealing surfaces. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Replacement > Page 3248 5. Remove the intake manifold. 6. To prevent entry of debris in the cylinder head tape the openings. 7. If required, clean and inspect the intake manifold. Refer to Intake Manifold Cleaning and Inspection (See: Service and Repair/Overhaul/26. Intake Manifold Cleaning and Inspection). Installation Procedure 1. Apply a 2-3 mm (1/8 in) wide, by 0.5-1.5 mm (1/16 in) high bead of sealant to the intake manifold. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Specifications/Adhesives, Fluids, Lubricants, and Sealers) for the correct part number. 2. Install the intake manifold. 3. Install the intake manifold bolts/nuts. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Replacement > Page 3249 Right Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Tighten the intake manifold bolts/nuts in the sequence shown. Tighten the bolts/nuts to 21 Nm (15 lb ft). 5. Install the fuel return junction block. Refer to Fuel Injection Fuel Feed Manifold Replacement (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Supply Line/Service and Repair/Fuel Injection Fuel Feed/Fuel Injection Fuel Feed Manifold Replacement). 6. Install the right fuel rail. Refer to Fuel Injection Fuel Feed Front Pipe Replacement - Right Side (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Supply Line/Service and Repair/Fuel Injection Fuel Feed/Fuel Injection Fuel Feed Front Pipe Replacement - Right Side). 7. Install the center intake manifold. Refer to Center Intake Manifold Replacement (See: ). Center Intake Manifold Replacement Center Intake Manifold Replacement Removal Procedure 1. Remove the exhaust gas recirculation (EGR) valve cooler tube. Refer to Exhaust Gas Recirculation Valve Cooler Replacement (See: Powertrain Management/Emission Control Systems/Exhaust Gas Recirculation/EGR Cooler/Service and Repair/Exhaust Gas Recirculation Valve Cooler Replacement). 2. Remove the water outlet tube. Refer to Water Outlet Tube Replacement (LU3) (See: Cooling System/Coolant Outlet/Service and Repair)Water Outlet Tube Replacement (LMM) (See: Cooling System/Coolant Outlet/Service and Repair). 3. Remove the intake manifold tube. 4. Remove and discard the 2 intake manifold tube gaskets. 5. Remove the turbocharger. Refer to Turbocharger Replacement (See: Powertrain Management/Fuel Delivery and Air Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Replacement > Page 3250 Induction/Turbocharger/Service and Repair/Turbocharger Replacement). 6. Disconnect the intake air temperature (IAT) sensor electrical connector (1). 7. Remove the IAT sensor (2). 8. Remove the center intake manifold bolts/nuts. 9. Pull-up the center intake manifold in order to remove. 10. Remove and discard the gaskets. 11. Clean the center intake manifold in cleaning solvent and air dry. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Replacement > Page 3251 1. Install NEW center intake manifold gaskets. 2. Install the center intake manifold. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the center intake manifold bolts/nuts. Tighten the bolts/nuts to 10 Nm (89 lb in). 4. Install the IAT sensor (2). Tighten the sensor to 10 Nm (89 lb in). 5. Connect the IAT sensor electrical connector (1). 6. Install the turbocharger. Refer to Turbocharger Replacement (See: Powertrain Management/Fuel Delivery and Air Induction/Turbocharger/Service and Repair/Turbocharger Replacement). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Replacement > Page 3252 7. Install 2 NEW O-rings onto the intake manifold tube. 8. Lubricate the O-rings with clean engine oil to aid in the installation. 9. Install the intake manifold tube. 10. Install the water outlet tube. Refer to Water Outlet Tube Replacement (LU3) (See: Cooling System/Coolant Outlet/Service and Repair)Water Outlet Tube Replacement (LMM) (See: Cooling System/Coolant Outlet/Service and Repair). 11. Install the EGR valve cooler tube. Refer to Exhaust Gas Recirculation Valve Cooler Replacement (See: Powertrain Management/Emission Control Systems/Exhaust Gas Recirculation/EGR Cooler/Service and Repair/Exhaust Gas Recirculation Valve Cooler Replacement). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Replacement > Page 3253 Intake Manifold: Service and Repair Intake Manifold Cover Replacement Intake Manifold Cover Replacement Removal Procedure 1. Loosen the intake manifold cover clamp (1) at the resonator. 2. Loosen the intake manifold cover bolt (2). 3. Remove the intake manifold cover. Installation Procedure 1. Install the intake manifold cover. 2. Tighten the intake manifold cover bolt (2) until snug. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Replacement > Page 3254 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Tighten the intake manifold cover clamp (1) at the resonator. Tighten the clamp to 6 Nm (53 lb in). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Replacement > Page 3255 Intake Manifold: Service and Repair Intake Manifold Tube Replacement Intake Manifold Tube Replacement Removal Procedure 1. Disconnect the negative battery cables. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 2. Open the intake air heater (IAH) harness lead cover (2). 3. Remove the engine wiring harness lead nut (1) from the IAH stud. 4. Remove the engine wiring harness lead (3) from the IAH stud. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Replacement > Page 3256 5. Remove the electrical harness bolts (1). 6. Reposition the harness clip from the intake manifold tube, as needed. 7. Remove the air inlet tube to intake manifold tube bolt and nut. 8. Disconnect the intake air heater electrical connector. 9. Disconnect the manifold absolute pressure (MAP) sensor electrical connector. 10. Remove the engine harness clip from the air inlet tube. 11. Remove the air inlet tube nuts and bolt. 12. Remove the air inlet tube. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Replacement > Page 3257 13. If necessary, remove the intake manifold tube. 14. If necessary, remove and discard the 2 O-ring seals from the tube. 15. Clean the gasket surfaces of the exhaust gas recirculation (EGR) cooler tube, intake manifold tube and inlet tube. Installation Procedure 1. If necessary, install NEW O-ring seals onto the tube. 2. If necessary, install the intake manifold tube. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Replacement > Page 3258 3. Install the air inlet tube and NEW gaskets. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the air inlet tube nuts and bolt. Tighten the nuts to 25 Nm (18 lb ft). 5. Connect the intake air heater electrical connector. 6. Connect the MAP sensor electrical connector. 7. Install the engine harness clip to the air inlet tube. 8. Install the air inlet tube to intake manifold tube bolt and nut. Tighten the bolt/nut to 10 Nm (89 lb in). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Replacement > Page 3259 9. Install the electrical harness bolts (1). Tighten the bolts to 4 Nm (35 lb in). 10. Install the engine wiring harness lead (3) to the IAH stud. 11. Install the engine wiring harness lead nut (1) to the IAH stud. Tighten the nut to 10 Nm (89 lb in). 12. Close the IAH harness lead cover (2). 13. Connect the negative battery cables. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair Crankshaft Main Bearing Seal: Service and Repair Crankshaft Rear Oil Seal Replacement Special Tools * J 44641 Crankshaft Rear Oil Seal Remover * J 44642 Crankshaft Rear Oil Seal Installer Removal Procedure 1. Remove the flywheel. Refer to Engine Flywheel Replacement (See: Transmission and Drivetrain/Flex Plate/Service and Repair/Engine Flywheel Replacement). 2. Clean the area around the crankshaft rear oil seal. 3. Install the button of J 44641 into the crankshaft. 4. Press the jaws of J 44641 into the felt portion of the seal far enough to engage the inner lip of the seal. 5. While holding the J 44641 tightly to the seal inner sleeve, tighten the jaw bolts. 6. Remove the crankshaft rear oil seal using J 44641 . Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Page 3264 1. Ensure that the crankshaft is free of oil and dirt. 2. Clean the seal bore in the flywheel housing. 3. Position the crankshaft rear oil seal onto the crankshaft. Important: J 44642 must be fully secured to the crankshaft to ensure proper seal depth. 4. Install J 44642 to the crankshaft. 5. Press the crankshaft rear oil seal into position using J 44642 , the tool will bottom out when the seal reaches the proper depth. 6. Remove J 44642 . 7. Install the flywheel. Refer to Engine Flywheel Replacement (See: Transmission and Drivetrain/Flex Plate/Service and Repair/Engine Flywheel Replacement). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair Front Crankshaft Seal: Service and Repair Crankshaft Front Oil Seal Replacement Special Tools * J 44644 Crankshaft Front Oil Seal Remover * J 44645 Crankshaft Front Oil Seal Installer Removal Procedure 1. Remove the crankshaft balancer. Refer to Crankshaft Balancer Replacement (See: Cylinder Block Assembly/Harmonic Balancer - Crankshaft Pulley/Service and Repair). 2. Install the button of J 44644 into the crankshaft. 3. Press the jaws of J 44644 into the felt portion of the seal far enough to engage the inner lip of the seal. 4. While holding the J 44644 tightly to the seal inner sleeve, tighten the jaw bolts. 5. Using J 44644 , remove the crankshaft front oil seal. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair > Page 3268 1. Clean the front crankshaft seal bore and the crankshaft. 2. Lubricate the crankshaft sealing surface with clean engine oil. 3. Place the crankshaft front oil seal onto the crankshaft. 4. Install J 44645 to the crankshaft. 5. Press the crankshaft front oil seal onto the crankshaft using J 44645 until the tool bottoms out. 6. Remove J 44645 . 7. Install the crankshaft balancer. Refer to Crankshaft Balancer Replacement (See: Cylinder Block Assembly/Harmonic Balancer - Crankshaft Pulley/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Technical Service Bulletins > Engine - Duramax(R) Valve Guide/Stem Oil Seal Change Valve Guide Seal: Technical Service Bulletins Engine - Duramax(R) Valve Guide/Stem Oil Seal Change INFORMATION Bulletin No.: 10-06-01-009 Date: October 06, 2010 Subject: Information on Duramax Valve Guide and Valve Stem Oil Seal Change Models: 2006-2010 Chevrolet Express Vans, Kodiak C4500/C5500 Series, Silverado 2006-2010 GMC Savana Vans, Sierra, TopKick C4500/C5500 Series Equipped with Duramax(TM) Diesel Engine (RPOs LLY, LBZ or LMM) A technician may notice a change in the valve guides and valve stem oil seals on replacement cylinder heads or engines for 2006-2010 model year vehicles. This change may also be noticed on 2006-2010 vehicles that have received a replacement cylinder head or engine during a previous repair. Beginning in 2010, production LGH and LML engines were made with a new design valve guide and pressed fit valve stem oil seal. Replacement cylinder heads and remanufactured engines for 2006-2010 vehicles will also be made with the new design valve guide and pressed fit valve stem oil seal. The new design requires special tool EN-49761 to install the valve stem oil seal to the correct height. Identify the valve guide design before servicing the valve stem oil seals on a 2006-2010 model year vehicle. The first design valve guide can be identified by the presence of a valve stem oil seal locating groove (1). This design used GM P/N 97212994. The second design valve guide does not have this groove, as the valve stem oil seal is a pressed fit to the guide (1). This design used GM P/N 12624396. When servicing an engine with the second design valve guides, be sure to use EN-49761 to install the valve stem oil seal to the correct height. The EN-49761 is tapped down until it bottoms on the lower valve spring seat. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Technical Service Bulletins > Engine - Duramax(R) Valve Guide/Stem Oil Seal Change > Page 3273 Parts Information Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Technical Service Bulletins > Page 3274 Valve Guide Seal: Service and Repair Valve Stem Oil Seal and Valve Spring Replacement Special Tools * J 26999 Compression Gauge * J 26999-20 Compression Gauge Adapter * J 44646 Valve Spring Compressor * J 44640 Valve Stem Seal Installer Removal Procedure 1. Remove the upper and lower fan shroud. Refer to Engine Coolant Fan Lower Shroud Replacement (Mechanical) (See: Cooling System/Fan Shroud/Service and Repair) and Engine Coolant Fan Upper Shroud Replacement (LMM Diesel) (See: Cooling System/Fan Shroud/Service and Repair)Engine Coolant Fan Upper Shroud Replacement (Mechanical) (See: Cooling System/Fan Shroud/Service and Repair). 2. Remove the valve rocker arm shaft, valve bridges, and pushrods for the cylinder head being serviced. Refer to Valve Rocker Arm, Shaft, and Push Rod Replacement (See: Camshaft, Lifters and Push Rods/Rocker Arm Assembly/Service and Repair). 3. Remove the glow plug for the cylinder requiring service. Refer to Glow Plug Replacement - Bank 1 (See: Powertrain Management/Glow Plug System/Glow Plug/Service and Repair/Glow Plug Replacement - Bank 1) or Glow Plug Replacement - Bank 2 (See: Powertrain Management/Glow Plug System/Glow Plug/Service and Repair/Glow Plug Replacement - Bank 2). 4. In order to apply shop air to the cylinders use the following procedures to modify J 26999-20 (1) and J 26999 (2): 1. Remove the valve core from J 26999-20 to allow air to flow. 2. Remove the quick connect fitting from J 26999 . 3. Adapt the quick connect fitting in order to use for shop air. 4. Connect the quick connect fitting to J 26999-20 . Note: Rotate the cylinder to be serviced to the bottom of the stroke. This is to ensure that the engine does not rotate when the compressed air is applied to the cylinder being serviced. 5. Install J 26999-20 into the glow plug hole for the cylinder being serviced. 6. Apply compressed air to hold the valves in place. If the compressed air is released, the valves can drop into the cylinder. Warning Compressed valve springs have high tension against the valve spring compressor. Valve springs that are not properly compressed by or released from the valve spring compressor can be ejected from the valve spring compressor with intense force. Use care when compressing or releasing the valve spring with the valve spring compressor and when removing or installing the valve stem keys. Failing to use care may cause personal injury. 7. Install J 44646 to the rocker arm bosses on the cylinder head. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Technical Service Bulletins > Page 3275 J 44646 should be installed in the rocker arm boss next to the cylinder being serviced. The pivot pin can be removed from the stand to allow the stand to be installed. The lever has different locating holes for the pivot pin depending on available clearance. The lever is also notched for different locations of the compressor. 8. Using J 44646 compress the valve spring. 9. Remove the valve keys (1) from the valve stem. 10. Carefully release the valve spring tension. 11. Remove the valve spring upper seat (2) and the valve spring (3). 12. Remove the valve stem oil seal (4). 13. Remove the valve spring lower seat (5). 14. Continue removing the remaining valve stem seals for the cylinder using the above procedure. Installation Procedure Caution: Air pressure should remain applied to the cylinder for installation. 1. Install the valve spring lower seat. 2. Install the valve stem seal using J 44640 . Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Technical Service Bulletins > Page 3276 3. Install the valve spring (3), the painted end of the valve spring goes toward the cylinder head. 4. Install the valve spring upper seat (2). Warning Compressed valve springs have high tension against the valve spring compressor. Valve springs that are not properly compressed by or released from the valve spring compressor can be ejected from the valve spring compressor with intense force. Use care when compressing or releasing the valve spring with the valve spring compressor and when removing or installing the valve stem keys. Failing to use care may cause personal injury. 5. Using J 44646 compress the valve spring. 6. Install the valve keys to the valve stem. Caution: The valve stem keys must correctly seat in the valve spring cap. Engine damage may occur by not installing properly. 7. Carefully release the valve spring pressure. Make sure the valve keys stay in place. 8. Continue to install the 3 remaining valve stem seals for the cylinder. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Technical Service Bulletins > Page 3277 9. Release the compressed air holding the valves in place. 10. Remove J 26999-20 (1) from the glow plug hole. 11. Continue to replace the valve stem seals on the remaining cylinders using the above procedures. 12. Install the glow plug. Refer to Glow Plug Replacement - Bank 1 (See: Powertrain Management/Glow Plug System/Glow Plug/Service and Repair/Glow Plug Replacement - Bank 1) or Glow Plug Replacement - Bank 2 (See: Powertrain Management/Glow Plug System/Glow Plug/Service and Repair/Glow Plug Replacement - Bank 2). 13. Install the valve rocker arm shaft, the valve bridges, and the push rods. Refer to Valve Rocker Arm, Shaft, and Push Rod Replacement (See: Camshaft, Lifters and Push Rods/Rocker Arm Assembly/Service and Repair). 14. Install the upper and lower fan shroud. Refer to Engine Coolant Fan Lower Shroud Replacement (Mechanical) (See: Cooling System/Fan Shroud/Service and Repair) and Engine Coolant Fan Upper Shroud Replacement (LMM Diesel) (See: Cooling System/Fan Shroud/Service and Repair)Engine Coolant Fan Upper Shroud Replacement (Mechanical) (See: Cooling System/Fan Shroud/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions Oil Level Sensor: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Schematic Symbols Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3283 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3284 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3285 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3286 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3287 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3288 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3289 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3290 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3291 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3292 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3293 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3294 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3295 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3296 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3297 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3298 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3299 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3300 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3301 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3302 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3303 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3304 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3305 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3306 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3307 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3308 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3309 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3310 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3311 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3312 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3313 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3314 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3315 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3316 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3317 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3318 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3319 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3320 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3321 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3322 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3323 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3324 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3325 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3326 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3327 Oil Level Sensor: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed with Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3328 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3329 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Connector Test Adapters) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3330 Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Test Lamp) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Fused Jumper Wires) * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage Drop) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Frequency) * Testing Ground and Low Reference Circuits (See: Testing and Inspection/Component Tests and General Diagnostics/Testing Ground and Low Reference Circuits) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fuses) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Circuit Breakers) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fusible Links) Troubleshooting with a Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Testing for a Short to Voltage Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3331 Testing for a Short to Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure tests for a short to voltage in a circuit. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the Digital Multimeter (DMM) to the V (DC) position. 4. Connect the positive lead of the DMM to one end of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. Turn ON the ignition and operate all accessories. 7. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Special Tools J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure). Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents). Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3332 The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the frequency of a signal. Note: Connecting the Digital Multimeter (DMM) to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Set to Hz on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3333 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the Digital Multimeter (DMM). 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the difference in voltage potential between 2 points. 1. Set the Digital Multimeter (DMM) to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3334 Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Backprobe Note: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3335 (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for Continuity Testing for Continuity Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures verify good continuity in a circuit. With a Digital Multimeter (DMM) 1. Set the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Select the MIN MAX function on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3336 Testing for Electrical Intermittents Testing for Electrical Intermittents Special Tools J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. Note: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions). 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3337 visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing for Terminal Fretting Some intermittent conditions can be caused by wire terminal fretting corrosion. Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can pile up enough at the electrical contact spots that the electrical resistance across the connection increases. Movement between the contacting surfaces as small as 10 to 100 microns can cause fretting. To put this in perspective, a sheet of paper is about 100 microns thick, so fretting motion is small and hard to see. Vibration and thermal expansion/contraction are the main sources that create fretting motion. Since vehicles vibrate and can experience large temperature swings, they are a good source for fretting motion. Tin, copper, nickel, and iron surfaces are all susceptible to fretting corrosion. Fretting corrosion can be difficult to see but it looks like small, dark smudges on the terminals contact surface. To correct a fretting condition disconnect the suspect connector and add Nyogel lubricant 760G (dielectric grease) to both sides of the connector terminals. Then reconnect the connector and wipe away any excess lubricant. This will correct the additional terminal contact resistance due to the terminal fretting corrosion. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3338 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics). * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Ground Distribution Schematics). Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Checking Aftermarket Accessories). * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3339 Note: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures test for a short to ground in a circuit. With a Digital Multimeter (DMM) 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohms position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Danger: High voltage circuits should only be tested using a digital multimeter (DMM) and test leads with at least a CAT III rating, such as the J 39200-A Digital Multimeter. Failure to follow the procedures exactly as written may result in serious injury or death. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Digital Multimeter (DMM) Basic Requirements Service information is validated using digital multimeters that meet or exceed the following requirements. Using a multimeter that does not meet these basic requirements may give inaccurate readings which could lead to an incorrect diagnosis. Display and Settings 1. Four digits displayed 2. Voltage, amperage, resistance, frequency, diode test settings, and min-max function 3. Display positive and negative values Voltage 1. Have at least 10 M ohm input impedance Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3340 2. Test a DC voltage range of 0.1-1000 V. 3. Test an AC voltage range of 0.1-1000 V. Amperage 1. Test a DC amperage range of 0.1µA-10 A. 2. Test an AC amperage range of 0.1µA-10 A. Resistance Test a resistance range of 0.1 ohm-40 Mohm and displays infinite for a value greater than 40 M ohm (O.L. (Over-load)) Frequency Test for a frequency range of 0.5 HZ-199 K HZ Diode Test 1. Apply at least 1 mA when performing the diode bias test 2. Display the break over voltage drop (0-3 V) of a forward biased diode 3. Display infinite (O.L. (Over-load)) when a diode is reverse biased Min-Max Readings 1. Can update at a 1 ms sample rate 2. Saves and displays minimum and maximum values Note: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Probe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors). * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the EL-38125-580 GM Approved Terminal Release Tool Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the EL-38125-580 GM Approved Terminal Release Tool Kit , ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the EL-38125-580 GM Approved Terminal Release Tool Kit label on the inside of the EL-38125-580 GM Approved Terminal Release Tool Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3341 Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/EPC Connectors AFL/EPC Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3342 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 3. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3343 View showing depressing of the lever lock release tab. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3344 6. Release the rear lower half of the wiredress cover. 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3345 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3346 Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Bosch Connectors (ECM) Bosch Connectors (ECM) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3347 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. 2. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3348 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-bladed tool to release the locking tabs and remove the dress cover. 4. The terminal positive assurance (TPA) is located in the front of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3349 5. Use a small flat-blade tool to remove TPA from the connector. 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3350 Note: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3351 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3352 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Terminal Replacement Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3353 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3354 5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Position Assurance Locks) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Terminal Position Assurance Locks) * AFL/EPC Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/AFL/EPC Connectors) * Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (BSK))Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (0.64))Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (2.8 JPT))Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (ECM)) * Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Weather Pack))Delphi Connectors (Push To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Push to Seat))Delphi Connectors Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3355 (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Pull to Seat))Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro-Pack 100W))Delphi Connectors (Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro .64))Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (12-Way)) * FCI Connectors (Lever Lock) (See: General Electrical Diagnostic Procedures/Connector Repairs/FCI Connectors (Lever Lock)) * JST Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/JST Connectors) * Kostal Connectors (Glow Plug Control Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Glow Plug Control Module))Kostal Connectors (Transmission) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Transmission)) * Molex Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Molex Connectors) * Sumitomo Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Sumitomo Connectors) * Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (CM 42-Way))Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Sensor))Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (0.25 Cap))Tyco/AMP Connectors (43-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (43-Way))Tyco/AMP Connectors (Door Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Door Module))Tyco/AMP Connectors (102-Way Inline) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (102-Way Inline))Tyco/AMP Connectors (Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Seat))Tyco/AMP Connectors (SIR) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (SIR)) * Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (2-Way))Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (16-Way)) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3356 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3357 * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3358 * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3359 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3360 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3361 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Push to Seat) Delphi Connectors (Push To Seat) Special Tools J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3362 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs). 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Terminated Lead Repair 1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice sleeves depending on the gauge size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Delphi Connectors (Pull to Seat) Delphi Connectors (Pull To Seat) Special Tools Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3363 J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Note: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3364 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. View of a typical Micro 64 connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3365 Depress the lock and pull the lever over and past the lock. View of the connector when released from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3366 View of another type of Micro 64 connector. Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3367 View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3368 Note: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3369 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3370 Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Note: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3371 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3372 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3373 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3374 1. Cut the wire as close to the terminal as possible. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3375 Terminal Replacement Procedure After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Special Tools J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Note: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals). 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12-Way) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3376 Delphi Connectors (12-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3377 4. Release the lower wire dress cover locking tab. 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3378 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3379 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors (Lever Lock) FCI Connectors (Lever Lock) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3380 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. The release tab is located on the top of the wiredress cover. 3. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3381 6. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3382 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3383 1. While depressing the lock, remove the connector from the component. 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3384 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. 4. View of the TPA when removed from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3385 5. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Glow Plug Control Module) Kostal Connectors (Glow Plug Control Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3386 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3387 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3388 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. Note: The front TPA cannot be removed from the connector. Only move it to the preset position. 6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm). 7. Use a small flat-blade tool to completely remove the rear TPA from the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3389 8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Transmission) Kostal Connectors (Transmission) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3390 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3391 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Terminal Replacement Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3392 After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3393 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3394 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3395 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3396 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3397 3. To assemble the connector, reverse the connector disassembly procedure. Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3398 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3399 7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3400 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3401 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3402 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3403 Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3404 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3405 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3406 6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (102-Way Inline) Tyco/AMP Connectors (102-Way Inline) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3407 View of a typical connector in the assembled position. 1. Pull the locking lever to the 90 degree position from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3408 2. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal. 3. Slide the male connector body out away from the guide plates. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3409 Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 4. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. 5. Using terminal release tool J 38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3410 6. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 7. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3411 8. The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool J-38125-11A or equivalent to release the locking tab and slide the connector off the female body. 9. Move the locking lever 180 degrees from the connected position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3412 10. With the locking lever in the 180 degree position the guide plates can be removed from the connector body. Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 11. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3413 12. Using terminal release tool J 38125-216, lift the terminal plate past the terminals and out of the connector body cavity. 13. Terminal plate will bind slightly on each corner. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3414 14. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 15. Using terminal release tool J 38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3415 16. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 17. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3416 18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever. 19. Slide the male connector body back inward toward the guide plates. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3417 20. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly. 21. Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Seat) Tyco/AMP Connectors (Seat) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3418 Removal Procedure 1. Grasp the locking slide lever and pull outward from the end of the connector. 2. As the slide lever is pulled out the mating connector is lifted from the seated position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3419 Note: TPA is keyed and can only be inserted in one direction. 3. Using terminal release tool J 38125-11A or equivalent, push the TPA tabs into the connector body. 4. Pull the TPA from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3420 5. Using terminal release tool J 38125-11A or equivalent, release the connector wire dress cover locking tab. 6. With the lock tab released, lift the connector wire dress cover from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3421 7. Using terminal release tool J 38125-212, press the prongs into the holes each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 8. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3422 9. Using terminal release tool J 38125-556, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (SIR) Tyco/AMP Connectors (SIR) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3423 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3424 3. Using terminal tool J-38125-11A or equivalent, release the wire dress cover locking tabs. 4. Pivot connector wire dress cover while removing from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3425 5. Using terminal tool J-38125-11A or equivalent, remove the TPA by lifting straight off the connector body. 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals Repairing Connector Terminals Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3426 Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gauge size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3427 2. Disconnect the connector from the component. 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3428 4. Relieve the tension on the nose piece retainers by inserting J 38125-12A into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. 5. Once the nose piece retainers are relaxed, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3429 6. On the opposite side of the nose piece, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3430 8. Insert the J 38125-553 tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3431 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. If the TPA is removed, be sure to reinstall it before reconnecting the connector. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3432 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Special Tools Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3433 J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Note: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3434 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3435 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3436 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3437 1. While depressing the lock, pull the two connector halves apart. Note: The TPA is fragile and may break if not done carefully. 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. 3. View of the male half of the connector with female terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3438 4. View of the female half of the connector with male terminals. 5. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. View of the female half of the connector with male terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3439 7. View of the male half of the connector with female terminals. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3440 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are a one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine if the element in the fuse is broken (2). If not broken (1), also check for continuity using a Digital Multimeter (DMM) or a continuity tester. If the element is broken or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a Digital Multimeter (DMM) at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gauge size. Repairing a Fusible Link Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3441 Flat Wire Repairs The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Special Tools J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool * J 38125-5 Ultra Torch Special Tool The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Note: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation). GMLAN Connector Terminal Repair Note: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) for the appropriate connector repair procedure. GMLAN Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3442 Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3443 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Special Tools J-38125 Terminal Repair Kit Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3444 repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs High Temperature Wiring Repairs Special Tools J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gauge size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3445 splice. Note: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3446 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3447 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the wire insulation has been chafed, or broken, enough to show the conductive portion of the wire, and the wire is not damaged, determine the length of insulation that needs to be repaired. If the repair is less than 280 mm (11 in), cut the wire within the damaged area. Then slide the appropriate heat shrink tubing (listed below) over the wire, and repair the wire by splicing the wires together. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Once the wire is spliced together slide heat shrink tubing over the damaged area and apply heat to seal the repaired wire. If the wire is damaged, or the damaged area is larger than 280 mm (11 in), then replace the damaged wire by splicing in a new section of wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3448 SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Special Tools J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3449 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3450 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3451 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Special Tools J-38125 Terminal Repair Kit Note: Use only DuraSeal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use DuraSeal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use DuraSeal splice sleeves where there are special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3452 * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3453 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3454 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the instructions for Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Staggering the splices by 65 mm (2.5 in) is recommended. Note: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product AL-36FR to replace the damaged mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Flat Wire Repairs) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/GMLAN Wiring Repairs) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Heated Oxygen Sensor Wiring Repairs) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves) * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Twisted or Shielded Cable) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Inline Harness Diodes) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/SIR/SRS Wiring Repairs) US English/Metric Conversion US English/Metric Conversion Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3455 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3456 Testing Ground and Low Reference Circuits Testing Ground and Low Reference Circuits Because a test lamp can light with up to 200 ohm in a ground or low reference circuit they are not recommended to be used for this type of test. A low impedance test lamp can light and indicate the circuit is good when there is as much as 20-30 ohm present, while a high impedance test lamp can light with up to 200 ohm present in the circuit. This is why the Digital Multi-Meter (DMM) is used when validating a ground or low reference circuit continuity. When using the DMM there are many vehicle conditions that can affect the ground and low reference continuity testing. If these conditions are not met, a ground or low reference circuit test can fail on a good circuit. This may cause longer diagnosis time and incorrect component replacement. Any current flow through a ground or low reference circuit, while being tested, will skew the DMM continuity reading, or display a reading higher than when there is no current flowing. Performing a ground or low reference circuit continuity test, in reference to the vehicles battery negative terminal, will have the highest risk of failing a good ground or low reference circuit test than any other ground reference point. The best ground test points would be a control module housing (if the control modules housing is metal and grounded), door jamb striker (if attached to metal), under dash metal frame work, engine block, or body ground studs (other than where the negative battery cable is attached). A typical DMM ground or low reference circuit continuity reading can be as high as 100 ohm with the ignition ON, and drop to 15-25 ohm after the ignition is turned OFF. The reading will drop below 10 ohm after 30-40 seconds, then below 5 ohm after 60 seconds. Once the vehicle completely goes to sleep (generally 3-10 minutes) the reading will drop below 0.3 ohm. The following list of conditions may need to be met to ensure a valid continuity reading on a ground or low reference circuit: * Ignition OFF * Key out of the ignition switch (when not equipped with keyless entry and remote start) * Retained Accessory Power (RAP) OFF (open and close the driver door after ignition OFF) * Battery charger set at a 2 A or less charge rate * Scan tool not communicating with any vehicle control module (in some cases it may need to be disconnected from the DLC) * All entry doors closed * Headlamps OFF (auto headlamps disabled) * Any delay lighting OFF * HVAC after blow OFF * Any accessory that can work when the ignition is OFF * Wait up to 60 seconds (after all other listed conditions are met) Activating the DOOR LOCK function with a key fob can greatly reduce the time to achieve a valid ground or low reference continuity test result. Terminal Removal Terminal Removal Special Tools * EL-38125-580 - Terminal Release Tool Kit * EL-35616 - Connector Test Adapter Kit For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repair procedures. 1. Find the appropriate connector end view within the connector end view section. The connector end view has the following information: Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3457 * Diagnostic probe tool * Terminal release tool * Terminal/terminated lead part numbers Note: Not using the proper test kit probe may cause damage to the terminal(s) that are probed. 2. Determine if a terminal is damaged. * Locate the diagnostic probe tool from the connector end view. The connector end view describes the color and part number to help the technician find and use the correct tool. * Connect the probe tool to the Digital Multimeter. * Insert the probe tool into the cavity and follow the procedures from the Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter). 3. Disconnect the connector body to perform the repair. 4. Use the following procedure to remove the terminal from the connector body. Note: Several procedures for specific connector bodies are called out in the Wiring Repairs section. * The terminal position assurance (TPA) and connector position assurance (CPA) should be removed before releasing the terminal for the connector body. * Look at the connector end view to locate the cavity of the damaged terminal and find the proper terminal release tool from the terminal release tool kit. Note: Using the incorrect terminal release tool can damage the connector body. * Insert the terminal release tool into the cavity. Note: Some terminals have a lever that must be disengaged before the terminal can be released. 5. Gently pull the wire out of the back of the connector. 6. Repair the terminal by following the Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) procedure. 7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminated Lead Repair Terminated Lead Repair Special Tools * J-38125-8 - Splice Sleeve Crimp Tool Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3458 * J-38125-5 - Ultra Torch For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) procedures. Terminated leads are terminals that are crimped onto wires. The terminated lead can be used throughout the vehicle since it is designed for temperatures up to 150°C. The length of the wire is 450 mm. The DuraSeal splice sleeve has the following 2 critical features: * A special heat shrink tubing that environmentally seals the splice. The shrink tubing contains a sealing adhesive inside the shrink tubing. * A cross hatched (knurled) core crimp that provides the necessary contact integrity for sensitive low energy circuits. 1. Use the connector end view to identify the correct terminated lead. 2. The terminated lead package should include a DuraSeal splice sleeve. If not, use the chart to identify the correct part. 3. Open the harness by removing any tape: Use a sewing seam ripper, or a comparable tool, to cut open the harness, to avoid wire insulation damage. 4. Depending on how many terminals need repairs, cut the terminal and wire back at least 40 mm. Try to keep the harness wire length the same. If more than one terminated lead is required, stagger the lengths by 40 mm. This helps reduce the bundle size of the wire harness. 5. Use the EL-38125-10 - tool in order to position the DuraSeal splice sleeve in the proper color nest of the splice sleeve crimp tool. The crimp tool has four nests, one for each color. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3459 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the J-38125-5 - ultra torch , apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3460 Oil Level Sensor: Connector Views Component Connector End Views Engine Oil Level (EOL) Switch (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3461 Oil Level Sensor: Electrical Diagrams Engine Mechanical Schematics Engine Oil Level Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Page 3462 Oil Level Sensor: Testing and Inspection Engine Oil Level Sensor Diagnosis Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Diagnostic Fault Information Typical Scan Tool Data Circuit/System Description The engine oil level sensor/switch is normally-closed with proper engine oil level. The switch opens when the engine oil level drops below a calibrated level. The engine control module (ECM) monitors the engine oil level signal circuit when the ignition is ON, and the engine is OFF. With the switch in the closed position, the ECM detects a low voltage on the signal circuit. With the switch in the open position, the ECM detects a high voltage on the signal circuit. When high voltage is detected on the signal circuit, the ECM will send a serial data message to the instrument panel cluster (IPC). The IPC will then display a message on the driver information center (DIC) or illuminate a low engine oil level lamp. The following information determines the message sent from the ECM to the IPC: * The Low Engine Oil Level message lamp is displayed only after the ECM detects a high voltage on the signal circuit for three consecutive ignition cycles, followed by an ignition OFF event from 15 minutes to greater than 50 minutes, depending on engine oil temperatures. * The Low Engine Oil Level message is turned OFF when the ECM detects a low voltage on the signal circuit after an ignition OFF event for greater than 90 seconds, followed by an ignition ON event for less than 1 second. Reference Information Schematic Reference * Engine Mechanical Schematics (See: Diagrams/Electrical Diagrams) * Instrument Cluster Schematics (See: Diagrams/Electrical Diagrams/Instrument Panel, Gauges and Warning Indicators/System Diagram/Instrument Cluster Schematics) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views) Description and Operation * Instrument Cluster Description and Operation (See: Instrument Panel, Gauges and Warning Indicators/Description and Operation/Instrument Cluster) * Indicator/Warning Message Description and Operation (See: Instrument Panel, Gauges and Warning Indicators/Description and Operation/Indicator/Warning Message) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Page 3463 Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning) for scan tool information. Circuit/System Verification 1. Verify proper engine oil level. Add oil as necessary. 2. Ignition ON, observe the scan tool Engine Oil Level parameter. The reading should be OK and change to low when the oil level sensor/switch harness connector is disconnected. Circuit/System Testing Note: Verify proper engine oil level before continuing with diagnosis. 1. Ignition OFF, disconnect the harness connector at the engine oil level sensor and/or switch. 2. Ignition OFF, test for less than 2 ohm between the ground circuit terminal B and ground. ‹› If greater than the specified range, test the ground circuit for an open/high resistance. 3. Ignition ON, verify the scan tool Engine Oil Level Switch parameter reads Low. ‹› If the Engine Oil Level Switch parameter reads OK, test the signal circuit terminal A for a short to ground. If the circuit tests normal, replace the ECM. Note: If a short to voltage is found on the signal circuit, the fuse in the 3A jumper wire will open. 4. Ignition ON, install a 3A fused jumper wire between the signal circuit terminal A and the ground circuit terminal B. Verify the scan tool Engine Oil Level Switch parameter reads OK. ‹› If the Engine Oil Level Switch parameter reads Low, test the signal circuit terminal A for an open/high resistance. If the circuit tests normal, replace the ECM. 5. If all circuits test normal, test or replace the engine oil level sensor and/or switch. Repair Instructions Perform the Diagnostic Repair Verification (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. * Engine Oil Level Sensor and/or Switch Replacement (See: Service and Repair) * Control Module References (See: Testing and Inspection/Programming and Relearning) for the ECM replacement, setup, and programming Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Page 3464 Oil Level Sensor: Service and Repair Engine Oil Level Sensor and/or Switch Replacement Removal Procedure 1. Remove the lower oil pan. Refer to Lower Oil Pan Replacement (See: Engine Lubrication/Oil Pan/Service and Repair/Lower Oil Pan Replacement). 2. Remove the oil level sensor clip (3). 3. Remove the oil level sensor bolt (2) and sensor (1). Installation Procedure Note: When routing the oil level sensor wire, ensure that the wire is routed along the side of the oil pan. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the oil level sensor (1) and bolt (2) and tighten to 9 Nm (80 lb in). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Diagrams > Page 3465 2. Install the oil level sensor clip (3). 3. Install the lower oil pan. Refer to Lower Oil Pan Replacement (See: Engine Lubrication/Oil Pan/Service and Repair/Lower Oil Pan Replacement ). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams Oil Pressure Sensor: Diagrams Component Connector End Views Engine Oil Pressure (EOP) Sensor (Diesel) Engine Oil Pressure (EOP) Sensor (Gas except LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Page 3469 Engine Oil Pressure (EOP) Sensor (LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Page 3470 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Page 3471 Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement Special Tools DT-48827 Skip Shift Socket Removal Procedure 1. Remove the left wheelhouse inner panel. Refer to Front Wheelhouse Liner Replacement - Left Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Left Side)Front Wheelhouse Liner Replacement - Left Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Left Side). Note: Clean the area around the sensor. Do not allow debris to enter the engine. 2. Disconnect the oil pressure sensor electrical connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Page 3472 3. Using DT-48827 , remove the oil pressure sensor (1). Installation Procedure 1. Apply sealant to the threads of the oil pressure sensor. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Specifications/Adhesives, Fluids, Lubricants, and Sealers) for the correct part number. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Using DT-48827 , install the oil pressure sensor (1). Tighten the sensor to 49 Nm (36 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams > Page 3473 3. Connect the oil pressure sensor electrical connector. 4. Install the left wheelhouse inner panel. Refer to Front Wheelhouse Liner Replacement - Left Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Left Side)Front Wheelhouse Liner Replacement - Left Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Left Side). 5. Check and add engine oil if necessary. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Specifications Camshaft Gear/Sprocket: Specifications Camshaft Gear Bolt.............................................................................................................................. ......................................................234 Nm (173 lb ft.) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications Timing Cover: Specifications Engine Front Cover Bolts .................................................................................................................... ......................................................... 25 Nm (18 lb ft) Upper Oil Pan To Engine Front Cover Bolt ................................................................................................................................................. 21 Nm (15 lb ft) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 3481 Timing Cover: Service and Repair Engine Front Cover Replacement Special Tools J 37228 Seal Cutter Removal Procedure 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 2. Remove the water pump. Refer to Water Pump Replacement (LU3) (See: Water Pump/Service and Repair)Water Pump Replacement (LMM) ( See: Water Pump/Service and Repair)Water Pump Replacement (V8) (See: Water Pump/Service and Repair). 3. Remove the crankshaft front oil seal. Refer to Crankshaft Front Oil Seal Replacement (See: Seals and Gaskets/Front Crankshaft Seal/Service and Repair). 4. Remove the right wheelhouse panel. Refer to Front Wheelhouse Liner Replacement - Right Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side)Front Wheelhouse Liner Replacement - Right Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side). 5. Disconnect the crankshaft position (CKP) sensor electrical connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 3482 6. Remove the CKP sensor bolt and sensor. 7. Remove the CKP sensor spacer bolts and spacer. 8. Remove and discard the O-rings from the sensor and the spacer. 9. Remove the upper oil pan to engine front cover bolts. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 3483 10. Remove the engine front cover bolts. 11. Separate the engine front cover from the cylinder block and upper oil pan using J 37228 . Note: Do not bend the turbocharger coolant pipe. 12. Remove the engine front cover. 13. If necessary, remove the pressure relief valve O-ring. 14. Clean and inspect the front cover. Refer to Engine Front Cover Cleaning and Inspection (See: Service and Repair/Overhaul/44. Engine Front Cover Cleaning and Inspection). Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 3484 1. If necessary, install a NEW pressure relief valve O-ring. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Lubricate the O-ring with engine oil. Tighten the valve to 39 Nm (29 lb ft). 3. Apply a 2-3 mm (1/8 in) wide by 0.5-1.5 mm (1/16 in) high, bead of sealant to the engine front cover sealing surface to the engine block. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Specifications/Adhesives, Fluids, Lubricants, and Sealers) for the correct part number. 4. Apply a 2-3 mm (1/8 in) wide by 0.5-1.5 mm (1/16 in) high, bead of sealant to the engine front cover sealing surface to the upper oil pan. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Specifications/Adhesives, Fluids, Lubricants, and Sealers) for the correct part number. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 3485 5. Install the engine front cover. 6. Install the engine front cover bolts. Tighten the bolts to 25 Nm (18 lb ft). 7. Install the upper oil pan to engine front cover bolts. Tighten the bolts to 21 Nm (15 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 3486 8. Install a NEW O-ring to the CKP sensor spacer. 9. Lubricate the O-ring with clean engine oil. Note: The crankshaft position sensor spacers are machined with different timing positions. However, if the crankshaft position sensor spacer requires replacement, replace with a grade "C" spacer. 10. Install the CKP sensor spacer and bolts. Tighten the bolts to 10 Nm (89 lb in). 11. Install a NEW O-ring to the CKP sensor. 12. Lubricate the O-ring with clean engine oil. 13. Install the CKP sensor and bolt. Tighten the bolt to 10 Nm (89 lb in). 14. Connect the CKP sensor electrical connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 3487 15. Install the right wheelhouse panel. Refer to Front Wheelhouse Liner Replacement - Right Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side)Front Wheelhouse Liner Replacement - Right Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side). 16. Install the crankshaft front oil seal. Refer to Crankshaft Front Oil Seal Replacement (See: Seals and Gaskets/Front Crankshaft Seal/Service and Repair). 17. Install the water pump. Refer to Water Pump Replacement (LU3) (See: Water Pump/Service and Repair)Water Pump Replacement (LMM) ( See: Water Pump/Service and Repair)Water Pump Replacement (V8) (See: Water Pump/Service and Repair). 18. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications During engine cranking, the pressure should be at least 10 MPa. With the engine running at idle the pressure should be close to the Desired Fuel Rail Pressure. As the engine speed increase, the Desired Fuel Rail Pressure and the Actual Fuel Rail Pressure should be within 2 MPa of each other. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 3492 Fuel Pressure: Service Precautions Relieving Fuel Pressure Warning Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis Fuel Pressure: Testing and Inspection Fuel System Diagnosis Fuel System Diagnosis Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Circuit/System Description Fuel is drawn by the fuel injection pump from the tank to the engine through the fuel supply lines. Fuel flows to the fuel filter/heater element housing , which combines a water separator, a prime pump, fuel heater element and a filter element. A mechanical fuel injection pump at the front of the engine valley includes the fuel supply pump and the high-pressure pump. The small section of the fuel pump assembly is the supply pump, which creates a vacuum to pull fuel from the fuel tank to the high-pressure pump. The vacuum varies with engine load and speed as indicated by the table below. The pump is engine-driven by the camshaft gear. From the high-pressure pump, the pressurized fuel flows to the left fuel rail. A balance pipe from the center of the left rail then feeds the right fuel rail. Each fuel rail supplies one bank of 4 fuel injectors. The fuel rail pressure sensor is mounted in the end of the right fuel rail. Fuel is used to cool and lubricate the fuel injectors and fuel injection pump. The fuel return system is designed to return this fuel to the fuel tank. If the high side fuel pressure becomes excessive, the fuel rail pressure relief valve releases the fuel into the fuel return system. The return fuel travels through the fuel cooler and then to the fuel tank. Diagnostic Aids An Engine Cranks but Will Not Run or Hard Start symptom may exist if air is being drawn into the fuel injection system due to the following conditions: * Fuel contamination-Refer to Contaminants-in-Fuel Diagnosis (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Contaminants-in-Fuel Diagnosis). * Deformed or cut O-rings at the fuel supply line connections * Improperly seated fuel supply line fittings * Porous or weathered rubber fuel supply lines * Fuel filter vent screw not tighten or cross threaded * Fuel filter not tighten properly Reference Information Special Tools * J-23738-A MityVac * EN-47969 Fuel Supply Diagnostic Hose * CH-48027 Digital Pressure Gauge * J 44581 Fuel Line Disconnect Tool Circuit/System Verification Observe the Actual Fuel Rail Pressure parameter with a scan tool. During engine cranking, the pressure should be at least 10 MPa. With the engine running at idle the pressure should be close to the Desired Fuel Rail Pressure. As the engine speed increase, the Desired Fuel Rail Pressure and the Actual Fuel Rail Pressure should be within 2 MPa of each other. Circuit/System Testing Note: Ensure that a sufficient amount of fuel is in the fuel tank to run the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis > Page 3495 1. Install the CH-48027 to the fuel system service port on the right front side of the engine. 2. Prime the fuel system until 10 psi is indicated on the CH-48027 . Fuel pressure should not drop below 2 psi in less than one minute. ‹› If fuel pressure drops below 2 psi in less than one minute, go to step 4. Note: It may be necessary to remove engine components for the visual inspections. 3. Attempt to start and idle the engine. Observe the CH-48027 during idle. The vacuum should be between 1-3 in Hg. ‹› If more than 3 in Hg is observed at idle, visually inspect the following items: * Fuel filter element for a restriction * Hoses and lines that are flattening when the engine is running, or have kinks that would restrict the flow of fuel ‹› If engine did not start and no vacuum was observed, refer to Fuel Injection Pump Replacement (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair). 4. Disconnect the fuel supply line at the engine and install a J-23738-A using the J 44581 to the engine side of the fuel supply line. 5. Apply vacuum to the fuel supply pipe until 25 in Hg has been reached. Wait for at least one minute to allow the fuel system to stabilize. Vacuum should not drop below 8 in Hg within 10 minutes. ‹› If vacuum cannot be obtained or the vacuum drops below 8 in Hg within 10 minutes, repair the air leak at fuel filter/heater element housing connections or at the fuel hoses/pipes on the engine supply line. 6. Remove both hoses from the fuel filter/heater element housing assembly. Cap the suction side port of the fuel filter/heater element housing assembly. Apply 25 in Hg to the discharge port of the fuel filter/heater element housing assembly. Vacuum should not drop below 8 in Hg within 10 minutes. ‹› If vacuum drops below 8 in Hg within 10 minutes, replace the fuel filter/heater element housing assembly. Note: The engine may start and then stall after briefly running. 7. Remove the J-23738-A from the fuel filter/heater element housing assembly. Install the removed fuel filter/heater element housing assembly, and cap off the fuel supply pipe on the engine. Crank the engine in 15-second intervals while observing the CH-48027 . More than 5 in Hg vacuum should be observed during cranking. ‹› If less than 5 in Hg was observed on the vacuum gauge during cranking, replace the fuel injection pump. Note: The engine may start, and then stall after briefly running. 8. Install the fuel supply line at the engine, and disconnect the chassis fuel supply line at the fuel tank. Install a J-23738-A to the supply hose at the fuel tank using the J 44581 . 9. Apply vacuum to the supply hose at the fuel tank until 25 in Hg has been reached. Wait for a least one minute for the fuel system to stabilize. Vacuum should not drop below 8 in Hg within 10 minutes. ‹› If vacuum cannot be obtained, or the vacuum drops below 8 in Hg within 10 minutes, repair the air leak in the fuel supply line between the engine and fuel tank, or the connection of the supply line to the engine. 10. Install all components and lines that were previously removed or disconnected. 11. Install the EN-47969 on the fuel supply line at the engine. Create a vertical loop in the hose to observe the incoming fuel for air bubbles. 12. Open the bleed screw on top of the fuel filter/heater element housing. Prime the system until fuel appears at the bleed screw. Continue to prime the fuel system until the engine starts and runs. 13. Run the engine for at least 10 minutes to allow the fuel system to stabilize, and purge any air from the system. Note: Changes in engine speed can cause an increase of air bubbles that enter the EN-47969 . An air pocket at the top of the EN-47969 loop is considered a normal condition. 14. At a stabilized idle, observe the fuel entering the EN-47969 for air bubbles. ‹› If air bubbles were observed entering the transparent hose, test the fuel sender for leaks. Refer to Fuel Sender Assembly Replacement (See: Instrument Panel, Gauges and Warning Indicators/Fuel Gauge Sender/Service and Repair). 15. Install the fuel sender, fuel tank, and all fuel system connections and components that were previously disconnected. Leave the EN-47969 connected to the fuel supply line. Prime the fuel system 30 times to remove the air from the fuel hoses. Continue to prime the fuel system until the engine starts and runs. Observe the fuel entering the transparent hose. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis > Page 3496 ‹› If air bubbles are still present, refer to Diagnostic Aids. ‹› If no air bubbles are present , remove the EN-47969 and run the engine to ensure no fuel leaks exist. Repair Instructions Perform the Diagnostic Repair Verification (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. * Fuel Injection Pump Replacement (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair) * Fuel Sender Assembly Replacement (See: Instrument Panel, Gauges and Warning Indicators/Fuel Gauge Sender/Service and Repair) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis > Page 3497 Fuel Pressure: Testing and Inspection Fuel System Diagnosis - High Pressure Side Fuel System Diagnosis - High Pressure Side Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Circuit/System Description High Pressure System The fuel injection pump at the front of the engine valley includes a fuel supply pump and a high-pressure pump. Fuel is drawn by the fuel supply pump from the primary fuel tank and delivered to the high-pressure pump. The pump is engine-driven by the camshaft gear. High pressure fuel is regulated by the fuel pressure regulator mounted on the fuel injection pump. From the high-pressure pump, the fuel moves to the left and right fuel rails through high pressure metal lines. Each fuel rail distributes high pressure fuel to one bank of 4 fuel injectors. The fuel pressure relief valve is location on the left rail, and relieves excessive fuel pressure which returns to the fuel tank. Return System The fuel return system routes fuel from the fuel injectors, the pressure relief valve, and the fuel injection pump. The return fuel travels to the fuel cooler and then to the fuel tank. This fuel is used to cool and lubricate the injection pump and the injectors. Diagnostic Aids * The fuel return volumes vary based on the American Petroleum Institute (API) rating of the diesel fuel. * A fuel injector may have high fuel return flow only at higher engine temperatures. Reference Information Special Tools * J 45873 Fuel Return Volume Test Kit * J-45873-30 Injector Flow Test Adapter Circuit/System Verification With the engine running at idle the Actual Fuel Pressure should be close to the Desired Fuel Rail Pressure. During engine cranking the Actual Fuel Pressure should be at least 10 MPa. Inspect the fuel return hoses and lines for external leaks or damage. Circuit/System Testing Important: If you were not referred to this test from another diagnostic, do not perform this procedure. Only perform this test when the fuel is more than 18°C (65°F). Important: Before replacing the fuel pressure relief valve, ensure that the break-away torque is within specifications. Refer to Fastener Tightening Specifications (See: Powertrain Management/Specifications). 1. Remove the fuel pressure relief valve return hose and plug the hose to prevent fuel leakage. 2. Install a section of rubber fuel hose on the fuel pressure relief valve connection and place loose end of hose into a clean fuel container. Important: Fuel that is contaminated with gasoline may cause permanent damage to the fuel pressure relief valve. Refer to Contaminants-in-Fuel Diagnosis (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Contaminants-in-Fuel Diagnosis). * If the engine cranks but does not start, crank engine for 15 seconds. Observe for fuel leaking from fuel pressure relief valve. ‹› If fuel leaks from the fuel pressure relief valve, replace the pressure relief valve. Refer to Fuel Pressure Relief Valve Replacement (See: Fuel Filter/Fuel Pressure Release/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis > Page 3498 * If the engine starts and runs, idle the engine while commanding the fuel rail pressure to 180 MPa with a scan tool. Observe for fuel leaking from fuel pressure relief valve. ‹› If fuel leaks from the fuel pressure relief valve, replace the pressure relief valve. Refer to Fuel Pressure Relief Valve Replacement (See: Fuel Filter/Fuel Pressure Release/Service and Repair). Important: Always replace the fuel return hose retaining clips on the fuel injectors with new clips after removing. 3. Remove the fuel return hose from the fuel injectors of the right cylinder bank. Refer to Fuel Injection Fuel Return Pipe Replacement - Right Side (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Return Line/Service and Repair/Fuel Injection Fuel Return Pipe Replacement - Right Side). 4. Connect the yellow hoses from the J 45873 to the J-45873-30 . 5. Connect the J-45873-30 with yellow hoses to each fuel injector return port of the right cylinder bank, and install the retaining clips. 6. Install the 4 yellow hoses in the J 45873 graduated cylinders in numerical order. 7. Connect the fuel return hoses to the J-45873-30 to prevent leakage. ‹› If the engine starts and runs, idle the engine until fuel start dripping into all the graduated cylinders and yellow hoses are full of fuel. Important: The engine cranking speed must be more than 150 RPM during the cranking portion of this test. ‹› If the engine does not start, crank the engine in 15-second intervals, with 1 minute cooling time between intervals, until fuel starts to flow into all of the graduated cylinders. 8. Elevate the 4 yellow hoses to retain the fuel in the hoses, and empty the 4 graduated cylinders into a suitable container. 9. Install the 4 yellow hoses in the J 45873 graduated cylinders in numerical order. ‹› If the engine starts and runs, idle the engine for 15 seconds. ‹› If the engine does not start, crank the engine for 15 seconds. Important: During replacement of the injectors, inspect the inlet and outlet fittings for corrosion or contamination. Refer to Contaminants-in-Fuel Diagnosis (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Contaminants-in-Fuel Diagnosis). 10. Measure the quantity of fuel in each of the graduated cylinders. Refer to Fuel System Specifications (See: Powertrain Management/Fuel Delivery and Air Induction/Specifications) for the desired quantities. ‹› If high return flows were recorded, replace those fuel injectors that had high return flow and retest the fuel return flow, referring to Fuel System Specifications (See: Powertrain Management/Fuel Delivery and Air Induction/Specifications). Replace any additional high return flow injectors and proceed to the next number step. 11. Install and connect all fuel system components that were previously removed or disconnected. 12. Remove the fuel return pipes from the fuel injectors of the left cylinder bank and repeat the fuel return flow test previously preformed on the right cylinder bank. ‹› If high return flows were recorded, replace those fuel injectors that had high return flow and retest the fuel return flow, referring to Fuel System Specifications (See: Powertrain Management/Fuel Delivery and Air Induction/Specifications). Replace any additional high return flow injectors and proceed to the next number step. 13. Install and connect all fuel system components that were previously removed or disconnected. 14. Start and idle the engine. You may have to prime the fuel system before the engine will start. Command the fuel pressure control to 180 MPa with a scan tool. The actual fuel pressure should be the same as the commanded pressure. ‹› If the engine does not start or the fuel pressure is less than 145 MPa when commanded, replace the fuel injection pump. 15. Command the fuel pressure control to 180 MPa with a scan tool. The fuel pressure should be able to reach 145 MPa when commanded. ‹› If the fuel pressure is less than the specified value, refer to Fuel System Diagnosis (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Fuel System Diagnosis). 16. Operate the vehicle in order to verify the repairs. Repair Instructions Perform the Diagnostic Repair Verification (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis > Page 3499 * Fuel Injection Pump Replacement (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair) * Fuel Pressure Relief Valve Replacement (See: Fuel Filter/Fuel Pressure Release/Service and Repair) * Fuel Injector Replacement (Right) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Injector/Service and Repair/Removal and Replacement/Fuel Injector Replacement (Right))Fuel Injector Replacement (Left) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Injector/Service and Repair/Removal and Replacement/Fuel Injector Replacement (Left)) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Idle Speed............................................................................................................................................ ......................................................................680 RPM Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 3503 Idle Speed: Service and Repair High Idle Switch Programming Before Programming a Control Module Important: DO NOT program a control module unless you are directed by a service procedure or you are directed by a General Motors Corporation service bulletin. Programming a control module at any other time will not permanently correct a customer's concern. Ensure the following conditions are met before programming a control module: * Vehicle system voltage - There is no charging system concern. All charging system concerns must be repaired before programming a control module. - Battery voltage is greater than 12 volts but less than 16 volts. The battery must be charged before programming the control module if the battery voltage is low. - A battery charger is NOT connected to the vehicle's battery. Incorrect system voltage or voltage fluctuations from a battery charger, may cause programming failure or control module damage. - Turn OFF or disable any system that may put a load on the vehicle's battery. * Twilight sentinel * Interior lights * Daytime running lights (DRL)-Applying the parking brake, on most vehicles, disables the DRL system. Refer to the Owner's Manual. * HVAC systems * Engine cooling fans, etc. * The ignition switch is in the proper position. The scan tool prompts you to turn ON the ignition, with the engine OFF. DO NOT change the position of the ignition switch during the programming procedure, unless instructed to do so. * All tool connections are secure. - The connection at the data link connector (DLC) - Voltage supply circuits * DO NOT disturb the tool harnesses while programming. If an interruption occurs during the programming procedure, programming failure or control module damage may occur. High Idle Switch Programming * Using the Tech 2, select Module Setup/PTO Options * Use soft keys to select desired settings. * When setting selections are complete, select Reprogram. Important: The ECM will not operate under the new value until the it has powered down once. * Turn OFF the ignition until communication with the ECM is lost, as indicated on the scan tool. * Start the vehicle and confirm the new settings by operating the high idle switch. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > Customer Interest for Air Cleaner Fresh Air Duct/Hose: > 08-06-04-054B > Jan > 11 > Diesel Engine - Low Power/MIL ON/DTC P0101 Air Cleaner Fresh Air Duct/Hose: Customer Interest Diesel Engine - Low Power/MIL ON/DTC P0101 TECHNICAL Bulletin No.: 08-06-04-054B Date: January 24, 2011 Subject: Snow or Ice Ingestion into Air Cleaner Element, Malfunction Indicator Lamp (MIL) Illuminated, Engine Power is Reduced Message Displayed, DTC P0101 Set (Perform Repair as Outlined) Models: 2007-2010 Chevrolet Silverado 2500/3500 Series 2007-2010 GMC Sierra 2500/3500 Series Equipped with Duramax(TM) Diesel Engine (RPO LMM) Supercede: This bulletin is being revised to provide a procedure to relocate the OAT sensor, if equipped with RPO CJ2. Please discard Corporate Bulletin 08-06-04-054A (Section 06 - Engine / Propulsion System). Condition Some customers may comment on the malfunction indicator lamp (MIL) being illuminated and an Engine Power is Reduced message being displayed. The technician may observe DTC P0101 set as current or in history. Cause This condition may be caused by snow being ingested into the air cleaner housing and accumulating in the air cleaner element, resulting in restricted airflow into the engine. Correction 1. Verify the condition by questioning the customer as to when the condition occurs (such as during or right after a snow storm). ‹› If the condition occurs as described above, proceed to Step 2. ‹› If the condition does not occur as described above, refer to Diagnostic Trouble Code (DTC) List Vehicle in SI. 2. Remove the air cleaner element. Refer to Air Cleaner Element Replacement in SI. 3. Inspect the air cleaner element for the following conditions: 1. Packed snow 2. Frozen ice 3. A soaking wet condition that would indicate previous snow ingestion 4. Excessive debris and contamination as a result of the ingestion ‹› If any of the above conditions are observed, replace the air cleaner element. Remove any snow or ice that may have accumulated in the air intake duct. Note Winter covers for trucks that are equipped with the Duramax(TM) Diesel Engine are included with vehicle orders that ship to the following areas: All of Canada, and the following states: Alaska, Colorado, Idaho, Maine, Michigan, Minnesota, Montana, New Hampshire, New York, North Dakota, South Dakota, Vermont, Wisconsin, Wyoming. These vehicles should not need a new cover. 4. Install the grille opening section ONLY (if using the 2 piece cover) of the winter front cover following the usage guidelines provided in the Owners Manual for the appropriate type winter cover. ‹› If the customer does not have a cover, obtain and install the grille opening section ONLY , GM P/N 25822811 (GMC) or GM P/N 25822812 (Chevrolet). 5. The grille opening cover MUST BE installed to ensure a complete repair, BEFORE ENCOUNTERING SNOW. This repair allows warm air to be circulated into the air cleaner. Additional Information to Advise Customer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > Customer Interest for Air Cleaner Fresh Air Duct/Hose: > 08-06-04-054B > Jan > 11 > Diesel Engine - Low Power/MIL ON/DTC P0101 > Page 3513 Important If the vehicle is driven in a snow storm before installing the winter cover and the customer chooses to resolve the issue, they must follow this procedure using the following steps: 1. Remove ANY ice or snow that may have accumulated in the air intake duct, BEFORE REPLACING the air cleaner element. 2. INSTALL the winter cover BEFORE continuing to drive the truck. 3. Turn OFF the ignition, and all electrical accessories and components. 4. Remove the key from the vehicle, THEN open and close the door. 5. WAIT for 2 minutes to allow the engine control module (ECM) to power down. This can be verified by watching for the instrument panel cluster (IPC) gage needles to drop slightly. 1. Allowing the ECM to power down will let DTC P0101 revert to a History DTC and the vehicle should return to full power if the issue has been eliminated. 2. Advise the customer to take the vehicle to the dealer as soon as possible to verify the condition has been eliminated. Ambient (Outside) Air Temperature Sensor Relocation For vehicles equipped with Automatic Temperature Control HVAC (RPO CJ2), the ambient (outside) air temperature sensor needs to be relocated using the following procedure: 1. Remove the radiator grille. Refer to the Radiator Grille Replacement procedure in SI. 2. Remove the ambient air sensor from its current location by carefully lifting the sensor from the radiator support cross bar. 3. Remove the harness clip nearest to the sensor. 4. Reinstall the ambient air sensor to the new location using the existing hole (1) in the lower section of the radiator support. 5. Reinstall the harness clip to the existing hole (2) in the radiator support. 6. Reinstall the radiator grille. Parts Information Warranty Information Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > Customer Interest for Air Cleaner Fresh Air Duct/Hose: > 08-06-04-054B > Jan > 11 > Diesel Engine - Low Power/MIL ON/DTC P0101 > Page 3514 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > Customer Interest for Air Cleaner Fresh Air Duct/Hose: > 08-06-04-054A > Jan > 10 > Engine - Reduced Power/MIL ON/DTC P0101 Air Cleaner Fresh Air Duct/Hose: Customer Interest Engine - Reduced Power/MIL ON/DTC P0101 TECHNICAL Bulletin No.: 08-06-04-054A Date: January 07, 2010 Subject: Snow or Ice Ingestion into Air Cleaner Element, Malfunction Indicator Lamp (MIL) Illuminated, Engine Power is Reduced Message Displayed, DTC P0101 Set (Perform Repair as Outlined) Models: 2007-2010 Chevrolet Silverado 2500/3500 Series 2007-2010 GMC Sierra 2500/3500 Series Equipped with Duramax(TM) Diesel Engine (RPO LMM) Please Refer to GMVIS Supercede: This bulletin is being revised to remove the graphic, update the Parts and Correction information and add information to advise a customer. Please discard Corporate Bulletin 08-06-04-054 (Section 06 - Engine / Propulsion System). Condition Some customers may comment on the malfunction indicator lamp (MIL) being illuminated and an Engine Power is Reduced message being displayed. The technician may observe DTC P0101 set as current or in history. Cause This condition may be caused by snow being ingested into the air cleaner housing and accumulating in the air cleaner element, resulting in restricted airflow into the engine. Correction 1. Verify the condition by questioning the customer as to when the condition occurs (such as during or right after a snow storm). ‹› If the condition occurs as described above, proceed to Step 2. ‹› If the condition does not occur as described above, refer to Diagnostic Trouble Code (DTC) List Vehicle in SI. 2. Remove the air cleaner element. Refer to Air Cleaner Element Replacement in SI. 3. Inspect the air cleaner element for the following conditions: 1. Packed snow 2. Frozen ice 3. A soaking wet condition that would indicate previous snow ingestion 4. Excessive debris and contamination as a result of the ingestion ‹› If any of the above conditions are observed, replace the air cleaner element. Remove any snow or ice that may have accumulated in the air intake duct. Note Winter covers for trucks that are equipped with the Duramax(TM) Diesel Engine are included with vehicle orders that ship to the following areas: All of Canada, and the following states: Alaska, Colorado, Idaho, Maine, Michigan, Minnesota, Montana, New Hampshire, New York, North Dakota, South Dakota, Vermont, Wisconsin, Wyoming. These vehicles should not need a new cover. 4. Install the grille opening section ONLY (if using the 2 piece cover) of the winter front cover following the usage guidelines provided in the Owners Manual for the appropriate type winter cover. ‹› If the customer does not have a cover, obtain and install the grille opening section ONLY, GM P/N 25822811 (GMC) or GM P/N 25822812 (Chevrolet). 5. The grille opening cover MUST BE installed to ensure a complete repair, BEFORE ENCOUNTERING SNOW. This repair allows warm air to be circulated into the air cleaner. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > Customer Interest for Air Cleaner Fresh Air Duct/Hose: > 08-06-04-054A > Jan > 10 > Engine - Reduced Power/MIL ON/DTC P0101 > Page 3519 Additional Information to Advise Customer Important If the vehicle is driven in a snow storm before installing the winter cover and the customer chooses to resolve the issue, they must follow this procedure using the following steps: 1. Remove ANY ice or snow that may have accumulated in the air intake duct, BEFORE REPLACING the air cleaner element. 2. INSTALL the winter cover BEFORE continuing to drive the truck. 3. Turn OFF the ignition, and all electrical accessories and components. 4. Remove the key from the vehicle, THEN open and close the door. 5. WAIT for 2 minutes to allow the engine control module (ECM) to power down. This can be verified by watching for the instrument panel cluster (IPC) gage needles to drop slightly. 1. Allowing the ECM to power down will let DTC P0101 revert to a History DTC and the vehicle should return to full power if the issue has been eliminated. 2. Advise the customer to take the vehicle to the dealer as soon as possible to verify the condition has been eliminated. Parts Information Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Cleaner Fresh Air Duct/Hose: > 08-06-04-054B > Jan > 11 > Diesel Engine - Low Power/MIL ON/DTC P0101 Air Cleaner Fresh Air Duct/Hose: All Technical Service Bulletins Diesel Engine - Low Power/MIL ON/DTC P0101 TECHNICAL Bulletin No.: 08-06-04-054B Date: January 24, 2011 Subject: Snow or Ice Ingestion into Air Cleaner Element, Malfunction Indicator Lamp (MIL) Illuminated, Engine Power is Reduced Message Displayed, DTC P0101 Set (Perform Repair as Outlined) Models: 2007-2010 Chevrolet Silverado 2500/3500 Series 2007-2010 GMC Sierra 2500/3500 Series Equipped with Duramax(TM) Diesel Engine (RPO LMM) Supercede: This bulletin is being revised to provide a procedure to relocate the OAT sensor, if equipped with RPO CJ2. Please discard Corporate Bulletin 08-06-04-054A (Section 06 - Engine / Propulsion System). Condition Some customers may comment on the malfunction indicator lamp (MIL) being illuminated and an Engine Power is Reduced message being displayed. The technician may observe DTC P0101 set as current or in history. Cause This condition may be caused by snow being ingested into the air cleaner housing and accumulating in the air cleaner element, resulting in restricted airflow into the engine. Correction 1. Verify the condition by questioning the customer as to when the condition occurs (such as during or right after a snow storm). ‹› If the condition occurs as described above, proceed to Step 2. ‹› If the condition does not occur as described above, refer to Diagnostic Trouble Code (DTC) List Vehicle in SI. 2. Remove the air cleaner element. Refer to Air Cleaner Element Replacement in SI. 3. Inspect the air cleaner element for the following conditions: 1. Packed snow 2. Frozen ice 3. A soaking wet condition that would indicate previous snow ingestion 4. Excessive debris and contamination as a result of the ingestion ‹› If any of the above conditions are observed, replace the air cleaner element. Remove any snow or ice that may have accumulated in the air intake duct. Note Winter covers for trucks that are equipped with the Duramax(TM) Diesel Engine are included with vehicle orders that ship to the following areas: All of Canada, and the following states: Alaska, Colorado, Idaho, Maine, Michigan, Minnesota, Montana, New Hampshire, New York, North Dakota, South Dakota, Vermont, Wisconsin, Wyoming. These vehicles should not need a new cover. 4. Install the grille opening section ONLY (if using the 2 piece cover) of the winter front cover following the usage guidelines provided in the Owners Manual for the appropriate type winter cover. ‹› If the customer does not have a cover, obtain and install the grille opening section ONLY , GM P/N 25822811 (GMC) or GM P/N 25822812 (Chevrolet). 5. The grille opening cover MUST BE installed to ensure a complete repair, BEFORE ENCOUNTERING SNOW. This repair allows warm air to be circulated into the air cleaner. Additional Information to Advise Customer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Cleaner Fresh Air Duct/Hose: > 08-06-04-054B > Jan > 11 > Diesel Engine - Low Power/MIL ON/DTC P0101 > Page 3525 Important If the vehicle is driven in a snow storm before installing the winter cover and the customer chooses to resolve the issue, they must follow this procedure using the following steps: 1. Remove ANY ice or snow that may have accumulated in the air intake duct, BEFORE REPLACING the air cleaner element. 2. INSTALL the winter cover BEFORE continuing to drive the truck. 3. Turn OFF the ignition, and all electrical accessories and components. 4. Remove the key from the vehicle, THEN open and close the door. 5. WAIT for 2 minutes to allow the engine control module (ECM) to power down. This can be verified by watching for the instrument panel cluster (IPC) gage needles to drop slightly. 1. Allowing the ECM to power down will let DTC P0101 revert to a History DTC and the vehicle should return to full power if the issue has been eliminated. 2. Advise the customer to take the vehicle to the dealer as soon as possible to verify the condition has been eliminated. Ambient (Outside) Air Temperature Sensor Relocation For vehicles equipped with Automatic Temperature Control HVAC (RPO CJ2), the ambient (outside) air temperature sensor needs to be relocated using the following procedure: 1. Remove the radiator grille. Refer to the Radiator Grille Replacement procedure in SI. 2. Remove the ambient air sensor from its current location by carefully lifting the sensor from the radiator support cross bar. 3. Remove the harness clip nearest to the sensor. 4. Reinstall the ambient air sensor to the new location using the existing hole (1) in the lower section of the radiator support. 5. Reinstall the harness clip to the existing hole (2) in the radiator support. 6. Reinstall the radiator grille. Parts Information Warranty Information Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Cleaner Fresh Air Duct/Hose: > 08-06-04-054B > Jan > 11 > Diesel Engine - Low Power/MIL ON/DTC P0101 > Page 3526 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Cleaner Fresh Air Duct/Hose: > 08-06-04-054A > Jan > 10 > Engine - Reduced Power/MIL ON/DTC P0101 Air Cleaner Fresh Air Duct/Hose: All Technical Service Bulletins Engine - Reduced Power/MIL ON/DTC P0101 TECHNICAL Bulletin No.: 08-06-04-054A Date: January 07, 2010 Subject: Snow or Ice Ingestion into Air Cleaner Element, Malfunction Indicator Lamp (MIL) Illuminated, Engine Power is Reduced Message Displayed, DTC P0101 Set (Perform Repair as Outlined) Models: 2007-2010 Chevrolet Silverado 2500/3500 Series 2007-2010 GMC Sierra 2500/3500 Series Equipped with Duramax(TM) Diesel Engine (RPO LMM) Please Refer to GMVIS Supercede: This bulletin is being revised to remove the graphic, update the Parts and Correction information and add information to advise a customer. Please discard Corporate Bulletin 08-06-04-054 (Section 06 - Engine / Propulsion System). Condition Some customers may comment on the malfunction indicator lamp (MIL) being illuminated and an Engine Power is Reduced message being displayed. The technician may observe DTC P0101 set as current or in history. Cause This condition may be caused by snow being ingested into the air cleaner housing and accumulating in the air cleaner element, resulting in restricted airflow into the engine. Correction 1. Verify the condition by questioning the customer as to when the condition occurs (such as during or right after a snow storm). ‹› If the condition occurs as described above, proceed to Step 2. ‹› If the condition does not occur as described above, refer to Diagnostic Trouble Code (DTC) List Vehicle in SI. 2. Remove the air cleaner element. Refer to Air Cleaner Element Replacement in SI. 3. Inspect the air cleaner element for the following conditions: 1. Packed snow 2. Frozen ice 3. A soaking wet condition that would indicate previous snow ingestion 4. Excessive debris and contamination as a result of the ingestion ‹› If any of the above conditions are observed, replace the air cleaner element. Remove any snow or ice that may have accumulated in the air intake duct. Note Winter covers for trucks that are equipped with the Duramax(TM) Diesel Engine are included with vehicle orders that ship to the following areas: All of Canada, and the following states: Alaska, Colorado, Idaho, Maine, Michigan, Minnesota, Montana, New Hampshire, New York, North Dakota, South Dakota, Vermont, Wisconsin, Wyoming. These vehicles should not need a new cover. 4. Install the grille opening section ONLY (if using the 2 piece cover) of the winter front cover following the usage guidelines provided in the Owners Manual for the appropriate type winter cover. ‹› If the customer does not have a cover, obtain and install the grille opening section ONLY, GM P/N 25822811 (GMC) or GM P/N 25822812 (Chevrolet). 5. The grille opening cover MUST BE installed to ensure a complete repair, BEFORE ENCOUNTERING SNOW. This repair allows warm air to be circulated into the air cleaner. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Cleaner Fresh Air Duct/Hose: > 08-06-04-054A > Jan > 10 > Engine - Reduced Power/MIL ON/DTC P0101 > Page 3531 Additional Information to Advise Customer Important If the vehicle is driven in a snow storm before installing the winter cover and the customer chooses to resolve the issue, they must follow this procedure using the following steps: 1. Remove ANY ice or snow that may have accumulated in the air intake duct, BEFORE REPLACING the air cleaner element. 2. INSTALL the winter cover BEFORE continuing to drive the truck. 3. Turn OFF the ignition, and all electrical accessories and components. 4. Remove the key from the vehicle, THEN open and close the door. 5. WAIT for 2 minutes to allow the engine control module (ECM) to power down. This can be verified by watching for the instrument panel cluster (IPC) gage needles to drop slightly. 1. Allowing the ECM to power down will let DTC P0101 revert to a History DTC and the vehicle should return to full power if the issue has been eliminated. 2. Advise the customer to take the vehicle to the dealer as soon as possible to verify the condition has been eliminated. Parts Information Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Air Cleaner Outlet Duct Replacement Air Cleaner Fresh Air Duct/Hose: Service and Repair Air Cleaner Outlet Duct Replacement Air Cleaner Outlet Duct Replacement Removal Procedure 1. Loosen the outlet duct clamps at the air cleaner assembly and the turbocharger. 2. Remove the air cleaner outlet duct. Installation Procedure Note: The air cleaner outlet duct must be fully seated against the positive stop feature on the turbocharger inlet and also must be fully seated against the positive stop features on both sides of the air cleaner assembly. 1. Install the air cleaner outlet duct. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Air Cleaner Outlet Duct Replacement > Page 3534 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Tighten the outlet duct clamps at the turbocharger and the air cleaner assembly. Tighten the clamps to 4 Nm (35 lb in). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Air Cleaner Outlet Duct Replacement > Page 3535 Air Cleaner Fresh Air Duct/Hose: Service and Repair Air Intake Pipe Replacement Air Intake Pipe Replacement Removal Procedure 1. Remove the water outlet tube. Refer to Water Outlet Tube Replacement (LU3) (See: Cooling System/Coolant Outlet/Service and Repair)Water Outlet Tube Replacement (LMM) (See: Cooling System/Coolant Outlet/Service and Repair). 2. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (See: Air Cleaner Outlet Duct Replacement). Note: It is not necessary to completely remove the PCV hose/pipe from the engine when removing the air intake pipe. 3. Remove the positive crankcase ventilation (PCV) hose/pipe from the air intake pipe. Refer to Positive Crankcase Ventilation Hose/Pipe/Tube Replacement (See: Powertrain Management/Emission Control Systems/Positive Crankcase Ventilation/PCV Valve Hose/Service and Repair). 4. Disconnect the engine wiring harness electrical connector from the turbocharger control solenoid valve. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Air Cleaner Outlet Duct Replacement > Page 3536 5. Remove the engine wiring harness clip (1) from the bracket on the turbocharger. 6. Reposition the turbocharger control solenoid valve wiring harness extension out of the way. Note: The clamp for the air intake pipe uses reverse threads. 7. Loosen the air intake pipe to turbocharger clamp (1). 8. Remove the air intake pipe (2) from the turbocharger. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Air Cleaner Outlet Duct Replacement > Page 3537 1. Clean the mating surfaces on the air intake pipe and the turbocharger. 2. Align the arrow (2) on the air intake pipe to the arrow (1) on the turbocharger. 3. Install the air intake pipe (2) into the turbocharger. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Note: The clamp for the air intake pipe uses reverse threads. 4. Tighten the air intake pipe to turbocharger clamp (1). Tighten the clamp to 4.6 Nm (41 lb in). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Air Cleaner Outlet Duct Replacement > Page 3538 5. Route the turbocharger control solenoid valve wiring harness extension into position. 6. Install the engine wiring harness clip (1) to the bracket on the turbocharger. 7. Connect the engine wiring harness electrical connector to the turbocharger control solenoid valve. 8. Install the PCV hose/pipe to the air intake pipe. Refer to Positive Crankcase Ventilation Hose/Pipe/Tube Replacement (See: Powertrain Management/Emission Control Systems/Positive Crankcase Ventilation/PCV Valve Hose/Service and Repair). 9. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (See: Air Cleaner Outlet Duct Replacement). 10. Install the water outlet tube. Refer to Water Outlet Tube Replacement (LU3) (See: Cooling System/Coolant Outlet/Service and Repair)Water Outlet Tube Replacement (LMM) (See: Cooling System/Coolant Outlet/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 08-06-04-054B > Jan > 11 > Diesel Engine - Low Power/MIL ON/DTC P0101 Air Filter Element: Customer Interest Diesel Engine - Low Power/MIL ON/DTC P0101 TECHNICAL Bulletin No.: 08-06-04-054B Date: January 24, 2011 Subject: Snow or Ice Ingestion into Air Cleaner Element, Malfunction Indicator Lamp (MIL) Illuminated, Engine Power is Reduced Message Displayed, DTC P0101 Set (Perform Repair as Outlined) Models: 2007-2010 Chevrolet Silverado 2500/3500 Series 2007-2010 GMC Sierra 2500/3500 Series Equipped with Duramax(TM) Diesel Engine (RPO LMM) Supercede: This bulletin is being revised to provide a procedure to relocate the OAT sensor, if equipped with RPO CJ2. Please discard Corporate Bulletin 08-06-04-054A (Section 06 - Engine / Propulsion System). Condition Some customers may comment on the malfunction indicator lamp (MIL) being illuminated and an Engine Power is Reduced message being displayed. The technician may observe DTC P0101 set as current or in history. Cause This condition may be caused by snow being ingested into the air cleaner housing and accumulating in the air cleaner element, resulting in restricted airflow into the engine. Correction 1. Verify the condition by questioning the customer as to when the condition occurs (such as during or right after a snow storm). ‹› If the condition occurs as described above, proceed to Step 2. ‹› If the condition does not occur as described above, refer to Diagnostic Trouble Code (DTC) List Vehicle in SI. 2. Remove the air cleaner element. Refer to Air Cleaner Element Replacement in SI. 3. Inspect the air cleaner element for the following conditions: 1. Packed snow 2. Frozen ice 3. A soaking wet condition that would indicate previous snow ingestion 4. Excessive debris and contamination as a result of the ingestion ‹› If any of the above conditions are observed, replace the air cleaner element. Remove any snow or ice that may have accumulated in the air intake duct. Note Winter covers for trucks that are equipped with the Duramax(TM) Diesel Engine are included with vehicle orders that ship to the following areas: All of Canada, and the following states: Alaska, Colorado, Idaho, Maine, Michigan, Minnesota, Montana, New Hampshire, New York, North Dakota, South Dakota, Vermont, Wisconsin, Wyoming. These vehicles should not need a new cover. 4. Install the grille opening section ONLY (if using the 2 piece cover) of the winter front cover following the usage guidelines provided in the Owners Manual for the appropriate type winter cover. ‹› If the customer does not have a cover, obtain and install the grille opening section ONLY , GM P/N 25822811 (GMC) or GM P/N 25822812 (Chevrolet). 5. The grille opening cover MUST BE installed to ensure a complete repair, BEFORE ENCOUNTERING SNOW. This repair allows warm air to be circulated into the air cleaner. Additional Information to Advise Customer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 08-06-04-054B > Jan > 11 > Diesel Engine - Low Power/MIL ON/DTC P0101 > Page 3547 Important If the vehicle is driven in a snow storm before installing the winter cover and the customer chooses to resolve the issue, they must follow this procedure using the following steps: 1. Remove ANY ice or snow that may have accumulated in the air intake duct, BEFORE REPLACING the air cleaner element. 2. INSTALL the winter cover BEFORE continuing to drive the truck. 3. Turn OFF the ignition, and all electrical accessories and components. 4. Remove the key from the vehicle, THEN open and close the door. 5. WAIT for 2 minutes to allow the engine control module (ECM) to power down. This can be verified by watching for the instrument panel cluster (IPC) gage needles to drop slightly. 1. Allowing the ECM to power down will let DTC P0101 revert to a History DTC and the vehicle should return to full power if the issue has been eliminated. 2. Advise the customer to take the vehicle to the dealer as soon as possible to verify the condition has been eliminated. Ambient (Outside) Air Temperature Sensor Relocation For vehicles equipped with Automatic Temperature Control HVAC (RPO CJ2), the ambient (outside) air temperature sensor needs to be relocated using the following procedure: 1. Remove the radiator grille. Refer to the Radiator Grille Replacement procedure in SI. 2. Remove the ambient air sensor from its current location by carefully lifting the sensor from the radiator support cross bar. 3. Remove the harness clip nearest to the sensor. 4. Reinstall the ambient air sensor to the new location using the existing hole (1) in the lower section of the radiator support. 5. Reinstall the harness clip to the existing hole (2) in the radiator support. 6. Reinstall the radiator grille. Parts Information Warranty Information Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 08-06-04-054B > Jan > 11 > Diesel Engine - Low Power/MIL ON/DTC P0101 > Page 3548 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 08-06-04-054A > Jan > 10 > Engine - Reduced Power/MIL ON/DTC P0101 Air Filter Element: Customer Interest Engine - Reduced Power/MIL ON/DTC P0101 TECHNICAL Bulletin No.: 08-06-04-054A Date: January 07, 2010 Subject: Snow or Ice Ingestion into Air Cleaner Element, Malfunction Indicator Lamp (MIL) Illuminated, Engine Power is Reduced Message Displayed, DTC P0101 Set (Perform Repair as Outlined) Models: 2007-2010 Chevrolet Silverado 2500/3500 Series 2007-2010 GMC Sierra 2500/3500 Series Equipped with Duramax(TM) Diesel Engine (RPO LMM) Please Refer to GMVIS Supercede: This bulletin is being revised to remove the graphic, update the Parts and Correction information and add information to advise a customer. Please discard Corporate Bulletin 08-06-04-054 (Section 06 - Engine / Propulsion System). Condition Some customers may comment on the malfunction indicator lamp (MIL) being illuminated and an Engine Power is Reduced message being displayed. The technician may observe DTC P0101 set as current or in history. Cause This condition may be caused by snow being ingested into the air cleaner housing and accumulating in the air cleaner element, resulting in restricted airflow into the engine. Correction 1. Verify the condition by questioning the customer as to when the condition occurs (such as during or right after a snow storm). ‹› If the condition occurs as described above, proceed to Step 2. ‹› If the condition does not occur as described above, refer to Diagnostic Trouble Code (DTC) List Vehicle in SI. 2. Remove the air cleaner element. Refer to Air Cleaner Element Replacement in SI. 3. Inspect the air cleaner element for the following conditions: 1. Packed snow 2. Frozen ice 3. A soaking wet condition that would indicate previous snow ingestion 4. Excessive debris and contamination as a result of the ingestion ‹› If any of the above conditions are observed, replace the air cleaner element. Remove any snow or ice that may have accumulated in the air intake duct. Note Winter covers for trucks that are equipped with the Duramax(TM) Diesel Engine are included with vehicle orders that ship to the following areas: All of Canada, and the following states: Alaska, Colorado, Idaho, Maine, Michigan, Minnesota, Montana, New Hampshire, New York, North Dakota, South Dakota, Vermont, Wisconsin, Wyoming. These vehicles should not need a new cover. 4. Install the grille opening section ONLY (if using the 2 piece cover) of the winter front cover following the usage guidelines provided in the Owners Manual for the appropriate type winter cover. ‹› If the customer does not have a cover, obtain and install the grille opening section ONLY, GM P/N 25822811 (GMC) or GM P/N 25822812 (Chevrolet). 5. The grille opening cover MUST BE installed to ensure a complete repair, BEFORE ENCOUNTERING SNOW. This repair allows warm air to be circulated into the air cleaner. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 08-06-04-054A > Jan > 10 > Engine - Reduced Power/MIL ON/DTC P0101 > Page 3553 Additional Information to Advise Customer Important If the vehicle is driven in a snow storm before installing the winter cover and the customer chooses to resolve the issue, they must follow this procedure using the following steps: 1. Remove ANY ice or snow that may have accumulated in the air intake duct, BEFORE REPLACING the air cleaner element. 2. INSTALL the winter cover BEFORE continuing to drive the truck. 3. Turn OFF the ignition, and all electrical accessories and components. 4. Remove the key from the vehicle, THEN open and close the door. 5. WAIT for 2 minutes to allow the engine control module (ECM) to power down. This can be verified by watching for the instrument panel cluster (IPC) gage needles to drop slightly. 1. Allowing the ECM to power down will let DTC P0101 revert to a History DTC and the vehicle should return to full power if the issue has been eliminated. 2. Advise the customer to take the vehicle to the dealer as soon as possible to verify the condition has been eliminated. Parts Information Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 08-06-04-054B > Jan > 11 > Diesel Engine - Low Power/MIL ON/DTC P0101 Air Filter Element: All Technical Service Bulletins Diesel Engine - Low Power/MIL ON/DTC P0101 TECHNICAL Bulletin No.: 08-06-04-054B Date: January 24, 2011 Subject: Snow or Ice Ingestion into Air Cleaner Element, Malfunction Indicator Lamp (MIL) Illuminated, Engine Power is Reduced Message Displayed, DTC P0101 Set (Perform Repair as Outlined) Models: 2007-2010 Chevrolet Silverado 2500/3500 Series 2007-2010 GMC Sierra 2500/3500 Series Equipped with Duramax(TM) Diesel Engine (RPO LMM) Supercede: This bulletin is being revised to provide a procedure to relocate the OAT sensor, if equipped with RPO CJ2. Please discard Corporate Bulletin 08-06-04-054A (Section 06 - Engine / Propulsion System). Condition Some customers may comment on the malfunction indicator lamp (MIL) being illuminated and an Engine Power is Reduced message being displayed. The technician may observe DTC P0101 set as current or in history. Cause This condition may be caused by snow being ingested into the air cleaner housing and accumulating in the air cleaner element, resulting in restricted airflow into the engine. Correction 1. Verify the condition by questioning the customer as to when the condition occurs (such as during or right after a snow storm). ‹› If the condition occurs as described above, proceed to Step 2. ‹› If the condition does not occur as described above, refer to Diagnostic Trouble Code (DTC) List Vehicle in SI. 2. Remove the air cleaner element. Refer to Air Cleaner Element Replacement in SI. 3. Inspect the air cleaner element for the following conditions: 1. Packed snow 2. Frozen ice 3. A soaking wet condition that would indicate previous snow ingestion 4. Excessive debris and contamination as a result of the ingestion ‹› If any of the above conditions are observed, replace the air cleaner element. Remove any snow or ice that may have accumulated in the air intake duct. Note Winter covers for trucks that are equipped with the Duramax(TM) Diesel Engine are included with vehicle orders that ship to the following areas: All of Canada, and the following states: Alaska, Colorado, Idaho, Maine, Michigan, Minnesota, Montana, New Hampshire, New York, North Dakota, South Dakota, Vermont, Wisconsin, Wyoming. These vehicles should not need a new cover. 4. Install the grille opening section ONLY (if using the 2 piece cover) of the winter front cover following the usage guidelines provided in the Owners Manual for the appropriate type winter cover. ‹› If the customer does not have a cover, obtain and install the grille opening section ONLY , GM P/N 25822811 (GMC) or GM P/N 25822812 (Chevrolet). 5. The grille opening cover MUST BE installed to ensure a complete repair, BEFORE ENCOUNTERING SNOW. This repair allows warm air to be circulated into the air cleaner. Additional Information to Advise Customer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 08-06-04-054B > Jan > 11 > Diesel Engine - Low Power/MIL ON/DTC P0101 > Page 3559 Important If the vehicle is driven in a snow storm before installing the winter cover and the customer chooses to resolve the issue, they must follow this procedure using the following steps: 1. Remove ANY ice or snow that may have accumulated in the air intake duct, BEFORE REPLACING the air cleaner element. 2. INSTALL the winter cover BEFORE continuing to drive the truck. 3. Turn OFF the ignition, and all electrical accessories and components. 4. Remove the key from the vehicle, THEN open and close the door. 5. WAIT for 2 minutes to allow the engine control module (ECM) to power down. This can be verified by watching for the instrument panel cluster (IPC) gage needles to drop slightly. 1. Allowing the ECM to power down will let DTC P0101 revert to a History DTC and the vehicle should return to full power if the issue has been eliminated. 2. Advise the customer to take the vehicle to the dealer as soon as possible to verify the condition has been eliminated. Ambient (Outside) Air Temperature Sensor Relocation For vehicles equipped with Automatic Temperature Control HVAC (RPO CJ2), the ambient (outside) air temperature sensor needs to be relocated using the following procedure: 1. Remove the radiator grille. Refer to the Radiator Grille Replacement procedure in SI. 2. Remove the ambient air sensor from its current location by carefully lifting the sensor from the radiator support cross bar. 3. Remove the harness clip nearest to the sensor. 4. Reinstall the ambient air sensor to the new location using the existing hole (1) in the lower section of the radiator support. 5. Reinstall the harness clip to the existing hole (2) in the radiator support. 6. Reinstall the radiator grille. Parts Information Warranty Information Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 08-06-04-054B > Jan > 11 > Diesel Engine - Low Power/MIL ON/DTC P0101 > Page 3560 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 08-06-04-054A > Jan > 10 > Engine - Reduced Power/MIL ON/DTC P0101 Air Filter Element: All Technical Service Bulletins Engine - Reduced Power/MIL ON/DTC P0101 TECHNICAL Bulletin No.: 08-06-04-054A Date: January 07, 2010 Subject: Snow or Ice Ingestion into Air Cleaner Element, Malfunction Indicator Lamp (MIL) Illuminated, Engine Power is Reduced Message Displayed, DTC P0101 Set (Perform Repair as Outlined) Models: 2007-2010 Chevrolet Silverado 2500/3500 Series 2007-2010 GMC Sierra 2500/3500 Series Equipped with Duramax(TM) Diesel Engine (RPO LMM) Please Refer to GMVIS Supercede: This bulletin is being revised to remove the graphic, update the Parts and Correction information and add information to advise a customer. Please discard Corporate Bulletin 08-06-04-054 (Section 06 - Engine / Propulsion System). Condition Some customers may comment on the malfunction indicator lamp (MIL) being illuminated and an Engine Power is Reduced message being displayed. The technician may observe DTC P0101 set as current or in history. Cause This condition may be caused by snow being ingested into the air cleaner housing and accumulating in the air cleaner element, resulting in restricted airflow into the engine. Correction 1. Verify the condition by questioning the customer as to when the condition occurs (such as during or right after a snow storm). ‹› If the condition occurs as described above, proceed to Step 2. ‹› If the condition does not occur as described above, refer to Diagnostic Trouble Code (DTC) List Vehicle in SI. 2. Remove the air cleaner element. Refer to Air Cleaner Element Replacement in SI. 3. Inspect the air cleaner element for the following conditions: 1. Packed snow 2. Frozen ice 3. A soaking wet condition that would indicate previous snow ingestion 4. Excessive debris and contamination as a result of the ingestion ‹› If any of the above conditions are observed, replace the air cleaner element. Remove any snow or ice that may have accumulated in the air intake duct. Note Winter covers for trucks that are equipped with the Duramax(TM) Diesel Engine are included with vehicle orders that ship to the following areas: All of Canada, and the following states: Alaska, Colorado, Idaho, Maine, Michigan, Minnesota, Montana, New Hampshire, New York, North Dakota, South Dakota, Vermont, Wisconsin, Wyoming. These vehicles should not need a new cover. 4. Install the grille opening section ONLY (if using the 2 piece cover) of the winter front cover following the usage guidelines provided in the Owners Manual for the appropriate type winter cover. ‹› If the customer does not have a cover, obtain and install the grille opening section ONLY, GM P/N 25822811 (GMC) or GM P/N 25822812 (Chevrolet). 5. The grille opening cover MUST BE installed to ensure a complete repair, BEFORE ENCOUNTERING SNOW. This repair allows warm air to be circulated into the air cleaner. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 08-06-04-054A > Jan > 10 > Engine - Reduced Power/MIL ON/DTC P0101 > Page 3565 Additional Information to Advise Customer Important If the vehicle is driven in a snow storm before installing the winter cover and the customer chooses to resolve the issue, they must follow this procedure using the following steps: 1. Remove ANY ice or snow that may have accumulated in the air intake duct, BEFORE REPLACING the air cleaner element. 2. INSTALL the winter cover BEFORE continuing to drive the truck. 3. Turn OFF the ignition, and all electrical accessories and components. 4. Remove the key from the vehicle, THEN open and close the door. 5. WAIT for 2 minutes to allow the engine control module (ECM) to power down. This can be verified by watching for the instrument panel cluster (IPC) gage needles to drop slightly. 1. Allowing the ECM to power down will let DTC P0101 revert to a History DTC and the vehicle should return to full power if the issue has been eliminated. 2. Advise the customer to take the vehicle to the dealer as soon as possible to verify the condition has been eliminated. Parts Information Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 3566 Air Filter Element: Service and Repair Air Cleaner Element Replacement Removal Procedure 1. Loosen the screw holding the air cleaner housing door in place. 2. Remove the air cleaner housing door. 3. Remove the air filter element. Installation Procedure 1. Stand facing the front fender on the passenger side of the vehicle. Insert the element into the housing. Place the palm of your hand on the inboard end of the element, and press the element into position. 2. Press both downward and inboard until the outboard end of the element clicks into place inboard of the locating tab. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 3567 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the air cleaner housing door and tighten the screw. Tighten the screw to 4 Nm (35 lb in). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair Fuel Pressure Relief Valve Replacement Removal Procedure 1. Remove the glow plug module and bracket. Refer to Glow Plug Control Module Replacement (See: Powertrain Management/Glow Plug System/Glow Plug Control Module/Service and Repair). 2. Remove the fuel pressure relief valve from the left fuel rail. Installation Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the fuel pressure relief valve to the left fuel rail. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Page 3572 Tighten the valve to 100 Nm (74 lb ft). 2. Install the glow plug module and bracket. Refer to Glow Plug Control Module Replacement (See: Powertrain Management/Glow Plug System/Glow Plug Control Module/Service and Repair). 3. Prime the fuel system. Refer to Fuel System Priming (See: Powertrain Management/Fuel Delivery and Air Induction/Service and Repair/Fuel System Priming). 4. Start the engine. If the engine stalls, repeat the above step. 5. Once the engine starts, inspect for fuel leaks. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications The minimum compression in any one cylinder is 2069 kPa (300 psi). There should not be more than 345 kPa (50 psi) difference between a suspect cylinder and the average compression of all 8 cylinders. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 3576 Compression Check: Testing and Inspection Engine Compression Test Special Tools * J 26999 - Compression Gauge * EN-47603 - Compression Gauge Adapter For equivalent regional tools, refer to Special Tools (See: Tools and Equipment/Special Tools). 1. Ensure that the vehicle's batteries are in good condition, and fully charged. 2. Operate the vehicle until the engine is at normal operating temperature. 3. Shut off engine. 4. Disconnect glow plug nut; remove all 8 glow plugs. All 8 glow plugs must be removed from the engine during each cylinder test to obtain valid test results. 5. Prior to taking a compression reading, verify the cranking speed is greater than 140 RPM. If the cranking speed is below 140 RPM, repair the slow cranking speed condition before continuing with the compression test. Refer to Engine Cranks Slowly (See: Starting and Charging/Testing and Inspection/Symptom Related Diagnostic Procedures/Engine Cranks Slowly). 6. Install the EN-47603 - adapter in the glow plug hole for the cylinder that is being checked. Caution: Do not add oil to any cylinder during a compression test as extensive engine damage may result. 7. Connect the J 26999 - gauge to the EN-47603 - adapter. Caution: Do not crank the engine using the ignition switch, as the fuel injectors and the glow plug circuits will be energized and engine damage may result. 8. Using a remote start switch, crank the engine for 6 compression strokes, puffs, for the cylinder being tested. 9. Observe the J 26999 - gauge and note the reading as the compression test is being performed. A normal cylinder reading will be indicated if compression builds up quickly and evenly to the specified level. An abnormal reading will be indicated if compression is low on the first compression stroke, starts increasing on the following compression strokes but does not reach the specified level. 10. Record the compression reading for the cylinder just tested. 11. Disconnect the J 26999 gauge from the EN-47603 - adapter and remove adapter from the glow plug hole. 12. Repeat steps 8 through 13 for all remaining cylinders. All 8 cylinders must be tested to obtain valid test results. Record the readings. 13. The minimum compression in any one cylinder is 2069 kPa (300 psi). There should not be more than 345 kPa (50 psi) difference between a suspect cylinder and the average compression of all 8 cylinders. Note: Cylinder to cylinder variation may be at the high end of the specification on engines with less than 20,000 km (12,427 miles). * Normal-Compression builds up quickly and evenly to the specified compression for each cylinder. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 3577 * Piston Rings Leaking-Compression is low on the first stroke. Compression builds up with the following strokes but does not reach normal. * Valves Leaking-Compression is low on the first stroke. Compression usually does not build up on the following strokes. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications Valve Clearance Adjustment Specifications Valve Lash ........................................................................................................................................... ...................................................... 0.3 mm (0.012 in) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Adjustments > On Vehicle Valve Clearance: Adjustments On Vehicle Valve Clearance Adjustment 1. Remove the fan clutch. Refer to Fan Clutch Replacement (Diesel) (See: Cooling System/Radiator Cooling Fan/Fan Clutch/Service and Repair). 2. Remove the upper valve rocker arm covers. Refer to Valve Rocker Arm Upper Cover Replacement - Left Side (See: Cylinder Head Assembly/Valve Cover/Service and Repair/Valve Rocker Arm Upper Cover Replacement - Left Side) and Valve Rocker Arm Upper Cover Replacement - Right Side (See: Cylinder Head Assembly/Valve Cover/Service and Repair/Valve Rocker Arm Upper Cover Replacement - Right Side). 3. Rotate the crankshaft in order to bring the number 1 cylinder to top dead center (TDC) of the compression stroke. The number 1 cylinder is the front cylinder on the right bank. The mark on the crankshaft balancer should be aligned with the mark on the engine. 4. Loosen the valve adjusting screws. 5. Insert a feeler gauge between the tip of the rocker arm and the valve bridge. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Adjustments > On Vehicle > Page 3583 6. Adjust the valve lash to 0.3 mm (0.012 in). Refer to Valve Clearance Adjustment Specifications (See: ) to determine which valves can be adjusted when the engine is at TDC. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 7. Tighten the lock nut. Tighten nut to 22 Nm (16 lb ft). 8. Rotate the crankshaft one revolution in order to bring the number 1 cylinder to TDC of the exhaust stroke. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Adjustments > On Vehicle > Page 3584 9. Loosen the valve adjusting screws. 10. Insert a feeler gauge between the tip of the rocker arm and the valve bridge. 11. Adjust the valve clearance to 0.3 mm (0.012 in). Refer to Valve Clearance Adjustment Specifications (See: ) to determine which valves can be adjusted when the engine is at TDC. 12. Tighten the lock nut. Tighten nut to 22 Nm (16 lb ft). 13. Install the upper valve rocker arm covers. Refer to Valve Rocker Arm Upper Cover Replacement - Left Side (See: Cylinder Head Assembly/Valve Cover/Service and Repair/Valve Rocker Arm Upper Cover Replacement - Left Side) and Valve Rocker Arm Upper Cover Replacement - Right Side (See: Cylinder Head Assembly/Valve Cover/Service and Repair/Valve Rocker Arm Upper Cover Replacement - Right Side). 14. Install the fan clutch. Refer to Fan Clutch Replacement (Diesel) (See: Cooling System/Radiator Cooling Fan/Fan Clutch/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Adjustments > On Vehicle > Page 3585 Valve Clearance: Adjustments Off Vehicle Valve Clearance Adjustment 1. Rotate the crankshaft to bring the number 1 cylinder at the top dead center of the compression stroke. The number 1 cylinder is the front cylinder on the right bank. The mark on the crankshaft balancer should be aligned with the mark on the engine. 2. Loosen the valve adjusting screws. 3. Insert a feeler gauge between the tip of the rocker arm and the valve bridge. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Adjustments > On Vehicle > Page 3586 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Adjust the valve lash to 0.3 mm (0.012 in). Refer to Valve Clearance Adjustment Specifications (See: ) to determine which valves that can be adjusted when the engine is at Top Dead Center. Tighten the valve lash lock nut to 22 Nm (16 lb ft). 5. Rotate the crankshaft one revolution to bring the number 1 cylinder at Top Dead Center of the exhaust stroke. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Adjustments > On Vehicle > Page 3587 6. Adjust the valve lash to 0.3 mm (0.012 in). Refer to Valve Clearance Adjustment Specifications (See: ) to determine which valves that can be adjusted when the engine is at Top Dead Center. Tighten the valve lash lock nut to 22 Nm (16 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications Water Pump: Specifications Water Pump Bolts ................................................................................................................................ ........................................................ 21 Nm (15 lb ft) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 3591 Water Pump: Service and Repair Water Pump Replacement (LMM) Removal Procedure 1. Remove the left wheelhouse inner panel. Refer to Front Wheelhouse Liner Replacement - Left Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Left Side)Front Wheelhouse Liner Replacement - Left Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Left Side). 2. Remove the thermostat housing crossover. Refer to Thermostat Housing Crossover Replacement (LMM) (See: Cooling System/Coolant Line/Hose/Service and Repair/Thermostat Housing Crossover Replacement). 3. Remove the crankshaft balancer. Refer to Crankshaft Balancer Replacement (See: Cylinder Block Assembly/Harmonic Balancer - Crankshaft Pulley/Service and Repair). 4. Remove the water pump to engine coolant pipe nuts. 5. Remove the engine wiring harness retainer from the inner stud. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 3592 6. Remove the water pump bolts. Note the location of the bolts. The bolts are three different lengths. 7. Remove the water pump. 8. Remove and discard the water pump O-ring and coolant pipe gasket. 9. If required, clean and inspect the water pump. Refer to Water Pump Cleaning and Inspection (See: Service and Repair/Overhaul/28. Water Pump Cleaning and Inspection). Installation Procedure 1. Lubricate the water pump O-ring with engine oil. 2. Install the engine coolant pipe gasket and water pump O-ring. 3. Install the water pump. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the water pump bolts. Ensure the correct length bolt is used in the proper location. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 3593 Tighten the bolts to 21 Nm (15 lb ft). 5. Install the engine wiring harness retainer on the water pump outlet pipe inner stud. 6. Install the water pump to engine coolant pipe nuts. Tighten the nuts to 21 Nm (15 lb ft). 7. Install the thermostat housing crossover. Refer to Thermostat Housing Crossover Replacement (LMM) (See: Cooling System/Coolant Line/Hose/Service and Repair/Thermostat Housing Crossover Replacement). 8. Install the crankshaft balancer. Refer to Crankshaft Balancer Replacement (See: Cylinder Block Assembly/Harmonic Balancer - Crankshaft Pulley/Service and Repair). 9. Install the left wheelhouse inner panel. Refer to Front Wheelhouse Liner Replacement - Left Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Left Side)Front Wheelhouse Liner Replacement - Left Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Left Side). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications COOLING SYSTEM Front Heat or A/C Only ........................................................................................................................ ........................................... 20.0 liters (21.2 quarts) Front Heat or A/C Plus Fuel Operated Heater (FOH) ...................................................................................................................... 20.9 liters (22.1 quarts) Front and Rear Heat or A/C Only .................................................................................................................................................... 21.5 liters (22.7 quarts) Front and Rear Heat or A/C Plus Fuel Operated Heater (FOH) ....................................................................................................... 22.4 liters (23.7 quarts) NOTE: All capacities are approximate. When adding, be sure to fill to the approximate level. Recheck fluid level after filling. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications > Page 3599 Coolant: Fluid Type Specifications ENGINE COOLANT The cooling system in the vehicle is filled with DEX-COOL engine coolant. This coolant is designed to remain in the vehicle for five years or 240 000 km (150,000 miles), whichever occurs first. The following explains the cooling system and how to check and add coolant when it is low. CAUTION: Adding only plain water to your cooling system can be dangerous. Plain water, or some other liquid such as alcohol, can boil before the proper coolant mixture will. Your vehicle's coolant warning system is set for the proper coolant mixture. With plain water or the wrong mixture, your engine could get too hot but you would not get the overheat warning. Your engine could catch fire and you or others could be burned. Use a 50/50 mixture of clean, drinkable water and DEX-COOL coolant. Use a 50/50 mixture of clean, drinkable water and DEX-COOL coolant. If using this mixture, nothing else needs to be added. This mixture: Gives freezing protection down to -34°F (-37°C). Gives boiling protection up to 265°F (129°C). Protects against rust and corrosion. Will not damage aluminum parts. Helps keep the proper engine temperature. NOTICE: If you use an improper coolant mixture, your engine could overheat and be badly damaged. The repair cost would not be covered by your warranty. Too much water in the mixture can freeze and crack the engine, radiator, heater core and other parts. NOTICE: If extra inhibitors and/or additives are used in the vehicle's cooling system, the vehicle could be damaged. Use only the proper mixture of the engine coolant listed for the cooling system. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Level Sensor > Component Information > Diagrams Coolant Level Sensor: Diagrams Component Connector End Views Engine Coolant Level Switch (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair > Thermostat Housing Crossover Replacement Coolant Line/Hose: Service and Repair Thermostat Housing Crossover Replacement Thermostat Housing Crossover Replacement (LMM) Removal Procedure 1. Remove the air cleaner. Refer to Air Cleaner Assembly Replacement (See: Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair). 2. Drain the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Service and Repair). 3. Disconnect the negative battery cables. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 4. Remove the drive belt. Refer to Drive Belt Replacement (See: Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair). 5. Disconnect the air conditioning (A/C) pressure switch electrical connector (1). 6. Disconnect the A/C compressor clutch electrical connector (2). 7. Remove the generator bracket. Refer to Generator Bracket Replacement (V6) (See: Starting and Charging/Charging System/Alternator/Service and Repair)Generator Bracket Replacement (6.6L) (See: Starting and Charging/Charging System/Alternator/Service and Repair)Generator Bracket Replacement (V8) (See: Starting and Charging/Charging System/Alternator/Service and Repair). 8. Remove the front oil fill tube. Refer to Oil Filler Tube Replacement (See: Engine/Engine Lubrication/Engine Oil Dip Stick - Dip Stick Tube/Service and Repair/Oil Filler Tube Replacement). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair > Thermostat Housing Crossover Replacement > Page 3607 9. Disconnect the engine coolant temperature (ECT) sensor electrical connectors. 10. Remove the water outlet. Refer to Water Outlet Tube Replacement (LU3) (See: Coolant Outlet/Service and Repair)Water Outlet Tube Replacement (LMM) (See: Coolant Outlet/Service and Repair). 11. Without disconnecting the power steering hoses, remove the power steering pump bolts and the power steering pump. Reposition the power steering pump and secure to the side. Refer to Power Steering Pump Replacement (4.8L, 5.3L, 6.0L, and 6.2L) (See: Steering and Suspension/Steering/Power Steering/Power Steering Pump/Service and Repair)Power Steering Pump Replacement (4.3L) (See: Steering and Suspension/Steering/Power Steering/Power Steering Pump/Service and Repair)Power Steering Pump Replacement (6.6L) (See: Steering and Suspension/Steering/Power Steering/Power Steering Pump/Service and Repair). 12. Remove the power steering pump bracket. Refer to Air Conditioning (A/C) Compressor and Power Steering Pump Bracket Replacement (See: Engine/Drive Belts, Mounts, Brackets and Accessories/Engine Accessory Bracket/Service and Repair). 13. Remove the bolts and wiring harness bracket at the thermostat housing. 14. Position the bracket and wiring harness aside. 15. Remove the cooling fan pulley. Refer to Fan Pulley Replacement (See: Radiator Cooling Fan/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair > Thermostat Housing Crossover Replacement > Page 3608 16. Reposition the turbocharger coolant return pipe hose clamp. 17. Remove the turbocharger coolant return pipe hose. 18. Remove the fuel line bracket bolt at the thermostat housing crossover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair > Thermostat Housing Crossover Replacement > Page 3609 19. Remove the water pump inlet pipe bolts. 20. Remove the thermostat housing crossover bolts and nuts. 21. Remove the thermostat housing crossover, with the bypass pipe. 22. Remove and discard the thermostat bypass pipe to water pump O-ring seal. 23. Remove and discard the thermostat housing crossover gaskets. 24. If necessary, perform the following: 1. Remove the thermostat bypass pipe from the thermostat housing crossover. 2. Remove and discard the thermostat bypass pipe O-ring seal. 3. Remove the thermostat cover bolts and cover. 4. Remove the thermostats. 5. Remove and discard the thermostat seals. 25. If required, clean and inspect the thermostat housing. Refer to Engine Coolant Thermostat Housing Cleaning and Inspection (See: Engine/Service and Repair/Overhaul/90. Engine Coolant Thermostat Housing Cleaning and Inspection). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair > Thermostat Housing Crossover Replacement > Page 3610 Installation Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. If necessary, perform the following: 1. Install NEW seals to the thermostats. 2. Install the thermostats. 3. Install the thermostat cover and bolts. Tighten the bolts to 21 Nm (15 lb ft). 4. Install a NEW O-ring seal to the thermostat bypass pipe. 5. Install the thermostat bypass pipe to the thermostat housing. 2. Install a NEW thermostat bypass pipe to water pump O-ring seal. 3. Install the thermostat housing crossover using NEW gaskets. 4. Install the thermostat housing crossover bolts and nuts. Tighten the bolts/nuts to 21 Nm (15 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair > Thermostat Housing Crossover Replacement > Page 3611 5. Install the water pump inlet pipe bolts. Tighten the bolts to 21 Nm (15 lb ft). 6. Install the fuel line bracket bolt at the thermostat housing crossover. Tighten the bolt to 21 Nm (15 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair > Thermostat Housing Crossover Replacement > Page 3612 7. Install the turbocharger coolant return pipe hose. 8. Position the turbocharger coolant return pipe hose clamp. 9. Install the wiring harness bracket and bolts to the thermostat housing. Tighten the bolts to 10 Nm (89 lb in). 10. Install the cooling fan pulley. Refer to Fan Pulley Replacement (See: Radiator Cooling Fan/Service and Repair). 11. Install the power steering pump bracket. Refer to Air Conditioning (A/C) Compressor and Power Steering Pump Bracket Replacement (See: Engine/Drive Belts, Mounts, Brackets and Accessories/Engine Accessory Bracket/Service and Repair). 12. Reposition the power steering pump and install the power steering pump bolts. Refer to Power Steering Pump Replacement (4.8L, 5.3L, 6.0L, and 6.2L) (See: Steering and Suspension/Steering/Power Steering/Power Steering Pump/Service and Repair)Power Steering Pump Replacement (4.3L) (See: Steering and Suspension/Steering/Power Steering/Power Steering Pump/Service and Repair)Power Steering Pump Replacement (6.6L) (See: Steering and Suspension/Steering/Power Steering/Power Steering Pump/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair > Thermostat Housing Crossover Replacement > Page 3613 13. Install the water outlet. Refer to Water Outlet Tube Replacement (LU3) (See: Coolant Outlet/Service and Repair)Water Outlet Tube Replacement (LMM) (See: Coolant Outlet/Service and Repair). 14. Connect the ECT sensor electrical connectors. 15. Install the front oil fill tube. Refer to Oil Filler Tube Replacement (See: Engine/Engine Lubrication/Engine Oil Dip Stick - Dip Stick Tube/Service and Repair/Oil Filler Tube Replacement). 16. Install the generator bracket. Refer to Generator Bracket Replacement (V6) (See: Starting and Charging/Charging System/Alternator/Service and Repair)Generator Bracket Replacement (6.6L) (See: Starting and Charging/Charging System/Alternator/Service and Repair)Generator Bracket Replacement (V8) (See: Starting and Charging/Charging System/Alternator/Service and Repair). 17. Connect the A/C compressor clutch electrical connector (2). 18. Connect the A/C cut out switch electrical connector (1). 19. Install the drive belt. Refer to Drive Belt Replacement (See: Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair). 20. Connect the negative battery cables. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair > Thermostat Housing Crossover Replacement > Page 3614 21. Fill the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Service and Repair). 22. Install the air cleaner. Refer to Air Cleaner Assembly Replacement (See: Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair > Thermostat Housing Crossover Replacement > Page 3615 Coolant Line/Hose: Service and Repair Engine Coolant Air Bleed Pipe Replacement (without AFM) Engine Coolant Air Bleed Pipe Replacement (without AFM) Removal Procedure 1. If replacing the rear coolant air bleed covers, remove the intake manifold. Refer to Intake Manifold Replacement (Without AFM) (See: Engine/Intake Manifold/Service and Repair)Intake Manifold Replacement (With AFM) (See: Engine/Intake Manifold/Service and Repair). Otherwise proceed to the next step. 2. Remove the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (). 3. Drain the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Service and Repair). 4. Reposition the radiator vent inlet hose clamp (1) at the coolant air bleed pipe fitting. 5. Remove the radiator vent inlet hose (2) from the coolant air bleed pipe fitting. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair > Thermostat Housing Crossover Replacement > Page 3616 6. Remove the coolant air bleed pipe bolts (309) (intake manifold shown removed for clarity). 7. Remove the coolant air bleed pipe (307) and seals (308). 8. Remove the coolant air bleed cover bolts (312), if required. 9. Remove the coolant air bleed covers (313) and seals (308), if required. 10. Remove the seals (308) from the coolant air bleed pipe and/or covers. 11. Discard the seals. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair > Thermostat Housing Crossover Replacement > Page 3617 Note: Position the O-ring seal (308) onto the nipple portion of the pipe. 1. Install the seals onto the coolant air bleed pipe and/or covers. 2. Install the coolant air bleed pipe (307) and seals (308) onto the cylinder heads. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the coolant air bleed pipe bolts (309). Tighten the bolts to 12 Nm (106 lb in). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair > Thermostat Housing Crossover Replacement > Page 3618 4. Install the coolant air bleed covers (313) and seals (308), if required. 5. Install the coolant air bleed cover bolts (312), if required. Tighten the bolts to 12 Nm (106 lb in). 6. Install the radiator vent inlet hose (2) to the coolant air bleed pipe fitting. 7. Position the radiator vent inlet hose clamp (1) at the coolant air bleed pipe fitting. 8. Install the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (). 9. Fill the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Service and Repair). 10. If the rear coolant air bleed covers were replaced, install the intake manifold. Refer to Intake Manifold Replacement (Without AFM) (See: Engine/Intake Manifold/Service and Repair)Intake Manifold Replacement (With AFM) (See: Engine/Intake Manifold/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair > Thermostat Housing Crossover Replacement > Page 3619 Coolant Line/Hose: Service and Repair Engine Coolant Air Bleed Pipe Replacement (with AFM) Engine Coolant Air Bleed Pipe Replacement (with AFM) Removal Procedure 1. Remove the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (). 2. Drain the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Service and Repair). 3. Reposition the radiator vent inlet hose clamp (1) at the coolant air bleed pipe fitting. 4. Remove the radiator vent inlet hose (2) from the coolant air bleed pipe fitting. 5. Remove the coolant air bleed pipe bolts (309) (intake manifold shown removed for clarity). 6. Remove the coolant air bleed pipe (307) and seals (308). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair > Thermostat Housing Crossover Replacement > Page 3620 7. Remove the coolant air bleed cover bolts (312), if required. 8. Discard the seals. Installation Procedure Note: Position the O-ring seal (308) onto the nipple portion of the pipe. 1. Install the seals onto the coolant air bleed pipe and/or covers. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair > Thermostat Housing Crossover Replacement > Page 3621 2. Install the coolant air bleed pipe (307) and seals (308) onto the cylinder heads. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the coolant air bleed pipe bolts (309). Tighten the bolts to 12 Nm (106 lb in). 4. Install the coolant air bleed covers (313) and seals (308), if required. 5. Install the coolant air bleed cover bolts (312), if required. Tighten the bolts to 12 Nm (106 lb in). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair > Thermostat Housing Crossover Replacement > Page 3622 6. Install the radiator vent inlet hose (2) to the coolant air bleed pipe fitting. 7. Position the radiator vent inlet hose clamp (1) at the coolant air bleed pipe fitting. 8. Install the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (). 9. Fill the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Service and Repair). 10. If the rear coolant air bleed covers were replaced, install the intake manifold. Refer to Intake Manifold Replacement (Without AFM) (See: Engine/Intake Manifold/Service and Repair)Intake Manifold Replacement (With AFM) (See: Engine/Intake Manifold/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Outlet > Component Information > Service and Repair Coolant Outlet: Service and Repair Water Outlet Tube Replacement (LMM) Removal Procedure 1. Remove the radiator inlet hose. Refer to Radiator Inlet Hose Replacement (Non-HP2) (See: Radiator Hose)Radiator Inlet Hose Replacement (Diesel) (See: Radiator Hose). 2. Remove the turbocharger coolant bypass valve. Refer to Turbocharger Coolant Bypass Valve Replacement (See: Powertrain Management/Fuel Delivery and Air Induction/Turbocharger/Service and Repair/Turbocharger Coolant Bypass Valve Replacement). 3. Remove the bolts and wiring harness bracket at the thermostat housing. 4. Position the bracket and wiring harness aside. 5. Disconnect the main engine electrical harness connectors. Lift up on the latches (1) in order to disconnect the connectors. 6. Open the harness clip (2). 7. Remove the main engine electrical harness connectors. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Outlet > Component Information > Service and Repair > Page 3626 8. Disconnect the turbocharger vane position sensor electrical connector (1). 9. Unclip the main engine electrical harness connectors from the main electrical connector harness bracket. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Outlet > Component Information > Service and Repair > Page 3627 10. Remove the main electrical connector harness bracket bolts (1). 11. Remove the main electrical connector harness bracket (2) and position aside. 12. Remove the manifold intake temperature sensor electrical connector from the water tube bracket. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Outlet > Component Information > Service and Repair > Page 3628 13. Remove the water outlet bolts. 14. Remove the water outlet. 15. Remove and discard the O-ring seal. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Outlet > Component Information > Service and Repair > Page 3629 1. Install a NEW O-ring seal to the water outlet. 2. Lubricate the O-ring seal with clean engine coolant. 3. Install the water outlet. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the water outlet bolts. Tighten the bolts to 21 Nm (15 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Outlet > Component Information > Service and Repair > Page 3630 5. Install the manifold intake temperature sensor electrical connector to the water tube bracket. 6. Install the main electrical harness bracket. 7. Install the main electrical harness bracket bolts. Tighten the bolts to 21 Nm (15 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Outlet > Component Information > Service and Repair > Page 3631 8. Install the main engine electrical harness connector bolts. Tighten the bolts to 10 Nm (89 lb in). 9. Install the main electrical connector harness bracket (2). 10. Install the main electrical connector harness bracket bolts (1). Tighten the bolts to 21 Nm (15 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Outlet > Component Information > Service and Repair > Page 3632 11. Clip the main engine electrical harness connectors to the main electrical connector harness bracket. 12. Connect the turbocharger vane position sensor electrical connector (1). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Outlet > Component Information > Service and Repair > Page 3633 13. Connect the main engine electrical harness connectors. 14. Push down on the latches (1) in order to connect the connectors. 15. Close the harness clip (2). 16. Install the wiring harness bracket and bolts to the thermostat housing. Tighten the bolts to 10 Nm (89 lb in). 17. Install the turbocharger coolant bypass valve. Refer to Turbocharger Coolant Bypass Valve Replacement (See: Powertrain Management/Fuel Delivery and Air Induction/Turbocharger/Service and Repair/Turbocharger Coolant Bypass Valve Replacement). 18. Install the radiator inlet hose. Refer to Radiator Inlet Hose Replacement (Non-HP2) (See: Radiator Hose)Radiator Inlet Hose Replacement (Diesel) (See: Radiator Hose). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Service and Repair > Radiator Surge Tank Replacement Coolant Reservoir: Service and Repair Radiator Surge Tank Replacement Radiator Surge Tank Replacement (Non-HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Service and Repair > Radiator Surge Tank Replacement > Page 3638 Coolant Reservoir: Service and Repair Radiator Surge Tank Inlet Hose/Pipe Replacement Radiator Surge Tank Inlet Hose/Pipe Replacement (Non-HP2) Removal Procedure 1. Drain the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Service and Repair). 2. Reposition the surge tank inlet hose clamp from the radiator. 3. Remove the surge tank inlet hose from the radiator. 4. Reposition the surge tank inlet hose clamp at the surge tank. 5. Remove the surge tank inlet hose (1) from the surge tank. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Service and Repair > Radiator Surge Tank Replacement > Page 3639 1. Install the surge tank inlet hose (1) to the surge tank. 2. Position the surge tank inlet hose clamp to the surge tank. 3. Install the surge tank inlet hose to the radiator. 4. Position the surge tank inlet hose clamp to the radiator. 5. Fill the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Service and Repair > Radiator Surge Tank Replacement > Page 3640 Coolant Reservoir: Service and Repair Radiator Vent Inlet Hose Replacement Radiator Vent Inlet Hose Replacement (Non-HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams Radiator Cooling Fan Motor: Diagrams Component Connector End Views Engine Cooling Fan - Left (Gas except LY6) Engine Cooling Fan - Right (Gas except LY6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Page 3645 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Page 3646 Radiator Cooling Fan Motor: Service and Repair Engine Coolant Fan Motor Replacement (Non-HP2) Removal Procedure 1. Remove the cooling blade(s). Refer to Engine Coolant Fan Replacement (Non-HP2) (See: Service and Repair). 2. Remove the cooling fan motor bolts. 3. Remove the cooling fan motor(s). Installation Procedure 1. Install the cooling fan motor(s). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Page 3647 2. Install the cooling fan motor bolts. Tighten the bolts to 10 Nm (89 lb in). 3. Install the cooling fan blades. Refer to Engine Coolant Fan Replacement (Non-HP2) (See: Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations Radiator Cooling Fan Motor Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 3651 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 3652 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 3653 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 3654 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 3655 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 3656 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 3657 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Testing and Inspection Fan Clutch: Testing and Inspection Fan Clutch Diagnosis Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Testing and Inspection > Page 3661 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Testing and Inspection > Page 3662 Fan Clutch: Service and Repair Fan Clutch Replacement (Diesel) Special Tools J 41240-5A Fan Clutch Wrench Removal Procedure 1. Remove the upper fan shroud. Refer to Engine Coolant Fan Upper Shroud Replacement (LMM Diesel) (See: Fan Shroud/Service and Repair )Engine Coolant Fan Upper Shroud Replacement (Mechanical) (See: Fan Shroud/Service and Repair). 2. Remove the 3 engine cooling fan shroud bolts (1). 3. Position the engine cooling fan shroud (1) forward to the radiator. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Testing and Inspection > Page 3663 4. Install a long pin bar into the fan hub (1). 5. Use a J 41240-5A to remove the fan hub nut (2) from the hub in a counterclockwise rotation. 6. Remove the fan and the engine cooling fan shroud as an assembly. 7. Remove the fan clutch bolts from the rear of the fan blade. 8. Separate the fan clutch from the fan blade. Installation Procedure Warning Do not use or attempt to repair a damaged cooling fan assembly. Replace damaged fans with new assemblies. An unbalanced cooling fan could fly apart causing personal injury and property damage. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Testing and Inspection > Page 3664 1. Install the fan clutch onto the fan blade. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the fan clutch bolts. Tighten the bolts to 23 Nm (17 lb ft). 3. Install the fan and engine cooling fan shroud assembly to the fan hub. 4. Use a J 41240-5A on the fan clutch hub nut (2) to install a long pry bar to the fan clutch hub (1). Tighten the nut clockwise to 56 Nm (41 lb ft). 5. Position the engine cooling fan shroud on the 3 mounting brackets (1). 6. Install the bolts. Loosely tighten the top mounting bolt at the oil filler neck. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Testing and Inspection > Page 3665 Note: Maintain a 6 mm (0.25 in) minimum clearance at all 3 places. 7. Center the engine cooling fan shroud to the fan blade in 3 places (1). Note: Improper installation could cause damage to the fan and shroud while vehicle is in service. 8. Make sure the orientation of the cooling fan shroud (1) and rubber seal (2) are installed correctly Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Testing and Inspection > Page 3666 9. Fully tighten the 3 engine cooling fan shroud bolts (1). Tighten the bolts to 8 Nm (71 lb in). 10. Install the upper fan shroud. Refer to Engine Coolant Fan Upper Shroud Replacement (LMM Diesel) (See: Fan Shroud/Service and Repair )Engine Coolant Fan Upper Shroud Replacement (Mechanical) (See: Fan Shroud/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps Coolant Temperature Sensor/Switch (For Computer): Customer Interest Engine - MIL ON P0116/P1400 Set In Very Cold Temps TECHNICAL Bulletin No.: 10-06-04-008A Date: January 24, 2011 Subject: Malfunction Indicator Lamp (MIL) Illuminated at Very Cold Ambient Temperatures When Using Engine Coolant Heater, DTC P0116 and/or P1400 Set (Relocate Engine Coolant Temperature (ECT) Sensor and Engine Coolant Heater Cord) Models: 2006-2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2006-2010 Cadillac Escalade 2006-2007 Chevrolet Monte Carlo 2006-2009 Chevrolet Impala SS, TrailBlazer 2006-2010 Chevrolet Avalanche, Express, Silverado Tahoe 2006-2009 GMC Envoy 2006-2010 GMC Savana, Sierra, Yukon 2006-2008 Pontiac Grand Prix 2006-2009 Saab 9-7X Equipped with V8 Engine RPO LC9, LH6, LH8, LH9, L76, LS2, LS4, LFA, LZ1, L92, L94, L9H or L20, L96, LMF, LMG, LY2, LY5, LY6 Please Refer to GMVIS Attention: To properly correct this condition, you must follow both of the procedures to relocate the ECT sensor and the engine coolant heater cord. Supercede: This bulletin is being revised to add cast iron block engine RPOs and to update the Warranty Information coverage period. Please discard Corporate Bulletin Number 10-06-04-008 (Section 06 - Engine/Propulsion System). Condition Some customers may comment that the malfunction indicator lamp (MIL) illuminates after starting the vehicle when they were using the engine coolant heater in very cold ambient temperatures. This usually occurs in a range of -23 to -40°C (-10 to -40°F) or colder. The technician may observe on a scan tool DTC P0116 and/or P1400 set as Current or in History. Cause This condition may be caused by the engine control module (ECM) determining that the ignition OFF time requirement has been met at start-up and interpreting the temperature difference between the engine coolant temperature (ECT) sensor and the intake air temperature (IAT) sensor as being outside of a calibrated range. Correction Important DO NOT replace the ECM for this condition. Relocating the ECT Sensor 1. Turn ON the ignition with the engine OFF. 2. Perform the diagnostic system check - vehicle. Refer to Diagnostic System Check - Vehicle in SI. ‹› If DTC P0116 and/or P1400 are set and the customer WAS using the engine coolant heater, proceed to Step 3. ‹› If DTC P0116 and/or P1400 are set and the customer WAS NOT using the engine coolant heater, refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. 3. Turn OFF the ignition. Warning To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 3676 under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator are still hot. 4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle. Refer to Cooling System Draining and Filling in SI. 7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor. 10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J 38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle. 13. Disconnect the wiring harness connector from the ECT sensor (2). 14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT sensor in the hole of the cylinder head where the plug was removed. Tighten Tighten to 20 Nm (15 lb ft). 18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was removed Tighten Tighten to 20 Nm (15 lb ft). Important Leave enough wire attached to the ECT sensor harness connector in order to create manageable splices that are at least 40 mm (1.5 in) away from the other splice. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 3677 20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit. Cut off the ECT sensor harness connector and wiring. 21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured TO or WITHIN an existing protective conduit. Note This step is to set up and verify the length of wiring that is required before cutting. 22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the appropriate length. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. 26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit using tie straps. Important You MUST run the engine at the specified RPM and until it reaches normal operating temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool down in order to top off the coolant level as needed. 28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI. 29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan tool to clear any DTCs. Relocating the Engine Coolant Heater Cord Important For reference, the procedure and graphics that are shown are from a Chevrolet Silverado, but are similar for the other vehicles listed above. 1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit from the engine compartment in order to determine the required extension cord length. 3. Obtain an extension cord with the following features: - 120 volt - 14/3 gauge - 15A capacity - Three prong - Polarized plug and receptacle - Chemical resistant - Grounded terminals - Designed for use in a cold outdoor environment - Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight - Maximum length of 2.5-3 m (8-10 ft) 4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N 12345579 (in Canada, use P/N 10953481) or an equivalent. 6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 3678 7. Wrap electrical tape around the connection as shown. 8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to the engine coolant crossover pipe as shown. 9. Continue to route the extension cord to the exit location desired by the customer as shown. 10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the engine coolant heater cord to the vehicle that were released to provide length. Part Information The extension cord may be obtained at any of the following outlets: - Lowes* - Home Depot* - Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number: CWRSJTOW3C14-10 USA: Cords should bear the UL symbol. Canada: Cords should bear the ULc symbol or CSA approval. *We believe these sources and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from these firms or for any such items that may be available from other sources. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 3679 Warranty Information (excluding Saab Models) For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps Coolant Temperature Sensor/Switch (For Computer): All Technical Service Bulletins Engine - MIL ON P0116/P1400 Set In Very Cold Temps TECHNICAL Bulletin No.: 10-06-04-008A Date: January 24, 2011 Subject: Malfunction Indicator Lamp (MIL) Illuminated at Very Cold Ambient Temperatures When Using Engine Coolant Heater, DTC P0116 and/or P1400 Set (Relocate Engine Coolant Temperature (ECT) Sensor and Engine Coolant Heater Cord) Models: 2006-2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2006-2010 Cadillac Escalade 2006-2007 Chevrolet Monte Carlo 2006-2009 Chevrolet Impala SS, TrailBlazer 2006-2010 Chevrolet Avalanche, Express, Silverado Tahoe 2006-2009 GMC Envoy 2006-2010 GMC Savana, Sierra, Yukon 2006-2008 Pontiac Grand Prix 2006-2009 Saab 9-7X Equipped with V8 Engine RPO LC9, LH6, LH8, LH9, L76, LS2, LS4, LFA, LZ1, L92, L94, L9H or L20, L96, LMF, LMG, LY2, LY5, LY6 Please Refer to GMVIS Attention: To properly correct this condition, you must follow both of the procedures to relocate the ECT sensor and the engine coolant heater cord. Supercede: This bulletin is being revised to add cast iron block engine RPOs and to update the Warranty Information coverage period. Please discard Corporate Bulletin Number 10-06-04-008 (Section 06 - Engine/Propulsion System). Condition Some customers may comment that the malfunction indicator lamp (MIL) illuminates after starting the vehicle when they were using the engine coolant heater in very cold ambient temperatures. This usually occurs in a range of -23 to -40°C (-10 to -40°F) or colder. The technician may observe on a scan tool DTC P0116 and/or P1400 set as Current or in History. Cause This condition may be caused by the engine control module (ECM) determining that the ignition OFF time requirement has been met at start-up and interpreting the temperature difference between the engine coolant temperature (ECT) sensor and the intake air temperature (IAT) sensor as being outside of a calibrated range. Correction Important DO NOT replace the ECM for this condition. Relocating the ECT Sensor 1. Turn ON the ignition with the engine OFF. 2. Perform the diagnostic system check - vehicle. Refer to Diagnostic System Check - Vehicle in SI. ‹› If DTC P0116 and/or P1400 are set and the customer WAS using the engine coolant heater, proceed to Step 3. ‹› If DTC P0116 and/or P1400 are set and the customer WAS NOT using the engine coolant heater, refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. 3. Turn OFF the ignition. Warning To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 3685 under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator are still hot. 4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle. Refer to Cooling System Draining and Filling in SI. 7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor. 10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J 38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle. 13. Disconnect the wiring harness connector from the ECT sensor (2). 14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT sensor in the hole of the cylinder head where the plug was removed. Tighten Tighten to 20 Nm (15 lb ft). 18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was removed Tighten Tighten to 20 Nm (15 lb ft). Important Leave enough wire attached to the ECT sensor harness connector in order to create manageable splices that are at least 40 mm (1.5 in) away from the other splice. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 3686 20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit. Cut off the ECT sensor harness connector and wiring. 21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured TO or WITHIN an existing protective conduit. Note This step is to set up and verify the length of wiring that is required before cutting. 22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the appropriate length. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. 26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit using tie straps. Important You MUST run the engine at the specified RPM and until it reaches normal operating temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool down in order to top off the coolant level as needed. 28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI. 29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan tool to clear any DTCs. Relocating the Engine Coolant Heater Cord Important For reference, the procedure and graphics that are shown are from a Chevrolet Silverado, but are similar for the other vehicles listed above. 1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit from the engine compartment in order to determine the required extension cord length. 3. Obtain an extension cord with the following features: - 120 volt - 14/3 gauge - 15A capacity - Three prong - Polarized plug and receptacle - Chemical resistant - Grounded terminals - Designed for use in a cold outdoor environment - Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight - Maximum length of 2.5-3 m (8-10 ft) 4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N 12345579 (in Canada, use P/N 10953481) or an equivalent. 6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 3687 7. Wrap electrical tape around the connection as shown. 8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to the engine coolant crossover pipe as shown. 9. Continue to route the extension cord to the exit location desired by the customer as shown. 10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the engine coolant heater cord to the vehicle that were released to provide length. Part Information The extension cord may be obtained at any of the following outlets: - Lowes* - Home Depot* - Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number: CWRSJTOW3C14-10 USA: Cords should bear the UL symbol. Canada: Cords should bear the ULc symbol or CSA approval. *We believe these sources and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from these firms or for any such items that may be available from other sources. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 3688 Warranty Information (excluding Saab Models) For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 3689 Coolant Temperature Sensor/Switch (For Computer): Diagrams Component Connector End Views Engine Coolant Temperature (ECT) Sensor (Diesel) Engine Coolant Temperature (ECT) Sensor (Gas) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 3690 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Engine Coolant Temperature Sensor Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Service and Repair > Cooling Fan and Shroud Replacement Fan Shroud: Service and Repair Cooling Fan and Shroud Replacement Cooling Fan and Shroud Replacement (Non-HP2) Removal Procedure 1. Drain the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Service and Repair) 2. Remove air inlet duct. 3. Disconnect upper radiator hose from radiator. 4. Disengage the radiator inlet hose clip (2) at the fan shroud. 5. If necessary, reposition the surge tank inlet hose clamp at the radiator. 6. If necessary, remove the surge tank inlet hose from the radiator. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Service and Repair > Cooling Fan and Shroud Replacement > Page 3695 7. Disconnect the electrical connectors from the cooling fans. 8. Remove the clip attaching the wiring harness to the shroud. 9. Remove transmission cooler lines bolts from fan shroud. 10. If necessary, open the engine oil cooler line clip and remove the cooler lines from the clip. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Service and Repair > Cooling Fan and Shroud Replacement > Page 3696 11. Remove the cooling fan shroud bolts. 12. Remove the cooling fan and shroud. Installation Procedure Note: Insert the 3 lower tabs into the radiator support flange. Keeping the shroud parallel to the radiator will ensure the correct installation of the lower tabs. 1. Install the cooling fan and shroud. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the cooling fan shroud bolts. Tighten the bolts to 9 Nm (80 lb in). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Service and Repair > Cooling Fan and Shroud Replacement > Page 3697 3. If equipped, install the cooler lines to the clip and close the clip. 4. Connect the electrical connectors to the cooling fans. 5. Install the clip attaching the wiring harness to the shroud. 6. Install the transmission cooling line bolts to fan shroud. Tighten the bolts to 4 Nm (35 lb in). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Service and Repair > Cooling Fan and Shroud Replacement > Page 3698 7. If necessary, install the surge tank inlet hose to the radiator. 8. If necessary, reposition the surge tank inlet hose clamp at the radiator. 9. Engage the radiator inlet hose clip (2) at the fan shroud. 10. Connect upper radiator hose from radiator. 11. Install air inlet duct. 12. Fill the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Service and Repair) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Service and Repair > Cooling Fan and Shroud Replacement > Page 3699 Fan Shroud: Service and Repair Engine Coolant Fan Upper Shroud Replacement Engine Coolant Fan Upper Shroud Replacement (LMM Diesel) Removal Procedure 1. Remove the air cleaner outlet duct. 2. Remove the A/C line retainer from the fan shroud. 3. Remove the transmission control module (TCM) retainer (1). 4. Remove TCM from the fan shroud and reposition. 5. Remove the fan shroud retainers (1). 6. Remove the fan shroud bolts (2). 7. Remove the upper fan shroud. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Service and Repair > Cooling Fan and Shroud Replacement > Page 3700 Installation Procedure 1. Install the upper fan shroud. 2. Install the fan shroud retainers (1). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the fan shroud bolts (2). Tighten the bolts to 9 Nm (80 lb in). 4. Install the transmission control module (TCM) (2). 5. Install the transmission control module (TCM) retainer (1). 6. Install the A/C line retainer to the fan shroud. 7. Install the air cleaner outlet duct. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Service and Repair > Cooling Fan and Shroud Replacement > Page 3701 Fan Shroud: Service and Repair Engine Coolant Fan Upper Shroud Replacement (Mechanical) Engine Coolant Fan Upper Shroud Replacement (Mechanical) Removal Procedure 1. Loosen the air cleaner outlet duct clamps from the throttle body. 2. Loosen the air cleaner outlet duct clamps from the mass airflow sensor (2). 3. Remove the air cleaner outlet duct. 4. If equipped remove the throttle body heater hose retainer from the fan shroud. 5. If equipped remove the inlet radiator hose retainer from the fan shroud. 6. Remove the fan shroud retainers. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Service and Repair > Cooling Fan and Shroud Replacement > Page 3702 7. Remove the fan shroud bolts 8. Remove the upper fan shroud. Installation Procedure 1. Install the upper fan shroud. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the fan shroud bolts. Tighten the bolts to 9 Nm (80 lb in). 3. Install the fan shroud retainers. 4. If equipped install the inlet radiator hose retainer to the fan shroud 5. If equipped install the throttle body heater hose retainer to the fan shroud. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Service and Repair > Cooling Fan and Shroud Replacement > Page 3703 6. Install the air cleaner outlet duct. 7. Tighten the air cleaner outlet duct clamp at the throttle body. Tighten the clamp to 4 Nm (35 lb in). 8. Tighten the air cleaner outlet duct clamp at the mass airflow sensor (2). Tighten the clamp to 4 Nm (35 lb in). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Service and Repair > Cooling Fan and Shroud Replacement > Page 3704 Fan Shroud: Service and Repair Engine Coolant Fan Lower Shroud Replacement (Mechanical) Engine Coolant Fan Lower Shroud Replacement (Mechanical) Removal Procedure 1. Remove the radiator. Refer to Radiator Replacement (LMM) (See: Radiator/Service and Repair/Removal and Replacement)Radiator Replacement (4.3L, 4.8L, 5.3L, and 6.0L) (See: Radiator/Service and Repair/Removal and Replacement). 2. Disengage the two clips from the radiator. 3. If equipped with engine oil cooler , remove the oil cooler hose clip from the lower fan shroud. 4. Remove the shroud from the vehicle. Installation Procedure 1. Install the lower fan shroud and ensure it is centered over lower radiator support. 2. Engage the two clips from the radiator. 3. If equipped with the engine oil cooler , Install the oil cooler hose clip to the lower fan shroud. 4. Install the radiator. Refer to Radiator Replacement (LMM) (See: Radiator/Service and Repair/Removal and Replacement)Radiator Replacement (4.3L, 4.8L, 5.3L, and 6.0L) (See: Radiator/Service and Repair/Removal and Replacement). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Heater Core Cover Replacement Heater Core: Service and Repair Heater Core Cover Replacement Heater Core Cover Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Heater Core Cover Replacement > Page 3709 Heater Core: Service and Repair Heater Core Replacement Heater Core Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heater Inlet Hose Replacement (Non-HP2) Heater Hose: Service and Repair Heater Inlet Hose Replacement (Non-HP2) Heater Inlet Hose Replacement (Non-HP2) Removal Procedure 1. Drain the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Service and Repair). 2. Remove the air intake tube. 3. Remove the heater and surge tank hoses from the mounting clip. 4. Squeeze the plastic retainer release tabs. Quick Connect Fittings 5. Pull the connection apart. 6. Remove the inlet heater hose from the water pump. 7. Remove the inlet heater hose. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heater Inlet Hose Replacement (Non-HP2) > Page 3714 Installation Procedure 1. Install the inlet heater hose. 2. Install the inlet heater hose to the water pump. 3. Connect the heater hose to the heater core. Important: Firmly push the quick connect onto the heater core pipe until you hear an audible click. 4. Install the heater and surge tank hoses to the mounting clip. 5. Install the air intake tube. 6. Fill the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heater Inlet Hose Replacement (Non-HP2) > Page 3715 Heater Hose: Service and Repair Heater Outlet Hose Replacement (Non-HP2) Heater Outlet Hose Replacement (Non-HP2) Removal Procedure 1. Drain the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Service and Repair). 2. Remove the air intake tube. 3. Remove the heater and surge tank hoses from the mounting clip. 4. Squeeze the plastic retainer release tabs. Quick Connect Fittings 5. Pull the connection apart. 6. Remove the outlet heater hose from the water pump. 7. Reposition the outlet heater hose clamp at the surge tank. 8. Remove the outlet heater hose from the surge tank. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heater Inlet Hose Replacement (Non-HP2) > Page 3716 9. Remove the outlet heater hose. Installation Procedure 1. Install the outlet heater hose. 2. Install the outlet heater hose to the water pump. 3. Install the outlet heater hose to the surge tank. 4. Install the outlet heater hose clamp to the surge tank. 5. Connect the heater and surge tank hoses to the heater core. Important: Firmly push the quick connect onto the heater core hose until you hear an audible click. 6. Pull the heater outlet hose to ensure the connection. 7. Install the heater and surge tank hoses to the mounting clip. 8. Install the air intake tube. 9. Fill the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service and Repair > Procedures Radiator: Procedures Radiator Cleaning Warning NEVER spray water on a hot heat exchanger. The resulting steam could cause personal injury. Caution: The heat exchanger fins are necessary for good heat transfer. Do not brush the fins. This may cause damage to the fins, reducing heat transfer. Note: Remove bugs, leaves, dirt and other debris by blowing compressed air through the engine side of the radiator. * Some conditions may require the use of warm water and a mild detergent. * Clean the A/C condenser fins. * Clean between the A/C condenser and radiator. * Clean the radiator cooling fins. * Straighten any damaged cooling fins. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service and Repair > Procedures > Page 3721 Radiator: Removal and Replacement Radiator Replacement Radiator Replacement (LMM) Radiator Air Upper Baffle and Deflector Replacement Radiator Air Upper Baffle and Deflector Replacement Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service and Repair > Procedures > Page 3722 1. Remove the radiator air upper baffle retainers (Qty 8). 2. Remove the radiator air upper baffle. Installation Procedure 1. Install the radiator air upper baffle. 2. Install the radiator air upper baffle retainers (Qty 8). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Testing and Inspection Radiator Cap: Testing and Inspection Pressure Cap Testing Special Tools * J 24460-01 Cooling System Pressure Tester * J 42401 Radiator Cap/Surge Tank Test Adapter Pressure Cap Testing Warning To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam under pressure if radiator cap or surge tank cap is removed while the engine and radiator are still hot. 1. Remove the pressure cap. 2. Wash the pressure cap sealing surface with water. Note: Lubricate J-42401 and pressure cap o-rings with coolant and press cap to seat o-ring on J-42401 before turning to engage threads. 3. Use the J 24460-01 (1) with J 42401 (2) in order to test the pressure cap. 4. Test the pressure cap for the following conditions: * Pressure release when the J 24460-01 exceeds the pressure rating of the pressure cap. * Maintain the rated pressure for at least 10 seconds. Note the rate of pressure loss. 5. Replace the pressure cap under the following conditions: * The pressure cap does not release pressure which exceeds the rated pressure of the cap. * The pressure cap does not hold the rated pressure. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information > Service and Repair > Radiator Inlet Hose Replacement Radiator Hose: Service and Repair Radiator Inlet Hose Replacement Radiator Inlet Hose Replacement (Diesel) Removal Procedure 1. Drain the engine coolant. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Service and Repair). 2. Move the hose clamps back on the radiator inlet hose. 3. Remove the radiator inlet hose from the radiator. 4. Remove the radiator inlet hose from the water outlet tube. Installation Procedure 1. Install the radiator inlet hose to the water outlet tube. 2. Install the radiator inlet hose to the radiator. 3. Install the hose clamps on the radiator outlet hose. 4. Fill the engine coolant. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information > Service and Repair > Radiator Inlet Hose Replacement > Page 3730 Radiator Hose: Service and Repair Radiator Outlet Hose Replacement Radiator Outlet Hose Replacement (Diesel) Removal Procedure 1. Drain the engine coolant. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Service and Repair). 2. Remove the upper and lower fan shroud. Refer to Engine Coolant Fan Upper Shroud Replacement (LMM Diesel) (See: Fan Shroud/Service and Repair)Engine Coolant Fan Upper Shroud Replacement (Mechanical) (See: Fan Shroud/Service and Repair) and Engine Coolant Fan Lower Shroud Replacement (Mechanical) (See: Fan Shroud/Service and Repair). 3. Remove the surge tank outlet hose (1) from the surge tank. 4. Remove the radiator outlet hose from the water pump. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information > Service and Repair > Radiator Inlet Hose Replacement > Page 3731 5. Remove the heater outlet hose from the radiator outlet hose. 6. Remove the radiator outlet hose from the radiator. 7. Remove the radiator outlet hose clip retainers from the brackets. 8. Remove the radiator outlet hose from the vehicle. Installation Procedure 1. Install the radiator outlet hose to the vehicle. 2. Install the radiator outlet hose and clamp to the radiator. Ensure the hose is positioned properly in order to prevent interference with the fan shroud. 3. Install the radiator outlet hose clip retainers to the brackets. 4. Install the surge tank outlet hose (1) to the surge tank. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information > Service and Repair > Radiator Inlet Hose Replacement > Page 3732 5. Install the radiator outlet hose and clamp to the water pump. 6. Install the heater outlet hose to the radiator outlet hose. 7. Install the upper and lower fan shroud. Refer to Engine Coolant Fan Upper Shroud Replacement (LMM Diesel) (See: Fan Shroud/Service and Repair)Engine Coolant Fan Upper Shroud Replacement (Mechanical) (See: Fan Shroud/Service and Repair) and Engine Coolant Fan Lower Shroud Replacement (Mechanical) (See: Fan Shroud/Service and Repair). 8. Fill the engine coolant. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information > Service and Repair > Radiator Inlet Hose Replacement > Page 3733 Radiator Hose: Service and Repair Radiator Hose Quick Connect Fitting Radiator Hose Quick Connect Fitting Removal Procedure 1. Using a bent-tip screwdriver or equivalent, pull on one of the open ends of the retaining ring in order to rotate the retaining ring. 2. Rotate the retaining ring (3) around the quick connector until the retaining ring is out of position and can be completely removed. 3. Remove the radiator outlet hose (2) from the quick connector fitting at the radiator (1). Installation Procedure Note: Do not install the retaining ring (3) onto the fitting by pushing the retaining ring down over the fitting. 1. Hook one of the open ends of the retaining ring (3) in one of the slots in the quick connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information > Service and Repair > Radiator Inlet Hose Replacement > Page 3734 2. Rotate the retaining ring (3) around the connector until the retaining ring is positioned with all 3 ears through the 3 slots. 3. Ensure the 3 retaining ring ears can be seen from the inside of the connector and the retaining ring can move freely in the slots. 4. Install the radiator outlet hose (2) onto the radiator quick connector fitting until a click is heard or felt. Pull back on the radiator outlet hose (2) to ensure a proper connection. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations Radiator Cooling Fan Motor Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 3739 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 3740 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 3741 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 3742 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 3743 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 3744 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 3745 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Coolant Level Sensor > Component Information > Diagrams Coolant Level Sensor: Diagrams Component Connector End Views Engine Coolant Level Switch (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps Coolant Temperature Sensor/Switch (For Computer): Customer Interest Engine - MIL ON P0116/P1400 Set In Very Cold Temps TECHNICAL Bulletin No.: 10-06-04-008A Date: January 24, 2011 Subject: Malfunction Indicator Lamp (MIL) Illuminated at Very Cold Ambient Temperatures When Using Engine Coolant Heater, DTC P0116 and/or P1400 Set (Relocate Engine Coolant Temperature (ECT) Sensor and Engine Coolant Heater Cord) Models: 2006-2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2006-2010 Cadillac Escalade 2006-2007 Chevrolet Monte Carlo 2006-2009 Chevrolet Impala SS, TrailBlazer 2006-2010 Chevrolet Avalanche, Express, Silverado Tahoe 2006-2009 GMC Envoy 2006-2010 GMC Savana, Sierra, Yukon 2006-2008 Pontiac Grand Prix 2006-2009 Saab 9-7X Equipped with V8 Engine RPO LC9, LH6, LH8, LH9, L76, LS2, LS4, LFA, LZ1, L92, L94, L9H or L20, L96, LMF, LMG, LY2, LY5, LY6 Please Refer to GMVIS Attention: To properly correct this condition, you must follow both of the procedures to relocate the ECT sensor and the engine coolant heater cord. Supercede: This bulletin is being revised to add cast iron block engine RPOs and to update the Warranty Information coverage period. Please discard Corporate Bulletin Number 10-06-04-008 (Section 06 - Engine/Propulsion System). Condition Some customers may comment that the malfunction indicator lamp (MIL) illuminates after starting the vehicle when they were using the engine coolant heater in very cold ambient temperatures. This usually occurs in a range of -23 to -40°C (-10 to -40°F) or colder. The technician may observe on a scan tool DTC P0116 and/or P1400 set as Current or in History. Cause This condition may be caused by the engine control module (ECM) determining that the ignition OFF time requirement has been met at start-up and interpreting the temperature difference between the engine coolant temperature (ECT) sensor and the intake air temperature (IAT) sensor as being outside of a calibrated range. Correction Important DO NOT replace the ECM for this condition. Relocating the ECT Sensor 1. Turn ON the ignition with the engine OFF. 2. Perform the diagnostic system check - vehicle. Refer to Diagnostic System Check - Vehicle in SI. ‹› If DTC P0116 and/or P1400 are set and the customer WAS using the engine coolant heater, proceed to Step 3. ‹› If DTC P0116 and/or P1400 are set and the customer WAS NOT using the engine coolant heater, refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. 3. Turn OFF the ignition. Warning To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 3759 under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator are still hot. 4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle. Refer to Cooling System Draining and Filling in SI. 7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor. 10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J 38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle. 13. Disconnect the wiring harness connector from the ECT sensor (2). 14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT sensor in the hole of the cylinder head where the plug was removed. Tighten Tighten to 20 Nm (15 lb ft). 18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was removed Tighten Tighten to 20 Nm (15 lb ft). Important Leave enough wire attached to the ECT sensor harness connector in order to create manageable splices that are at least 40 mm (1.5 in) away from the other splice. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 3760 20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit. Cut off the ECT sensor harness connector and wiring. 21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured TO or WITHIN an existing protective conduit. Note This step is to set up and verify the length of wiring that is required before cutting. 22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the appropriate length. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. 26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit using tie straps. Important You MUST run the engine at the specified RPM and until it reaches normal operating temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool down in order to top off the coolant level as needed. 28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI. 29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan tool to clear any DTCs. Relocating the Engine Coolant Heater Cord Important For reference, the procedure and graphics that are shown are from a Chevrolet Silverado, but are similar for the other vehicles listed above. 1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit from the engine compartment in order to determine the required extension cord length. 3. Obtain an extension cord with the following features: - 120 volt - 14/3 gauge - 15A capacity - Three prong - Polarized plug and receptacle - Chemical resistant - Grounded terminals - Designed for use in a cold outdoor environment - Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight - Maximum length of 2.5-3 m (8-10 ft) 4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N 12345579 (in Canada, use P/N 10953481) or an equivalent. 6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 3761 7. Wrap electrical tape around the connection as shown. 8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to the engine coolant crossover pipe as shown. 9. Continue to route the extension cord to the exit location desired by the customer as shown. 10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the engine coolant heater cord to the vehicle that were released to provide length. Part Information The extension cord may be obtained at any of the following outlets: - Lowes* - Home Depot* - Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number: CWRSJTOW3C14-10 USA: Cords should bear the UL symbol. Canada: Cords should bear the ULc symbol or CSA approval. *We believe these sources and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from these firms or for any such items that may be available from other sources. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 3762 Warranty Information (excluding Saab Models) For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps Coolant Temperature Sensor/Switch (For Computer): All Technical Service Bulletins Engine - MIL ON P0116/P1400 Set In Very Cold Temps TECHNICAL Bulletin No.: 10-06-04-008A Date: January 24, 2011 Subject: Malfunction Indicator Lamp (MIL) Illuminated at Very Cold Ambient Temperatures When Using Engine Coolant Heater, DTC P0116 and/or P1400 Set (Relocate Engine Coolant Temperature (ECT) Sensor and Engine Coolant Heater Cord) Models: 2006-2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2006-2010 Cadillac Escalade 2006-2007 Chevrolet Monte Carlo 2006-2009 Chevrolet Impala SS, TrailBlazer 2006-2010 Chevrolet Avalanche, Express, Silverado Tahoe 2006-2009 GMC Envoy 2006-2010 GMC Savana, Sierra, Yukon 2006-2008 Pontiac Grand Prix 2006-2009 Saab 9-7X Equipped with V8 Engine RPO LC9, LH6, LH8, LH9, L76, LS2, LS4, LFA, LZ1, L92, L94, L9H or L20, L96, LMF, LMG, LY2, LY5, LY6 Please Refer to GMVIS Attention: To properly correct this condition, you must follow both of the procedures to relocate the ECT sensor and the engine coolant heater cord. Supercede: This bulletin is being revised to add cast iron block engine RPOs and to update the Warranty Information coverage period. Please discard Corporate Bulletin Number 10-06-04-008 (Section 06 - Engine/Propulsion System). Condition Some customers may comment that the malfunction indicator lamp (MIL) illuminates after starting the vehicle when they were using the engine coolant heater in very cold ambient temperatures. This usually occurs in a range of -23 to -40°C (-10 to -40°F) or colder. The technician may observe on a scan tool DTC P0116 and/or P1400 set as Current or in History. Cause This condition may be caused by the engine control module (ECM) determining that the ignition OFF time requirement has been met at start-up and interpreting the temperature difference between the engine coolant temperature (ECT) sensor and the intake air temperature (IAT) sensor as being outside of a calibrated range. Correction Important DO NOT replace the ECM for this condition. Relocating the ECT Sensor 1. Turn ON the ignition with the engine OFF. 2. Perform the diagnostic system check - vehicle. Refer to Diagnostic System Check - Vehicle in SI. ‹› If DTC P0116 and/or P1400 are set and the customer WAS using the engine coolant heater, proceed to Step 3. ‹› If DTC P0116 and/or P1400 are set and the customer WAS NOT using the engine coolant heater, refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. 3. Turn OFF the ignition. Warning To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 3768 under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator are still hot. 4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle. Refer to Cooling System Draining and Filling in SI. 7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor. 10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J 38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle. 13. Disconnect the wiring harness connector from the ECT sensor (2). 14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT sensor in the hole of the cylinder head where the plug was removed. Tighten Tighten to 20 Nm (15 lb ft). 18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was removed Tighten Tighten to 20 Nm (15 lb ft). Important Leave enough wire attached to the ECT sensor harness connector in order to create manageable splices that are at least 40 mm (1.5 in) away from the other splice. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 3769 20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit. Cut off the ECT sensor harness connector and wiring. 21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured TO or WITHIN an existing protective conduit. Note This step is to set up and verify the length of wiring that is required before cutting. 22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the appropriate length. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. 26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit using tie straps. Important You MUST run the engine at the specified RPM and until it reaches normal operating temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool down in order to top off the coolant level as needed. 28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI. 29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan tool to clear any DTCs. Relocating the Engine Coolant Heater Cord Important For reference, the procedure and graphics that are shown are from a Chevrolet Silverado, but are similar for the other vehicles listed above. 1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit from the engine compartment in order to determine the required extension cord length. 3. Obtain an extension cord with the following features: - 120 volt - 14/3 gauge - 15A capacity - Three prong - Polarized plug and receptacle - Chemical resistant - Grounded terminals - Designed for use in a cold outdoor environment - Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight - Maximum length of 2.5-3 m (8-10 ft) 4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N 12345579 (in Canada, use P/N 10953481) or an equivalent. 6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 3770 7. Wrap electrical tape around the connection as shown. 8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to the engine coolant crossover pipe as shown. 9. Continue to route the extension cord to the exit location desired by the customer as shown. 10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the engine coolant heater cord to the vehicle that were released to provide length. Part Information The extension cord may be obtained at any of the following outlets: - Lowes* - Home Depot* - Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number: CWRSJTOW3C14-10 USA: Cords should bear the UL symbol. Canada: Cords should bear the ULc symbol or CSA approval. *We believe these sources and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from these firms or for any such items that may be available from other sources. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 3771 Warranty Information (excluding Saab Models) For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 3772 Coolant Temperature Sensor/Switch (For Computer): Diagrams Component Connector End Views Engine Coolant Temperature (ECT) Sensor (Diesel) Engine Coolant Temperature (ECT) Sensor (Gas) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 3773 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Engine Coolant Temperature Sensor Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications Thermostat: Specifications The thermostat should begin to open at ........................................................................................................................................................... 87°C (188°F) The thermostat should be fully open at ............................................................................................................................................................ 97°C (206°F) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 3777 Thermostat: Service and Repair Engine Coolant Thermostat Replacement (Gas) Removal Procedure 1. Remove the thermostat housing. Refer to Engine Coolant Thermostat Housing Replacement (LFA,LH6, LMG,LY2, LY5,LY6) (See: Thermostat Housing/Service and Repair). 2. Remove the thermostat. Installation Procedure 1. Install the thermostat. 2. Install the thermostat housing. Refer to Engine Coolant Thermostat Housing Replacement (LFA,LH6, LMG,LY2, LY5,LY6) (See: Thermostat Housing/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Housing, Engine Cooling > Component Information > Service and Repair Thermostat Housing: Service and Repair Engine Coolant Thermostat Housing Replacement (LFA,LH6, LMG,LY2, LY5,LY6) Removal Procedure 1. Drain the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Service and Repair). 2. Remove the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (). 3. Reposition the radiator outlet hose clamp at the water pump inlet. 4. Remove the radiator outlet hose from the water pump inlet. 5. Remove the water pump inlet bolts (1). 6. Remove the water pump inlet from the water pump. 7. Remove and discard the water pump inlet seal. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Housing, Engine Cooling > Component Information > Service and Repair > Page 3781 Installation Procedure 1. Install a NEW water pump inlet seal to the water pump inlet. 2. Position the water pump inlet to the water pump. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the water pump inlet bolts (1) and tighten to 15 Nm (11 lb ft). 4. Install the radiator outlet hose to the water pump inlet. 5. Position the radiator outlet hose clamp at the water pump inlet. 6. Install the air cleaner outlet duct. Refer to Air Cleaner Resonator Outlet Duct Replacement (). 7. Fill the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Turbocharger Coolant Line > Component Information > Service and Repair Turbocharger Coolant Line: Service and Repair Turbocharger Coolant Hoses/Pipes Replacement (LMM Outlet Pipe) Removal Procedure 1. Remove the turbocharger coolant inlet pipe. Refer to Turbocharger Coolant Hoses/Pipes Replacement (LMM Outlet Pipe) . 2. Remove the generator mounting bracket. Refer to Generator Bracket Replacement (V6) (See: Starting and Charging/Charging System/Alternator/Service and Repair)Generator Bracket Replacement (6.6L) (See: Starting and Charging/Charging System/Alternator/Service and Repair)Generator Bracket Replacement (V8) (See: Starting and Charging/Charging System/Alternator/Service and Repair). 3. Remove the exhaust gas recirculation (EGR) cooler assembly. Refer to Exhaust Gas Recirculation Valve Cooler Replacement (See: Powertrain Management/Emission Control Systems/Exhaust Gas Recirculation/EGR Cooler/Service and Repair/Exhaust Gas Recirculation Valve Cooler Replacement). 4. Remove the cooling fan clutch. Refer to Fan Clutch Replacement (Diesel) (See: Radiator Cooling Fan/Fan Clutch/Service and Repair). 5. Reposition the hose clamp at the bypass pipe. 6. Remove the turbocharger coolant outlet hose from the bypass pipe. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Turbocharger Coolant Line > Component Information > Service and Repair > Page 3785 7. Reposition the turbocharger coolant outlet hose clamp. 8. Remove the turbocharger coolant outlet hose from the pipe on the turbocharger. 9. Remove the turbocharger coolant outlet pipe bolt and nut. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Turbocharger Coolant Line > Component Information > Service and Repair > Page 3786 10. If necessary, remove the turbocharger. Refer to Turbocharger Replacement (See: Powertrain Management/Fuel Delivery and Air Induction/Turbocharger/Service and Repair/Turbocharger Replacement). 11. If necessary, remove the coolant outlet pipe clip bolt (3) from the turbocharger. 12. If necessary, remove the coolant outlet pipe. Installation Procedure 1. If necessary, install the coolant outlet pipe. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. If necessary, install the coolant outlet pipe clip bolt (3) to the turbocharger. Tighten the bolt to 9 Nm (80 lb in). 3. If necessary, install the turbocharger. Refer to Turbocharger Replacement (See: Powertrain Management/Fuel Delivery and Air Induction/Turbocharger/Service and Repair/Turbocharger Replacement). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Turbocharger Coolant Line > Component Information > Service and Repair > Page 3787 4. Install the turbocharger coolant outlet pipe bolt and nut. Tighten the bolt/nut to 9 Nm (80 lb in). 5. Install the turbocharger coolant outlet hose to the pipe on the turbocharger. 6. Position the turbocharger coolant outlet hose clamp. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Turbocharger Coolant Line > Component Information > Service and Repair > Page 3788 7. Install the turbocharger coolant outlet hose to the bypass pipe. 8. Position the hose clamp at the bypass pipe. 9. Install the cooling fan clutch. Refer to Fan Clutch Replacement (Diesel) (See: Radiator Cooling Fan/Fan Clutch/Service and Repair). 10. Install the EGR cooler assembly. Refer to Exhaust Gas Recirculation Valve Cooler Replacement (See: Powertrain Management/Emission Control Systems/Exhaust Gas Recirculation/EGR Cooler/Service and Repair/Exhaust Gas Recirculation Valve Cooler Replacement). 11. Install the generator mounting bracket. Refer to Generator Bracket Replacement (V6) (See: Starting and Charging/Charging System/Alternator/Service and Repair)Generator Bracket Replacement (6.6L) (See: Starting and Charging/Charging System/Alternator/Service and Repair)Generator Bracket Replacement (V8) (See: Starting and Charging/Charging System/Alternator/Service and Repair). 12. Install the turbocharger coolant inlet pipe. Refer to Turbocharger Coolant Hoses/Pipes Replacement (LMM Outlet Pipe) . Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications Water Pump: Specifications Water Pump Bolts ................................................................................................................................ ........................................................ 21 Nm (15 lb ft) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 3792 Water Pump: Service and Repair Water Pump Replacement (LMM) Removal Procedure 1. Remove the left wheelhouse inner panel. Refer to Front Wheelhouse Liner Replacement - Left Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Left Side)Front Wheelhouse Liner Replacement - Left Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Left Side). 2. Remove the thermostat housing crossover. Refer to Thermostat Housing Crossover Replacement (LMM) (See: Coolant Line/Hose/Service and Repair/Thermostat Housing Crossover Replacement). 3. Remove the crankshaft balancer. Refer to Crankshaft Balancer Replacement (See: Engine/Cylinder Block Assembly/Harmonic Balancer Crankshaft Pulley/Service and Repair). 4. Remove the water pump to engine coolant pipe nuts. 5. Remove the engine wiring harness retainer from the inner stud. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 3793 6. Remove the water pump bolts. Note the location of the bolts. The bolts are three different lengths. 7. Remove the water pump. 8. Remove and discard the water pump O-ring and coolant pipe gasket. 9. If required, clean and inspect the water pump. Refer to Water Pump Cleaning and Inspection (See: Engine/Service and Repair/Overhaul/28. Water Pump Cleaning and Inspection). Installation Procedure 1. Lubricate the water pump O-ring with engine oil. 2. Install the engine coolant pipe gasket and water pump O-ring. 3. Install the water pump. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the water pump bolts. Ensure the correct length bolt is used in the proper location. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 3794 Tighten the bolts to 21 Nm (15 lb ft). 5. Install the engine wiring harness retainer on the water pump outlet pipe inner stud. 6. Install the water pump to engine coolant pipe nuts. Tighten the nuts to 21 Nm (15 lb ft). 7. Install the thermostat housing crossover. Refer to Thermostat Housing Crossover Replacement (LMM) (See: Coolant Line/Hose/Service and Repair/Thermostat Housing Crossover Replacement). 8. Install the crankshaft balancer. Refer to Crankshaft Balancer Replacement (See: Engine/Cylinder Block Assembly/Harmonic Balancer Crankshaft Pulley/Service and Repair). 9. Install the left wheelhouse inner panel. Refer to Front Wheelhouse Liner Replacement - Left Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Left Side)Front Wheelhouse Liner Replacement - Left Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Left Side). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Technical Service Bulletins > Recalls for Exhaust Temperature Sensor: > 11054 > Apr > 11 > Recall - Replace Exhaust Gas Temperature Sensor Technical Service Bulletin # 11054 Date: 110412 Recall - Replace Exhaust Gas Temperature Sensor PRODUCT EMISSION Bulletin No.: 11054 Date: April 12, 2011 Subject: 11054 - Reduced Engine Performance and Emission Control - Replace Exhaust Gas Temperature Sensors Models: 2010 Chevrolet Express, Silverado HD 2010 GMC Savana, Sierra HD With 6.6L V8 Duramax Diesel Engine (LMM) 2007-2009 Chevrolet Express, Kodiak, Silverado HD 2007-2009 GMC Savana, Sierra HD, TopKick With 6.6L V8 Duramax Diesel Engine (LMM) Serviced with a Suspect EGT Sensor Condition General Motors has decided to conduct a Voluntary Emission Recall involving certain 2010 model year Chevrolet Express, Silverado HD; and GMC Savana, Sierra HD vehicles equipped with a 6.6L V8 Duramax diesel engine (LMM); and 2007-2009 model year Chevrolet Express, Kodiak, Silverado HD; and GMC Savana, Sierra HD, and TopKick vehicles equipped with a 6.6L V8 Duramax diesel engine (LMM) that may have been serviced with a suspect Exhaust Gas Temperature (EGT) sensor. On these vehicles, the circuit board welds on the EGT sensors in the exhaust system may not be to GM specification. If a weld fails, the Service Engine Soon light will illuminate in the instrument panel, the exhaust gas may not be filtered properly, and the engine power may be reduced. Correction Dealers are to replace both EGT sensors. Vehicles Involved Involved are certain 2010 model year Chevrolet Express, Silverado HD; and GMC Savana, Sierra HD vehicles equipped with a 6.6L V8 Duramax diesel engine (LMM); and 2007-2009 model year Chevrolet Express, Kodiak, Silverado HD; and GMC Savana, Sierra HD, and TopKick vehicles equipped with a 6.6L V8 Duramax diesel engine (LMM) that may have been serviced with a suspect EGT sensor. Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Required Field Actions section in the Global Warranty system. Not all vehicles may be involved. For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to US and Canadian dealers through the GM GlobalConnect Recall Reports, or sent directly to export dealers. Dealers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information Parts required to complete this recall are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Service Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Technical Service Bulletins > Recalls for Exhaust Temperature Sensor: > 11054 > Apr > 11 > Recall - Replace Exhaust Gas Temperature Sensor > Page 3805 1. Remove and replace position 1 and position 2 exhaust gas temperature sensors (1). Refer to Exhaust Temperature Sensor Replacement in SI. 2. CALIFORNIA, CONNECTICUT, MASSACHUSETTS, MAINE, OREGON, VERMONT, & WASHINGTON VEHICLES ONLY: Install a Recall Identification Label. Also, for California vehicles complete a "Proof of Correction" certificate upon recall completion. Recall Identification Label California/Connecticut/Massachusetts/Maine/Oregon/Vermont/Washington Vehicles Only) Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five-digit dealer code of the dealer performing the recall service. This information may be inserted with a ballpoint pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Recall Identification Label, be sure to pull the tab to allow adhesion of the clear protective covering. Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials by ordering on the web from DWD Store, www.gmdealerworld.com, and then click on the DWD Store link. Request Item Number S-1015 when ordering. Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a transaction using the table below. Customer Notification - For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter included with this bulletin). In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper maintenance. The vehicle may fail a state or local emission inspection test if the recall work is not completed. Customer Notification - For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the attached sample letter. In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Technical Service Bulletins > Recalls for Exhaust Temperature Sensor: > 11054 > Apr > 11 > Recall - Replace Exhaust Gas Temperature Sensor > Page 3806 maintenance. The vehicle may fail a state or local emission inspection test if the recall work is not completed. Dealer Recall Responsibility All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. ***THE FOLLOWING 2 PARAGRAPHS ARE NOT FOR CANADA OR EXPORT*** When a California emissions recall is completed by a GM dealer, the dealer must provide the vehicle owner a "Proof of Correction Certificate" which the owner may need to present to the California Department Of Motor Vehicles (DMV) when renewing their vehicle registration. Without this correction certificate, the owner may be unable to renew their vehicle registration. Additional Certificates can be obtained, at no charge, from Dealer Support Materials by ordering on the web from the DWD Store, www.gmdealerworld.com, and then click on the DWD Store link; request GM Item Number 1825 when ordering. Disclaimer Owner Letter Owner Letter Dear General Motors Customer: This notice is sent to inform you that General Motors is conducting a voluntary emission recall that includes your vehicle. Reason For This Recall: General Motors has decided to conduct a Voluntary Emission Recall involving certain 2010 model year Chevrolet Express, Silverado HD; and GMC Savana, Sierra HD vehicles equipped with a 6.6L V8 Duramax diesel engine; and 2007-2009 model year Chevrolet Express, Kodiak, Silverado HD; and GMC Savana, Sierra HD, and TopKick vehicles equipped with a 6.6L V8 Duramax diesel engine that may have been serviced with a suspect Exhaust Gas Temperature (EGT) sensor. The circuit board welds on the EGT sensors in the exhaust system may not be to GM specification. If a weld fails, the Service Engine Soon light will illuminate in the instrument panel, the exhaust gas may not be filtered properly, and the engine power may be reduced. What Will Be Done: Your GM dealer will replace both EGT sensors. This service will be performed for you at no charge. What You Should Do: Please contact your GM dealer as soon as possible to arrange a service date and to assure parts availability. Instructions for making this correction have been sent to your dealer. Please ask your dealer if you wish to know how much time will be needed to schedule, process, and repair your vehicle. If you have any questions or need any assistance, just contact your dealer or the appropriate Customer Assistance Center at the number listed below. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Technical Service Bulletins > Recalls for Exhaust Temperature Sensor: > 11054 > Apr > 11 > Recall - Replace Exhaust Gas Temperature Sensor > Page 3807 Emission Law Information: In order to ensure your full protection under the emission warranty made applicable to your vehicle by State and Federal Law, and your right to participate in future recalls, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could legally be determined to be lack of proper maintenance of your vehicle. Also, your vehicle may fail a state or local emission inspection if this recall is not accomplished. IMPORTANT MESSAGE FOR CALIFORNIA RESIDENTS The California Air Resources Board (CARB) requires vehicle emission recalls be completed prior to California registration renewal. Uncorrected emission recalls will result in the inability to renew your California vehicle registration. At the time of emission recall completion, your California dealer will issue a "Proof of Correction Certificate". Keep this certificate and, if required, present it to the Department of Motor Vehicles when renewing your California registration as proof of recall completion. We are sorry to cause you this inconvenience; however, we have taken this action in the interest of your continued satisfaction with our products. Jim Moloney General Director, Customer and Relationship Services 11054 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exhaust Temperature Sensor: > 11054 > Apr > 11 > Recall - Replace Exhaust Gas Temperature Sensor Technical Service Bulletin # 11054 Date: 110412 Recall - Replace Exhaust Gas Temperature Sensor PRODUCT EMISSION Bulletin No.: 11054 Date: April 12, 2011 Subject: 11054 - Reduced Engine Performance and Emission Control - Replace Exhaust Gas Temperature Sensors Models: 2010 Chevrolet Express, Silverado HD 2010 GMC Savana, Sierra HD With 6.6L V8 Duramax Diesel Engine (LMM) 2007-2009 Chevrolet Express, Kodiak, Silverado HD 2007-2009 GMC Savana, Sierra HD, TopKick With 6.6L V8 Duramax Diesel Engine (LMM) Serviced with a Suspect EGT Sensor Condition General Motors has decided to conduct a Voluntary Emission Recall involving certain 2010 model year Chevrolet Express, Silverado HD; and GMC Savana, Sierra HD vehicles equipped with a 6.6L V8 Duramax diesel engine (LMM); and 2007-2009 model year Chevrolet Express, Kodiak, Silverado HD; and GMC Savana, Sierra HD, and TopKick vehicles equipped with a 6.6L V8 Duramax diesel engine (LMM) that may have been serviced with a suspect Exhaust Gas Temperature (EGT) sensor. On these vehicles, the circuit board welds on the EGT sensors in the exhaust system may not be to GM specification. If a weld fails, the Service Engine Soon light will illuminate in the instrument panel, the exhaust gas may not be filtered properly, and the engine power may be reduced. Correction Dealers are to replace both EGT sensors. Vehicles Involved Involved are certain 2010 model year Chevrolet Express, Silverado HD; and GMC Savana, Sierra HD vehicles equipped with a 6.6L V8 Duramax diesel engine (LMM); and 2007-2009 model year Chevrolet Express, Kodiak, Silverado HD; and GMC Savana, Sierra HD, and TopKick vehicles equipped with a 6.6L V8 Duramax diesel engine (LMM) that may have been serviced with a suspect EGT sensor. Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Required Field Actions section in the Global Warranty system. Not all vehicles may be involved. For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to US and Canadian dealers through the GM GlobalConnect Recall Reports, or sent directly to export dealers. Dealers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information Parts required to complete this recall are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Service Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exhaust Temperature Sensor: > 11054 > Apr > 11 > Recall - Replace Exhaust Gas Temperature Sensor > Page 3813 1. Remove and replace position 1 and position 2 exhaust gas temperature sensors (1). Refer to Exhaust Temperature Sensor Replacement in SI. 2. CALIFORNIA, CONNECTICUT, MASSACHUSETTS, MAINE, OREGON, VERMONT, & WASHINGTON VEHICLES ONLY: Install a Recall Identification Label. Also, for California vehicles complete a "Proof of Correction" certificate upon recall completion. Recall Identification Label California/Connecticut/Massachusetts/Maine/Oregon/Vermont/Washington Vehicles Only) Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five-digit dealer code of the dealer performing the recall service. This information may be inserted with a ballpoint pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Recall Identification Label, be sure to pull the tab to allow adhesion of the clear protective covering. Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials by ordering on the web from DWD Store, www.gmdealerworld.com, and then click on the DWD Store link. Request Item Number S-1015 when ordering. Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a transaction using the table below. Customer Notification - For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter included with this bulletin). In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper maintenance. The vehicle may fail a state or local emission inspection test if the recall work is not completed. Customer Notification - For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the attached sample letter. In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exhaust Temperature Sensor: > 11054 > Apr > 11 > Recall - Replace Exhaust Gas Temperature Sensor > Page 3814 maintenance. The vehicle may fail a state or local emission inspection test if the recall work is not completed. Dealer Recall Responsibility All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. ***THE FOLLOWING 2 PARAGRAPHS ARE NOT FOR CANADA OR EXPORT*** When a California emissions recall is completed by a GM dealer, the dealer must provide the vehicle owner a "Proof of Correction Certificate" which the owner may need to present to the California Department Of Motor Vehicles (DMV) when renewing their vehicle registration. Without this correction certificate, the owner may be unable to renew their vehicle registration. Additional Certificates can be obtained, at no charge, from Dealer Support Materials by ordering on the web from the DWD Store, www.gmdealerworld.com, and then click on the DWD Store link; request GM Item Number 1825 when ordering. Disclaimer Owner Letter Owner Letter Dear General Motors Customer: This notice is sent to inform you that General Motors is conducting a voluntary emission recall that includes your vehicle. Reason For This Recall: General Motors has decided to conduct a Voluntary Emission Recall involving certain 2010 model year Chevrolet Express, Silverado HD; and GMC Savana, Sierra HD vehicles equipped with a 6.6L V8 Duramax diesel engine; and 2007-2009 model year Chevrolet Express, Kodiak, Silverado HD; and GMC Savana, Sierra HD, and TopKick vehicles equipped with a 6.6L V8 Duramax diesel engine that may have been serviced with a suspect Exhaust Gas Temperature (EGT) sensor. The circuit board welds on the EGT sensors in the exhaust system may not be to GM specification. If a weld fails, the Service Engine Soon light will illuminate in the instrument panel, the exhaust gas may not be filtered properly, and the engine power may be reduced. What Will Be Done: Your GM dealer will replace both EGT sensors. This service will be performed for you at no charge. What You Should Do: Please contact your GM dealer as soon as possible to arrange a service date and to assure parts availability. Instructions for making this correction have been sent to your dealer. Please ask your dealer if you wish to know how much time will be needed to schedule, process, and repair your vehicle. If you have any questions or need any assistance, just contact your dealer or the appropriate Customer Assistance Center at the number listed below. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exhaust Temperature Sensor: > 11054 > Apr > 11 > Recall - Replace Exhaust Gas Temperature Sensor > Page 3815 Emission Law Information: In order to ensure your full protection under the emission warranty made applicable to your vehicle by State and Federal Law, and your right to participate in future recalls, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could legally be determined to be lack of proper maintenance of your vehicle. Also, your vehicle may fail a state or local emission inspection if this recall is not accomplished. IMPORTANT MESSAGE FOR CALIFORNIA RESIDENTS The California Air Resources Board (CARB) requires vehicle emission recalls be completed prior to California registration renewal. Uncorrected emission recalls will result in the inability to renew your California vehicle registration. At the time of emission recall completion, your California dealer will issue a "Proof of Correction Certificate". Keep this certificate and, if required, present it to the Department of Motor Vehicles when renewing your California registration as proof of recall completion. We are sorry to cause you this inconvenience; however, we have taken this action in the interest of your continued satisfaction with our products. Jim Moloney General Director, Customer and Relationship Services 11054 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Service and Repair > Exhaust Temperature Sensor Replacement Position 1 Exhaust Temperature Sensor: Service and Repair Exhaust Temperature Sensor Replacement Position 1 Exhaust Temperature Sensor Replacement - Position 1 Removal Procedure Caution: The exhaust temperature sensor and exhaust pressure differential sensor line fittings may be difficult to remove when the engine exhaust system temperature is below 48°C (120°F). Excessive force may damage the threads in the exhaust manifold or exhaust pipe. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the exhaust temperature sensor electrical connector (1) from the chassis wiring harness electrical connector (2). 3. Remove the exhaust temperature sensor. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Service and Repair > Exhaust Temperature Sensor Replacement Position 1 > Page 3818 Note: A special anti-seize compound is used in the sensor or line fittings threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor or line fitting easier to remove. New, or service replacement sensors or line fittings already have the compound applied to the threads. If the sensor or line fittings are removed from an exhaust component and if for any reason the sensor or line fitting are reinstalled, the threads must have anti-seize compound applied before reinstallation. 1. If reinstalling the old temperature sensor or differential pressor sensor line fittings, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the exhaust temperature sensor. Tighten the sensor to 45 Nm (33 lb ft). 3. Connect the exhaust temperature sensor electrical connector (1) to the chassis wiring harness electrical connector (2). 4. Lower the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Service and Repair > Exhaust Temperature Sensor Replacement Position 1 > Page 3819 Exhaust Temperature Sensor: Service and Repair Exhaust Temperature Sensor Replacement Position 2 Exhaust Temperature Sensor Replacement - Position 2 Removal Procedure Caution: The exhaust temperature sensor and exhaust pressure differential sensor line fittings may be difficult to remove when the engine exhaust system temperature is below 48°C (120°F). Excessive force may damage the threads in the exhaust manifold or exhaust pipe. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the exhaust temperature sensor (3) electrical connector from the chassis wiring harness electrical connector (4). 3. Remove the exhaust temperature sensor. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Service and Repair > Exhaust Temperature Sensor Replacement Position 1 > Page 3820 Note: A special anti-seize compound is used in the sensor or line fittings threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor or line fitting easier to remove. New, or service replacement sensors or line fittings already have the compound applied to the threads. If the sensor or line fittings are removed from an exhaust component and if for any reason the sensor or line fitting are reinstalled, the threads must have anti-seize compound applied before reinstallation. 1. If reinstalling the old temperature sensor or differential pressor sensor line fittings, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the exhaust temperature sensor. Tighten the sensor to 45 Nm (33 lb ft). 3. Connect the exhaust temperature sensor (3) electrical connector to the chassis wiring harness electrical connector (4). 4. Lower the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Continuous Trap Oxidizer, Diesel Emissions > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Exhaust Pressure Differential Sensor Replacement (Pickup) Exhaust Pressure Differential Sensor: Service and Repair Exhaust Pressure Differential Sensor Replacement (Pickup) Exhaust Pressure Differential Sensor Replacement (Pickup) Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the chassis wiring harness electrical connector (1) from the exhaust differential pressure sensor (2). 3. Reposition the exhaust differential pressure sensor pipe assembly hose clamps (3). 4. Remove the exhaust differential pressure sensor pipe assembly hoses from the sensor. 5. Remove the exhaust differential pressure sensor bracket bolts (1). 6. Remove the exhaust differential pressure sensor (2). Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Continuous Trap Oxidizer, Diesel Emissions > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Exhaust Pressure Differential Sensor Replacement (Pickup) > Page 3826 1. Position the exhaust differential pressure sensor (2) to the bracket. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the exhaust differential pressure sensor bracket bolts (1). Tighten the bolts to 9 Nm (80 lb in). 3. Install the exhaust differential pressure sensor pipe assembly hoses to the sensor. 4. Position the exhaust differential pressure sensor pipe assembly hose clamps (3). 5. Connect the chassis wiring harness electrical connector (1) to the exhaust differential pressure sensor (2). 6. Lower the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Continuous Trap Oxidizer, Diesel Emissions > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Exhaust Pressure Differential Sensor Replacement (Pickup) > Page 3827 Exhaust Pressure Differential Sensor: Service and Repair Exhaust Pressure Differential Sensor Replacement (Cab/Chassis) Exhaust Pressure Differential Sensor Replacement (Cab/Chassis) Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the chassis wiring harness electrical connector (1) from the exhaust differential pressure sensor (2). 3. Reposition the exhaust differential pressure sensor pipe assembly hose clamps (3). 4. Remove the exhaust differential pressure sensor pipe assembly hoses from the sensor. 5. Remove the exhaust differential pressure sensor bracket bolts (1). 6. Remove the exhaust differential pressure sensor (2). Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Continuous Trap Oxidizer, Diesel Emissions > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Exhaust Pressure Differential Sensor Replacement (Pickup) > Page 3828 1. Position the exhaust differential pressure sensor (2) to the bracket. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the exhaust differential pressure sensor bracket bolts (1). Tighten the bolts to 9 Nm (80 lb in). 3. Install the exhaust differential pressure sensor pipe assembly hoses to the sensor. 4. Position the exhaust differential pressure sensor pipe assembly hose clamps (3). 5. Connect the chassis wiring harness electrical connector (1) to the exhaust differential pressure sensor (2). 6. Lower the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Continuous Trap Oxidizer, Diesel Emissions > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Exhaust Pressure Differential Sensor Replacement (Pickup) > Page 3829 Exhaust Pressure Differential Sensor: Service and Repair Exhaust Pressure Differential Sensor Pipe Replacement (Pickup) Exhaust Pressure Differential Sensor Pipe Replacement (Pickup) Removal Procedure Caution: The exhaust temperature sensor and exhaust pressure differential sensor line fittings may be difficult to remove when the engine exhaust system temperature is below 48°C (120°F). Excessive force may damage the threads in the exhaust manifold or exhaust pipe. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Reposition the exhaust differential pressure sensor pipe assembly hose clamps (3). 3. Remove the exhaust differential pressure sensor pipe assembly hoses from the sensor. 4. Remove the exhaust differential pressure sensor pipe bracket bolt and nut. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Continuous Trap Oxidizer, Diesel Emissions > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Exhaust Pressure Differential Sensor Replacement (Pickup) > Page 3830 5. Loosen the exhaust differential pressure sensor pipe assembly fittings (1). 6. Remove the exhaust differential pressure sensor pipe assembly. Installation Procedure Note: A special anti-seize compound is used in the sensor or line fittings threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor or line fitting easier to remove. New, or service replacement sensors or line fittings already have the compound applied to the threads. If the sensor or line fittings are removed from an exhaust component and if for any reason the sensor or line fitting are reinstalled, the threads must have anti-seize compound applied before reinstallation. 1. If reinstalling the old temperature sensor or differential pressor sensor line fittings, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Continuous Trap Oxidizer, Diesel Emissions > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Exhaust Pressure Differential Sensor Replacement (Pickup) > Page 3831 Note: Ensure to route the pipe assembly over the frame crossmember. 2. Position and install the exhaust differential pressure sensor pipe assembly to the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Tighten the exhaust differential pressure sensor pipe assembly fittings (1). Tighten the fittings to 45 Nm (33 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Continuous Trap Oxidizer, Diesel Emissions > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Exhaust Pressure Differential Sensor Replacement (Pickup) > Page 3832 4. Position the exhaust differential pressure sensor pipe bracket to the exhaust hanger and install the bolt and nut. Tighten the bracket bolt/nut to 9 Nm (80 lb in). 5. Install the exhaust differential pressure sensor pipe assembly hoses to the sensor. 6. Position the exhaust differential pressure sensor pipe assembly hose clamps (3). 7. Lower the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Continuous Trap Oxidizer, Diesel Emissions > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Exhaust Pressure Differential Sensor Replacement (Pickup) > Page 3833 Exhaust Pressure Differential Sensor: Service and Repair Exhaust Pressure Differential Sensor Pipe Replacement (Cab/Chassis) Exhaust Pressure Differential Sensor Pipe Replacement (Cab/Chassis) Removal Procedure Caution: The exhaust temperature sensor and exhaust pressure differential sensor line fittings may be difficult to remove when the engine exhaust system temperature is below 48°C (120°F). Excessive force may damage the threads in the exhaust manifold or exhaust pipe. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Reposition the exhaust differential pressure sensor pipe assembly hose clamps (3). 3. Remove the exhaust differential pressure sensor pipe assembly hoses from the sensor. 4. Remove the exhaust differential pressure sensor pipe bracket bolt and nut. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Continuous Trap Oxidizer, Diesel Emissions > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Exhaust Pressure Differential Sensor Replacement (Pickup) > Page 3834 5. Loosen the exhaust differential pressure sensor pipe assembly fittings (1). 6. Remove the exhaust differential pressure sensor pipe assembly. Installation Procedure Note: A special anti-seize compound is used in the sensor or line fittings threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor or line fitting easier to remove. New, or service replacement sensors or line fittings already have the compound applied to the threads. If the sensor or line fittings are removed from an exhaust component and if for any reason the sensor or line fitting are reinstalled, the threads must have anti-seize compound applied before reinstallation. 1. If reinstalling the old temperature sensor or differential pressor sensor line fittings, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Continuous Trap Oxidizer, Diesel Emissions > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Exhaust Pressure Differential Sensor Replacement (Pickup) > Page 3835 Note: Ensure to route the pipe assembly over the frame crossmember. 2. Position and install the exhaust differential pressure sensor pipe assembly to the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Tighten the exhaust differential pressure sensor pipe assembly fittings (1). Tighten the fittings to 45 Nm (33 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Continuous Trap Oxidizer, Diesel Emissions > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Exhaust Pressure Differential Sensor Replacement (Pickup) > Page 3836 4. Position the exhaust differential pressure sensor pipe bracket to the exhaust hanger and install the bolt and nut. Tighten the bracket bolt/nut to 9 Nm (80 lb in). 5. Install the exhaust differential pressure sensor pipe assembly hoses to the sensor. 6. Position the exhaust differential pressure sensor pipe assembly hose clamps (3). 7. Lower the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Diesel Particle Filter (DPF) > Component Information > Technical Service Bulletins > Exhaust System - DIC Clean Exhaust Filter Mssg/DTC P2463 Diesel Particle Filter (DPF): Technical Service Bulletins Exhaust System - DIC Clean Exhaust Filter Mssg/DTC P2463 INFORMATION Bulletin No.: 10-06-05-002 Date: March 04, 2010 Subject: "Clean Exhaust Filter See Owners Manual Now" Message Displayed on Driver Information Center (DIC), DTC P2463 May Be Set - Inform Customer on Driving Conditions Required for a Self Cleaning of Diesel Particulate Filter (DPF) Models: 2007-2009 Chevrolet Kodiak 2007-2010 Chevrolet Express, Silverado 2007-2009 GMC TopKick 2007-2010 GMC Savana, Sierra Equipped With Duramax(TM) Diesel Engine RPO LMM Please Refer to GMVIS The "CLEAN EXHAUST FILTER SEE OWNERS MANUAL NOW" message may be displayed on the driver information center (DIC) with a DTC P2463 set. This is a result of the customer NOT DRIVING the vehicle at the required speed and necessary amount of time for a self cleaning (regeneration) of the diesel particulate filter (DPF) to occur when the message is displayed. CLEAN EXHAUST FILTER SEE OWNERS MANUAL NOW The "CLEAN EXHAUST FILTER SEE OWNERS MANUAL NOW", message will appear on the driver information center (DIC) when a DPF regeneration is required. This message is displayed to NOTIFY the DRIVER that the status of the vehicle has changed and ACTION is required by the DRIVER to correct the condition. The message is not a onetime display and will occur periodically through the lifetime of the vehicle when a DPF regeneration is required based on engine run time, fuel consumed and distance traveled since the last DPF regeneration. 1. Perform the Diagnostic System Check - Vehicle. 2. Is DTC P2463 set? ‹› If DTC P2463 is set, refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. After following the diagnostic procedure return to this bulletin and PROCEED to Step 3. ‹› If DTC P2463 is not set, then proceed to Step 3 and inform the customer as indicated. Important ADVISE THE CUSTOMER ABOUT ALL OF THE FOLLOWING INFORMATION: 3. The importance of the message and responding to it immediately. Clearing the message will only make the message disappear temporarily and not correct the problem. 4. Guide the customer to their Duramax(TM) Diesel Engine Owners Manual Supplement and review the information titled: "Diesel Particulate Filter", in order to familiarize them with the operation of the system. 5. Extended idle time should be avoided while the "Clean Exhaust Filter" message is displayed because the DPF system is not capable of self cleaning at idle. 6. Instruct the customer that the most efficient way to clean the filter is to DRIVE the vehicle at more than 50 km/h (30 mph) for approximately 20-30 minutes, UNTIL the warning message goes OFF. 7. Ignoring the message and continuing to drive with the DPF warning message ON and the exhaust filter not being cleaned as required will eventually result in the following: 1. The malfunction indicator lamp (MIL) will illuminate at which point the DPF warning message will be displayed and a chime will also sound. 2. Diagnostic Trouble Code DTC P2463 will be set as a result of excessive soot loading in the DPF. 3. The Engine Power Is Reduced message will be displayed. The engine WILL operate in reduced engine power when this occurs. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Diesel Particle Filter (DPF) > Component Information > Technical Service Bulletins > Exhaust System - DIC Clean Exhaust Filter Mssg/DTC P2463 > Page 3841 4. Once this occurs, self cleaning of the DPF is no longer possible and dealer service will be necessary. 5. Possible irreversible damage to the DPF may occur, requiring repair or replacement. 6. Advise the customer that if following the diagnostic procedure for DTC P2463 in SI results in a DPF system malfunction NOT BEING found, the Diesel Particulate Filter (DPF) Service Regeneration SHOULD NOT BE CHARGED TO GM WARRANTY. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Diesel Particle Filter (DPF) > Component Information > Service and Repair > Diesel Particulate Filter (DPF) Service Regeneration Diesel Particle Filter (DPF): Service and Repair Diesel Particulate Filter (DPF) Service Regeneration Diesel Particulate Filter (DPF) Service Regeneration Warning Tailpipe outlet exhaust temperature will be greater than 300°C (572°F) during service regeneration. To help prevent personal injury or property damage from fire or burns, perform the following: 1. Do not connect any shop exhaust removal hoses to the vehicle's tailpipe. 2. Park the vehicle outdoors and keep people, other vehicles, and combustible material away during service regeneration. 3. Do not leave the vehicle unattended. Warning To avoid extremely elevated exhaust temperatures, inspect and remove any debris or mud build up at the exhaust cooler located at the tailpipe. Caution: Due to the elevated engine temperatures created while performing this procedure it is imperative to keep the front of vehicle in an open environment, with the hood open, away from any walls or buildings. This will ensure proper airflow across the radiator. Note: If you were not referred to this document from another diagnostic, DO NOT perform this procedure. Conditions for Running The following conditions must be met in order to enable DPF Service Regeneration: Note: Do not refuel the vehicle during DPF Service Regeneration. * DTCs P2463 or P244B are the only active DTCs displayed. * The battery voltage is greater than 10 volts. * The engine speed is between 600-1,250 RPM. * The exhaust gas temperature (EGT) sensors 1 and 2 are less than 400°C (752°F). * The engine coolant temperature (ECT) sensor 1 is between 70-115°C (158-239°F). * The brake pedal and accelerator pedal are in the released position. * The transmission is in Park or Neutral. Test Procedure 1. Clear all DTCs with a scan tool before proceeding with DPF Service Regeneration. 2. Observe the scan tool DPF Regenerations Completed parameter and record the value. 3. Check the following fluid levels before and after this procedure: * Engine oil * Engine coolant * Power steering * Transmission * Fuel level should be over 15 percent to ensure a successful regeneration. 4. Park the vehicle outside the facility, away from any obstacles, place the transmission in Park and apply the parking brake. 5. Ensure the hood is open. 6. Select DPF Service Regeneration in the Output Controls menu and follow the instruction on the scan tool. 7. Command the DPF Service Regeneration ON with a scan tool. ‹› If the service regeneration failed to start, repair the vehicle for the condition indicated by the scan tool DPF Regen Inhibit Reason parameter. Refer to the Service Regeneration Unsuccessful table. 8. The DPF Service Regeneration will take approximately 35 minutes consisting of the following: 1. 8 minutes for the exhaust system to warm up, with the engine speed slowly increasing to 1,600 RPM, then 2,200 RPM and finally 2,500 RPM 2. 20 minutes for the DPF to regenerate at an engine speed between 2,200-2,500 RPM 3. 3 minutes for the exhaust system to cool down with the engine speed will slowly returning to 1,400 RPM 4. 3 minutes at 800 RPM, then idle speed of 680 RPM 9. The DPF Service Regeneration will be terminated if any of the following actions are performed: Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Diesel Particle Filter (DPF) > Component Information > Service and Repair > Diesel Particulate Filter (DPF) Service Regeneration > Page 3844 * Applying the brake pedal * Applying the accelerator pedal * Selecting Drive or Reverse * Commanding DPF Service Regeneration OFF using the scan tool or disconnecting the scan tool from the vehicle Note: * The DPF Service Regeneration will terminate if the DPF or ECT temperatures exceed a calibrated threshold. * Temporary blue, gray, or white smoke during this procedure may be an indication of a fuel with high sulfur content. 10. After the service regeneration completes, clear all DTCs and turn the ignition OFF for 90 seconds. ‹› If the service regeneration did not complete or aborted, replace the Exhaust Particulate Filter. 11. Engine running, perform the following within 10 minutes of a successful service regeneration. Operate the vehicle within the following Conditions for Running DTC P2002. Refer to DTC P2002 (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P2002). ‹› If DTC P2002 or P244B sets, replace the Exhaust Particulate Filter. 12. Verify that the scan tool DPF Regenerations Completed parameter has increased by one. ‹› If the value has not increased by one, refer to Service Regeneration Unsuccessful. Service Regeneration Unsuccessful The scan tool DPF Regeneration Inhibit reason parameter will display a reason for not enabling or aborting the DPF service regeneration. Refer to the reasons that are displayed and the corrective action for each reason. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Diesel Particle Filter (DPF) > Component Information > Service and Repair > Diesel Particulate Filter (DPF) Service Regeneration > Page 3845 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Diesel Particle Filter (DPF) > Component Information > Service and Repair > Diesel Particulate Filter (DPF) Service Regeneration > Page 3846 Diesel Particle Filter (DPF): Service and Repair Diesel Particulate Filter (DPF) Regeneration Enable Diesel Particulate Filter (DPF) Regeneration Enable Important: The DPF Regeneration Enable is required when specific service procedures have been performed. Do not perform a DPF Regeneration Enable unless instructed to in the Repair Instruction section of the service procedure. After the system repair perform the following to avoid possible damage to the DPF. 1. Ignition ON, clear all DTCs with a scan tool. 2. Select DPF Regeneration Enable within the Special Function menu. 3. Select ON. ‹› The selection can be confirmed by the DPF Regeneration Reason parameter indicating Device Control. 4. Exit the Special Function Menu. The scan tool can now be removed. The vehicle will perform an active Regeneration as soon as the engine running conditions are met. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications Exhaust Manifold: Specifications Right Left Exhaust Manifold Bolt/Nut.................................................................................................................... ........................................................57 Nm (42 lb ft.) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold Replacement - Left SIde Exhaust Manifold: Service and Repair Exhaust Manifold Replacement - Left SIde Exhaust Manifold Replacement - Left Side (6.6L) Removal Procedure 1. Remove the charge air cooler inlet pipe. Refer to Charge Air Cooler Inlet Pipe Replacement (See: Powertrain Management/Fuel Delivery and Air Induction/Turbocharger/Intercooler/Intercooler Duct/Service and Repair/Charge Air Cooler Inlet Pipe Replacement). 2. Remove the wheelhouse liner. Refer to Front Wheelhouse Liner Replacement - Right Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side)Front Wheelhouse Liner Replacement - Right Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side). 3. Perform the following steps working through the wheelhouse opening. 4. Remove the steering coupling nut (1) and bolt (2) at the upper intermediate steering shaft. 5. Separate the steering shaft coupling from the intermediate shaft. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold Replacement - Left SIde > Page 3852 6. Remove the exhaust pipe to exhaust manifold bolts (1). 7. Remove the exhaust manifold heat shield bolts (1) and shield (2). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold Replacement - Left SIde > Page 3853 8. Remove the exhaust manifold bolts and nuts in the sequence shown. 9. Remove the exhaust manifold and gasket. Discard the gasket. Installation Procedure Left 1. Install the a NEW exhaust manifold gasket onto the manifold studs. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold Replacement - Left SIde > Page 3854 Important: Position the exhaust pipe gaskets with the tabs shown. Failure to do so will cause improper alignment of the gaskets and result in exhaust leaks. 2. Position a NEW exhaust pipe gasket (1) between the exhaust manifold and the exhaust pipe. Align the tabs (2) on the gasket to face outward. 3. Install the exhaust manifold onto the studs. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install and tighten the exhaust manifold bolts and nuts in the sequence shown to 57 Nm (42 lb ft). 5. Tighten the 4 center bolts/nuts an additional pass to 57 Nm (42 lb ft) Left 6. Install and tighten the exhaust pipe to exhaust manifold bolts in the sequence shown (1, 2, and 3) to 53 Nm (39 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold Replacement - Left SIde > Page 3855 7. Position the exhaust manifold heat shield (2) to the manifold and install the bolts (1) and tighten to 10 Nm (89 lb in). 8. Install the steering shaft coupling to the intermediate shaft. 9. Install the steering shaft coupling nut (1) and bolt (2) at the steering shaft coupling and tighten to 50 Nm (37 lb in). 10. Install the wheelhouse liner. Refer to Front Wheelhouse Liner Replacement - Right Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side)Front Wheelhouse Liner Replacement - Right Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side). 11. Remove the charge air cooler inlet pipe. Refer to Charge Air Cooler Inlet Pipe Replacement (See: Powertrain Management/Fuel Delivery and Air Induction/Turbocharger/Intercooler/Intercooler Duct/Service and Repair/Charge Air Cooler Inlet Pipe Replacement). 12. Lower the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold Replacement - Left SIde > Page 3856 Exhaust Manifold: Service and Repair Exhaust Manifold Replacement - Right Side Exhaust Manifold Replacement - Right Side (6.6L) Removal Procedure 1. Remove the wheelhouse liner. Refer to Front Wheelhouse Liner Replacement - Right Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side)Front Wheelhouse Liner Replacement - Right Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side). 2. Perform the following steps working through the wheelhouse opening, remove the exhaust pipe to turbocharger exhaust pipe bracket bolt. 3. Remove the exhaust pipe to exhaust manifold bolts (1) and bracket. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold Replacement - Left SIde > Page 3857 4. Remove the exhaust manifold heat shield bolts (1) and shield. 5. Remove the exhaust manifold bolts and nuts in the proper sequence. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold Replacement - Left SIde > Page 3858 6. Remove the exhaust manifold and exhaust manifold to pipe gasket. 7. Remove the oil level indicator tube bolt (2) and rotate the oil level indicator tube out of the way. 8. Remove and discard the exhaust manifold gasket (1). Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold Replacement - Left SIde > Page 3859 1. Install a NEW exhaust manifold gasket (1) onto the studs. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Rotate the oil level indicator tube into position and install the oil level indicator tube bolt (2) and tighten to 21 Nm (15 lb ft). 3. Position a NEW exhaust pipe gasket between the exhaust manifold and exhaust pipe. Align the tabs on the gasket to face downward. 4. Install the exhaust manifold onto the studs. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold Replacement - Left SIde > Page 3860 Right 5. Install and tighten the exhaust manifold bolts and nuts in the sequence shown and tighten to 57 Nm (42 lb ft). 6. Tighten the 4 center bolts/nuts an additional pass to 57 Nm (42 lb ft). 7. Position the exhaust manifold heat shield to the manifold and install the exhaust manifold bolts (1) and tighten to 10 Nm (89 lb in). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold Replacement - Left SIde > Page 3861 Important: Position the exhaust pipe gaskets with the tabs shown. Failure to do so will cause improper alignment of the gaskets and result in exhaust leaks. 8. Install a NEW gasket (1) to the exhaust manifold with the tabs (2) facing downward. 9. Install the exhaust pipe bracket and the exhaust pipe to exhaust manifold bolts (1). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold Replacement - Left SIde > Page 3862 10. Tighten the exhaust pipe to exhaust manifold bolts in the sequence shown (4, 5, and 6) to 53 Nm (39 lb ft). 11. Install the exhaust pipe to turbocharger exhaust pipe bracket bolt and tighten to 34 Nm (25 lb ft). 12. Install the wheelhouse liner. Refer to Front Wheelhouse Liner Replacement - Right Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side)Front Wheelhouse Liner Replacement - Right Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side). 13. Lower the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust Manifold Pipe Replacement Exhaust Pipe: Service and Repair Exhaust Manifold Pipe Replacement Exhaust Manifold Pipe Replacement Removal Procedure 1. Remove the heated oxygen sensor (HO2S). Refer to Heated Oxygen Sensor Replacement Bank 2 Sensor 1 (2500 Series - Cab/Chassis) ()Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 (2500 Series) ()Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 (1500 Series) (). 2. Support the transmission with a suitable transmission jack. 3. Remove the transmission mount to transmission support nuts. 4. Using the transmission jack, raise the transmission up off of the transmission support. 5. Remove the transmission support crossmember bolts. 6. Remove the transmission support crossmember. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust Manifold Pipe Replacement > Page 3867 7. Remove the exhaust muffler to exhaust manifold pipe nuts (1). 8. Remove the exhaust manifold pipe to exhaust manifold nuts. 9. Using the transmission jack, lower the transmission slightly. 10. Separate any necessary exhaust muffler insulators so that the pipe may be separated from the muffler. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust Manifold Pipe Replacement > Page 3868 11. Remove the exhaust manifold pipe. 12. Discard the exhaust manifold pipe gasket. Installation Procedure 1. Install a NEW exhaust manifold pipe gasket onto the muffler studs. 2. Install the exhaust manifold pipe. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust Manifold Pipe Replacement > Page 3869 3. Install any necessary exhaust muffler insulators that were separated from the muffler. 4. Using the transmission jack, raise the transmission slightly. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Install the exhaust manifold pipe to exhaust manifold nuts and tighten to 50 Nm (37 lb ft). 6. Install the exhaust muffler to exhaust manifold pipe nuts (1) and tighten to 45 Nm (33 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust Manifold Pipe Replacement > Page 3870 7. Position the transmission support crossmember. 8. Install the transmission support crossmember bolts and tighten to 95 Nm (70 lb ft). 9. Using the transmission jack, lower the transmission onto the transmission support. 10. Install the transmission mount to transmission support nuts and tighten to 40 Nm (30 lb ft). 11. Remove the support from the transmission. 12. Install the HO2S. Refer to Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 (2500 Series - Cab/Chassis) ()Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 (2500 Series) ()Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 (1500 Series) (). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust Manifold Pipe Replacement > Page 3871 Exhaust Pipe: Service and Repair Turbocharger Exhaust Pipe Replacement Turbocharger Exhaust Pipe Replacement (6.6L) Removal Procedure 1. Remove the transmission. Refer to Transmission Replacement (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Service and Repair). 2. Remove the glow plug control module and both brackets. Refer to Glow Plug Control Module Replacement (See: Powertrain Management/Glow Plug System/Glow Plug Control Module/Service and Repair). 3. Remove the exhaust gas recirculation (EGR) valve cooler. Refer to Exhaust Gas Recirculation Valve Cooler Replacement (See: Powertrain Management/Emission Control Systems/Exhaust Gas Recirculation/EGR Cooler/Service and Repair/Exhaust Gas Recirculation Valve Cooler Replacement). 4. Remove the turbocharger upper heat shield bolts and shield. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust Manifold Pipe Replacement > Page 3872 5. Loosen the turbocharger exhaust pipe to turbocharger clamp bolt (1). 6. Remover the catalytic converter. Refer to Catalytic Converter Replacement (LY6 with Exhaust Flange) (See: Catalytic Converter/Service and Repair)Catalytic Converter Replacement (L9H with Exhaust Flange) (See: Catalytic Converter/Service and Repair)Catalytic Converter Replacement (Gen IV Engines with Exhaust Clamp) (See: Catalytic Converter/Service and Repair)Catalytic Converter Replacement (LFA with Exhaust Clamp) (See: Catalytic Converter/Service and Repair)Catalytic Converter Replacement (LMM) (See: Catalytic Converter/Service and Repair). 7. Perform the following steps working through the wheelhouse opening, Remove the transmission fluid fill tube to bellhousing nuts. 8. Position the transmission fluid fill tube to the right side of the vehicle. The tube does not require removal from the transmission. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust Manifold Pipe Replacement > Page 3873 9. Remove the turbocharger exhaust pipe heat shield bolts and shield. 10. Remove the turbocharger exhaust pipe to bracket bolt (1). 11. Remove the turbocharger exhaust pipe. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust Manifold Pipe Replacement > Page 3874 1. Install the turbocharger exhaust pipe into the clamp and position the pipe flat against the turbocharger. 2. Loosely install the turbocharger exhaust pipe to bracket bolt (1). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Position the turbocharger exhaust pipe heat shield and install the heat shield bolts. Tighten the bolts to 10 Nm (89 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust Manifold Pipe Replacement > Page 3875 4. Position the transmission fluid fill tube. 5. Install the transmission fluid fill tube to bellhousing nuts. Tighten the nuts to 18 Nm (13 lb ft). Note: Prior to tightening the turbocharger exhaust clamp, ensure that the turbocharger exhaust pipe is inserted into the clamp. 6. Tighten the turbocharger exhaust pipe to turbocharger clamp bolt (1). Tighten the bolt to 15 Nm (11 lb ft). 7. Install the catalytic converter. Refer to Catalytic Converter Replacement (LY6 with Exhaust Flange) (See: Catalytic Converter/Service and Repair)Catalytic Converter Replacement (L9H with Exhaust Flange) (See: Catalytic Converter/Service and Repair)Catalytic Converter Replacement (Gen IV Engines with Exhaust Clamp) (See: Catalytic Converter/Service and Repair)Catalytic Converter Replacement (LFA with Exhaust Clamp) (See: Catalytic Converter/Service and Repair)Catalytic Converter Replacement (LMM) (See: Catalytic Converter/Service and Repair). 8. Tighten the turbocharger exhaust pipe to bracket bolt. Tighten the bolt to 34 Nm (25 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust Manifold Pipe Replacement > Page 3876 9. Install the turbocharger upper heat shield and bolts. Tighten the bolts to 10 Nm (89 lb in). 10. Install the EGR valve cooler. Refer to Exhaust Gas Recirculation Valve Cooler Replacement (See: Powertrain Management/Emission Control Systems/Exhaust Gas Recirculation/EGR Cooler/Service and Repair/Exhaust Gas Recirculation Valve Cooler Replacement). 11. Install the glow plug control module and both brackets. Refer to Glow Plug Control Module Replacement (See: Powertrain Management/Glow Plug System/Glow Plug Control Module/Service and Repair). 12. Install the transmission. Refer to Transmission Replacement (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust Manifold Pipe Replacement > Page 3877 Exhaust Pipe: Service and Repair Exhaust Pipe Replacement - Left Side Exhaust Pipe Replacement - Left Side Removal Procedure 1. Remove the turbocharger exhaust pipe. Refer to Turbocharger Exhaust Pipe Replacement (6.6L) (See: Turbocharger Exhaust Pipe Replacement). 2. Remove the transmission. Refer to Transmission Replacement (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Service and Repair). 3. Remove the exhaust heat shield nuts (2) and heat shield (3) from the dash panel. 4. Remove the exhaust pipe heat shield bolts and shield. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust Manifold Pipe Replacement > Page 3878 5. Remove the exhaust pipe bolts in the sequence shown. 6. Remove the exhaust pipe and gaskets. Discard the gaskets. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust Manifold Pipe Replacement > Page 3879 1. Position the exhaust pipe to the turbocharger and the exhaust manifold. 2. Install a NEW gasket (1) to the turbocharger with the tab (2) facing outward. Important: Position the exhaust pipe gaskets with the tabs shown. Failure to do so will cause improper alignment of the gaskets and result in exhaust leaks. 3. Loosely install the exhaust pipe to turbocharger bolts. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust Manifold Pipe Replacement > Page 3880 4. Position the exhaust pipe with a NEW gasket (1) to the exhaust manifold. Align the tabs (2) on the gasket to face outward. Important: Position the exhaust pipe gaskets with the tabs shown. Failure to do so will cause improper alignment of the gaskets and result in exhaust leaks. 5. Loosely install the exhaust pipe to exhaust manifold bolts. Left Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 6. Tighten the exhaust pipe bolts in the sequence shown to 53 Nm (39 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust Manifold Pipe Replacement > Page 3881 7. Install the exhaust pipe heat shield bolts and tighten to 10 Nm (89 lb in). 8. Install the left side exhaust heat shield (3) at the dash panel. 9. Install the heat shield nuts (2) and tighten to 9 Nm (80 lb in). 10. Install the transmission. Refer to Transmission Replacement (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Service and Repair). 11. Install the turbocharger exhaust pipe. Refer to Turbocharger Exhaust Pipe Replacement (6.6L) (See: Turbocharger Exhaust Pipe Replacement). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust Manifold Pipe Replacement > Page 3882 Exhaust Pipe: Service and Repair Exhaust Pipe Replacement - Right Side Exhaust Pipe Replacement - Right Side Removal Procedure 1. Remove the turbocharger exhaust pipe. Refer to Turbocharger Exhaust Pipe Replacement (6.6L) (See: Turbocharger Exhaust Pipe Replacement). 2. Remove the upper exhaust gas recirculation cooling pipe. Refer to Exhaust Gas Recirculation Coolant Hoses/Pipes Replacement (See: Powertrain Management/Emission Control Systems/Exhaust Gas Recirculation/EGR Cooler/Service and Repair/Exhaust Gas Recirculation Coolant Hoses/Pipes Replacement). 3. Remove the exhaust pipe bolts in the proper sequence. 4. Remove the exhaust pipe, bracket and gaskets. Discard the gaskets. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust Manifold Pipe Replacement > Page 3883 Installation Procedure 1. Position the exhaust pipe with a NEW gasket to the turbocharger, EGR cooler and the exhaust manifold. 2. Install a NEW gasket (1) to turbocharger and align the tab (2) to face outward. 3. Loosely install the exhaust pipe to turbocharger bolts. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust Manifold Pipe Replacement > Page 3884 4. Position the exhaust pipe with a NEW gasket (1) to the exhaust manifold. Align the tabs (2) on the gasket to face downward. 5. Loosely install the exhaust pipe to exhaust manifold bolts. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 6. Tighten the exhaust pipe bolts in the sequence shown to 53 Nm (39 lb ft). 7. Install the upper exhaust gas recirculation cooling pipe. Refer to Exhaust Gas Recirculation Coolant Hoses/Pipes Replacement (See: Powertrain Management/Emission Control Systems/Exhaust Gas Recirculation/EGR Cooler/Service and Repair/Exhaust Gas Recirculation Coolant Hoses/Pipes Replacement). 8. Install the turbocharger exhaust pipe. Refer to Turbocharger Exhaust Pipe Replacement (6.6L) (See: Turbocharger Exhaust Pipe Replacement). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Service and Repair Exhaust Pipe/Muffler Hanger: Service and Repair Exhaust Hanger Mounting Bracket Replacement (without L96/E63/ZW9) Removal Procedure 1. If equipped with a 6.0L engine, remove the exhaust manifold pipe. Refer to Exhaust Manifold Pipe Replacement (See: Exhaust Pipe/Service and Repair/Exhaust Manifold Pipe Replacement). 2. If equipped with a 6.0L engine, remove the left catalytic converter. Refer to Catalytic Converter Replacement - Left Side (Cab Chassis) (See: Catalytic Converter/Service and Repair). 3. If equipped with a 6.6L engine, remove the catalytic converter. Refer to Catalytic Converter Replacement (LY6 with Exhaust Flange) (See: Catalytic Converter/Service and Repair)Catalytic Converter Replacement (L9H with Exhaust Flange) (See: Catalytic Converter/Service and Repair)Catalytic Converter Replacement (Gen IV Engines with Exhaust Clamp) (See: Catalytic Converter/Service and Repair)Catalytic Converter Replacement (LFA with Exhaust Clamp) (See: Catalytic Converter/Service and Repair)Catalytic Converter Replacement (LMM) ( See: Catalytic Converter/Service and Repair). 4. If equipped with a 4L80-E automatic transmission, regular production option (RPO) MT1, remove the exhaust pipe hanger bracket bolts and bracket. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Service and Repair > Page 3888 5. If equipped with a Allison(R) automatic transmission, RPO MW7, remove the exhaust pipe hanger bracket bolt/stud and bracket. 6. If equipped with a 6L90-E automatic transmission, RPO MYD, remove the exhaust pipe hanger bracket bolts and bracket. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Service and Repair > Page 3889 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. If equipped with a 6L90-E automatic transmission, RPO MYD, install the exhaust pipe hanger bracket and bolts and tighten to 25 Nm (18 lb ft). 2. If equipped with a Allison(R) automatic transmission, RPO MW7, install the exhaust pipe hanger bracket and bolt/stud and tighten to 25 Nm (18 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Service and Repair > Page 3890 3. If equipped with a 4L80-E automatic transmission, RPO MT1, install the exhaust pipe hanger bracket and bolts and tighten to 25 Nm (18 lb ft). 4. If equipped with a 6.6L engine, install the catalytic converter. Refer to Catalytic Converter Replacement (LY6 with Exhaust Flange) (See: Catalytic Converter/Service and Repair)Catalytic Converter Replacement (L9H with Exhaust Flange) (See: Catalytic Converter/Service and Repair)Catalytic Converter Replacement (Gen IV Engines with Exhaust Clamp) (See: Catalytic Converter/Service and Repair)Catalytic Converter Replacement (LFA with Exhaust Clamp) (See: Catalytic Converter/Service and Repair)Catalytic Converter Replacement (LMM) ( See: Catalytic Converter/Service and Repair). 5. If equipped with a 6.0L engine, install the left catalytic converter. Refer to Catalytic Converter Replacement - Left Side (Cab Chassis) (See: Catalytic Converter/Service and Repair). 6. If equipped with a 6.0L engine, install the exhaust manifold pipe. Refer to Exhaust Manifold Pipe Replacement (See: Exhaust Pipe/Service and Repair/Exhaust Manifold Pipe Replacement). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Service and Repair > Exhaust Manifold Heat Shield Replacement - Right Side Heat Shield: Service and Repair Exhaust Manifold Heat Shield Replacement - Right Side Exhaust Manifold Heat Shield Replacement - Right Side (V8) Removal Procedure 1. Remove the right wheelhouse liner. Refer to Front Wheelhouse Liner Replacement - Right Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side)Front Wheelhouse Liner Replacement - Right Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side). 2. Remove the exhaust manifold heat shield bolts and heat shield from the exhaust manifold. Installation Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Service and Repair > Exhaust Manifold Heat Shield Replacement - Right Side > Page 3895 1. Position the exhaust manifold heat shield to the exhaust manifold and install the heat shield bolts. Tighten the bolts to 9 Nm (80 lb in). 2. Install the right wheelhouse liner. Refer to Front Wheelhouse Liner Replacement - Right Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side)Front Wheelhouse Liner Replacement - Right Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Service and Repair > Exhaust Manifold Heat Shield Replacement - Right Side > Page 3896 Heat Shield: Service and Repair Exhaust Manifold Heat Shield Replacement - Left Side Exhaust Manifold Heat Shield Replacement - Left Side (V8) Removal Procedure 1. Remove the right wheelhouse liner. Refer to Front Wheelhouse Liner Replacement - Right Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side)Front Wheelhouse Liner Replacement - Right Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side). 2. Remove the exhaust manifold heat shield bolts and heat shield from the exhaust manifold. Installation Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Service and Repair > Exhaust Manifold Heat Shield Replacement - Right Side > Page 3897 1. Position the exhaust manifold heat shield to the exhaust manifold and install the heat shield bolts. Tighten the bolts to 9 Nm (80 lb in). 2. Install the right wheelhouse liner. Refer to Front Wheelhouse Liner Replacement - Right Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side)Front Wheelhouse Liner Replacement - Right Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Service and Repair > Exhaust Manifold Heat Shield Replacement - Right Side > Page 3898 Heat Shield: Service and Repair Floor Panel Heat Shield Replacement Floor Panel Heat Shield Replacement Removal Procedure 1. Remove the catalytic converter. Refer to Catalytic Converter Replacement (LY6 with Exhaust Flange) (See: Catalytic Converter/Service and Repair)Catalytic Converter Replacement (L9H with Exhaust Flange) (See: Catalytic Converter/Service and Repair)Catalytic Converter Replacement (Gen IV Engines with Exhaust Clamp) (See: Catalytic Converter/Service and Repair)Catalytic Converter Replacement (LFA with Exhaust Clamp) (See: Catalytic Converter/Service and Repair)Catalytic Converter Replacement (LMM) (See: Catalytic Converter/Service and Repair). 2. If vehicle has a regular cab, remove the exhaust heat shield nuts. 3. Remove the exhaust front heat shield (1) and/or the rear exhaust heat shield (2) from the studs. 4. If vehicle has extended cab, remove the exhaust heat shield nuts. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Service and Repair > Exhaust Manifold Heat Shield Replacement - Right Side > Page 3899 5. Remove the exhaust front heat shield (1) and/or the rear exhaust heat shield (2) from the studs. 6. If vehicle has a crew cab, remove the exhaust heat shield nuts. 7. Remove the exhaust front heat shield (1) and/or the rear exhaust heat shield (2) from the studs. Installation Procedure 1. If vehicle has a crew cab, position and install the rear exhaust heat shield (2) and/or the front exhaust heat shield (1) to the underbody studs. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the exhaust heat shield nuts and tighten to 9 Nm (80 lb in). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Service and Repair > Exhaust Manifold Heat Shield Replacement - Right Side > Page 3900 3. If vehicle has a extended cab, position and install the rear exhaust heat shield (2) and/or the front exhaust heat shield (1) to the underbody studs. 4. Install the exhaust heat shield nuts and tighten to 9 Nm (80 lb in). 5. If vehicle has a regular cab, position and install the rear exhaust heat shield (2) and/or the front exhaust heat shield (1) to the studs. 6. Install the exhaust heat shield nuts and tighten to 9 Nm (80 lb in). 7. Install the catalytic converter. Refer to Catalytic Converter Replacement (LY6 with Exhaust Flange) (See: Catalytic Converter/Service and Repair)Catalytic Converter Replacement (L9H with Exhaust Flange) (See: Catalytic Converter/Service and Repair)Catalytic Converter Replacement (Gen IV Engines with Exhaust Clamp) (See: Catalytic Converter/Service and Repair)Catalytic Converter Replacement (LFA with Exhaust Clamp) (See: Catalytic Converter/Service and Repair)Catalytic Converter Replacement (LMM) (See: Catalytic Converter/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Service and Repair > Exhaust Manifold Heat Shield Replacement - Right Side > Page 3901 Heat Shield: Service and Repair Exhaust Heat Shield Replacement - Dash Panel Exhaust Heat Shield Replacement - Dash Panel Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the exhaust heat shield nuts. 3. Remove both wheelhouse panels. Refer to Front Wheelhouse Liner Replacement - Right Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side)Front Wheelhouse Liner Replacement - Right Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side) and Front Wheelhouse Liner Replacement - Left Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Left Side)Front Wheelhouse Liner Replacement - Left Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Left Side). 4. Remove the exhaust heat shield (1, 3) from the dash panel studs. 5. Remove the heat shield (1, 3) through the respective wheelwell. Installation Procedure 1. Install the heat shields (1, 3) through the respective wheelwell. 2. Install the exhaust heat shield (1, 3) to the dash panel studs. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the exhaust heat shield nuts and tighten to 9 Nm (80 lb in). 4. Lower the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Exhaust Muffler Replacement Muffler: Service and Repair Exhaust Muffler Replacement Exhaust Muffler Replacement (6.6L) Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the spare tire, if necessary. 3. Install adjustable jack stands under the rear axle, if necessary. 4. Remove the rear axle vent hose from the rear axle, if necessary. 5. Remove the vent hose swivel clip from the rear brake crossover pipe, if necessary. 6. Remove the rear shock absorbers lower bolts and nuts, if necessary. 7. Lower the rear axle using the adjustable jack stands, if necessary. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Exhaust Muffler Replacement > Page 3906 8. Remove the exhaust muffler to exhaust particulate filter nuts (1). 9. With the aid of an assistant, support the exhaust muffler. 10. Remove the exhaust muffler hangers from the exhaust insulators (1). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Exhaust Muffler Replacement > Page 3907 11. Remove the exhaust muffler. (2500/3500 crew cab shown, regular/extended cabs similar). 12. Remove and discard the exhaust particulate filter to muffler gasket. Installation Procedure 1. Install a NEW gasket onto the exhaust muffler studs. 2. Install the exhaust muffler to the particulate filter. 3. With the aid of an assistant, support the exhaust muffler. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Exhaust Muffler Replacement > Page 3908 4. Install the exhaust muffler hangers to the exhaust insulators (1). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Install the exhaust muffler to exhaust particulate filter nuts (1) and tighten to 45 Nm (33 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Exhaust Muffler Replacement > Page 3909 6. Raise the rear axle using the adjustable jack stands, if necessary. 7. Install the rear shock absorbers lower bolts and nuts, if necessary and tighten to 95 Nm (70 lb ft). 8. Install the rear axle vent hose to the rear axle, if necessary. 9. Connect the vent hose swivel clip to the rear brake crossover pipe, if necessary. 10. Remove the adjustable jack stands from under the rear axle, if necessary. 11. Install the spare tire, if necessary. 12. Lower the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Exhaust Muffler Replacement > Page 3910 Muffler: Service and Repair Exhaust Muffler Replacement (Cab Chassis) Exhaust Muffler Replacement (Cab Chassis and 6.0L) Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the spare tire, if necessary. 3. Install adjustable jack stands under the rear axle, if necessary. 4. If equipped with a 8.6 or a 9.5 inch ring gear, remove the rear axle vent hose from the rear axle, if necessary. 5. Remove the vent hose swivel clip from the rear brake crossover pipe, if necessary. 6. If equipped with a 10.5 inch ring gear, remove the rear axle vent hose from the rear axle, if necessary. 7. Remove the vent hose swivel clip from the rear brake crossover pipe, if necessary. 8. Remove the rear shock absorber lower bolts and nuts, if necessary. 9. Lower the rear axle using the adjustable jack stands, if necessary. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Exhaust Muffler Replacement > Page 3911 10. Remove the exhaust muffler to exhaust manifold pipe nuts (1). 11. Loosen the exhaust muffler clamp (3). 12. Remove the heated oxygen sensor (HO2S). Refer to Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 (2500 Series - Cab/Chassis) ()Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 (2500 Series) ()Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 (1500 Series) (). 13. Lubricate the 4 insulators where the muffler assembly hangers are inserted in order to ease removal. 14. With the aid of an assistant, remove the insulators (1-4) from the front, intermediate, and rear muffler assembly hangers and remove the muffler assembly. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Exhaust Muffler Replacement > Page 3912 1. Lubricate the 4 insulators where the muffler assembly hangers are inserted in order to ease installation. 2. With the aid of an assistant, position and install the muffler assembly. 3. Install the insulators (1-4) to the front, intermediate, and rear muffler assembly hangers. 4. Install the HO2S. Refer to Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 (2500 Series - Cab/Chassis) ()Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 (2500 Series) ()Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 (1500 Series) (). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Tighten the exhaust muffler clamp (3) to 47 Nm (35 lb ft). 6. Install the exhaust muffler to exhaust manifold pipe nuts (1) and tighten to 45 Nm (33 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Exhaust Muffler Replacement > Page 3913 7. Raise the rear axle using the adjustable jack stands, if necessary. 8. Install the rear shock absorber lower bolts and nuts, if necessary and tighten to 95 Nm (70 lb ft). 9. If equipped with a 10.5 inch ring gear, install the rear axle vent hose to the rear axle, if necessary. 10. Connect the vent hose swivel clip to the rear brake crossover pipe, if necessary. 11. If equipped with a 8.6 or a 9.5 inch ring gear, install the rear axle vent hose to the rear axle, if necessary. 12. Install the vent hose swivel clip to the rear brake crossover pipe, if necessary. 13. Remove the adjustable jack stands from under the rear axle, if necessary. 14. Install the spare tire, if necessary. 15. Lower the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Seals and Gaskets, Exhaust > Exhaust Pipe Gasket > Component Information > Service and Repair > Exhaust Seal Replacement Exhaust Pipe Gasket: Service and Repair Exhaust Seal Replacement Exhaust Seal Replacement (V8) Removal Procedure 1. Remove the catalytic converter. Refer to Catalytic Converter Replacement (LY6 with Exhaust Flange) (See: Catalytic Converter/Service and Repair)Catalytic Converter Replacement (L9H with Exhaust Flange) (See: Catalytic Converter/Service and Repair)Catalytic Converter Replacement (Gen IV Engines with Exhaust Clamp) (See: Catalytic Converter/Service and Repair)Catalytic Converter Replacement (LFA with Exhaust Clamp) (See: Catalytic Converter/Service and Repair)Catalytic Converter Replacement (LMM) (See: Catalytic Converter/Service and Repair). 2. Remove and discard the appropriate exhaust seal (1 or 2). (1500 series shown, 2500 series similar). Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Seals and Gaskets, Exhaust > Exhaust Pipe Gasket > Component Information > Service and Repair > Exhaust Seal Replacement > Page 3919 1. Install the NEW appropriate exhaust seal (1 or 2). (1500 series shown, 2500 series similar). 2. Install the catalytic converter. Refer to Catalytic Converter Replacement (LY6 with Exhaust Flange) (See: Catalytic Converter/Service and Repair)Catalytic Converter Replacement (L9H with Exhaust Flange) (See: Catalytic Converter/Service and Repair)Catalytic Converter Replacement (Gen IV Engines with Exhaust Clamp) (See: Catalytic Converter/Service and Repair)Catalytic Converter Replacement (LFA with Exhaust Clamp) (See: Catalytic Converter/Service and Repair)Catalytic Converter Replacement (LMM) (See: Catalytic Converter/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Seals and Gaskets, Exhaust > Exhaust Pipe Gasket > Component Information > Service and Repair > Exhaust Seal Replacement > Page 3920 Exhaust Pipe Gasket: Service and Repair Exhaust Seal Replacement (ZW9 Cab Chassis) Exhaust Seal Replacement (ZW9 Cab Chassis) Removal Procedure 1. Remove the left catalytic converter, if required. Refer to Catalytic Converter Replacement - Left Side (Cab Chassis) (See: Catalytic Converter/Service and Repair). 2. Remove the exhaust manifold pipe, if required. Refer to Exhaust Manifold Pipe Replacement (See: Exhaust Pipe/Service and Repair/Exhaust Manifold Pipe Replacement). 3. Remove and discard the appropriate exhaust seal (1) or gasket (2). Installation Procedure 1. Install the NEW appropriate exhaust seal (1) or gasket (2). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Seals and Gaskets, Exhaust > Exhaust Pipe Gasket > Component Information > Service and Repair > Exhaust Seal Replacement > Page 3921 2. Install the exhaust manifold pipe, if required. Refer to Exhaust Manifold Pipe Replacement (See: Exhaust Pipe/Service and Repair/Exhaust Manifold Pipe Replacement). 3. Install the left catalytic converter, if required. Refer to Catalytic Converter Replacement - Left Side (Cab Chassis) (See: Catalytic Converter/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Technical Service Bulletins > Recalls for Exhaust Temperature Sensor: > 11054 > Apr > 11 > Recall - Replace Exhaust Gas Temperature Sensor Technical Service Bulletin # 11054 Date: 110412 Recall - Replace Exhaust Gas Temperature Sensor PRODUCT EMISSION Bulletin No.: 11054 Date: April 12, 2011 Subject: 11054 - Reduced Engine Performance and Emission Control - Replace Exhaust Gas Temperature Sensors Models: 2010 Chevrolet Express, Silverado HD 2010 GMC Savana, Sierra HD With 6.6L V8 Duramax Diesel Engine (LMM) 2007-2009 Chevrolet Express, Kodiak, Silverado HD 2007-2009 GMC Savana, Sierra HD, TopKick With 6.6L V8 Duramax Diesel Engine (LMM) Serviced with a Suspect EGT Sensor Condition General Motors has decided to conduct a Voluntary Emission Recall involving certain 2010 model year Chevrolet Express, Silverado HD; and GMC Savana, Sierra HD vehicles equipped with a 6.6L V8 Duramax diesel engine (LMM); and 2007-2009 model year Chevrolet Express, Kodiak, Silverado HD; and GMC Savana, Sierra HD, and TopKick vehicles equipped with a 6.6L V8 Duramax diesel engine (LMM) that may have been serviced with a suspect Exhaust Gas Temperature (EGT) sensor. On these vehicles, the circuit board welds on the EGT sensors in the exhaust system may not be to GM specification. If a weld fails, the Service Engine Soon light will illuminate in the instrument panel, the exhaust gas may not be filtered properly, and the engine power may be reduced. Correction Dealers are to replace both EGT sensors. Vehicles Involved Involved are certain 2010 model year Chevrolet Express, Silverado HD; and GMC Savana, Sierra HD vehicles equipped with a 6.6L V8 Duramax diesel engine (LMM); and 2007-2009 model year Chevrolet Express, Kodiak, Silverado HD; and GMC Savana, Sierra HD, and TopKick vehicles equipped with a 6.6L V8 Duramax diesel engine (LMM) that may have been serviced with a suspect EGT sensor. Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Required Field Actions section in the Global Warranty system. Not all vehicles may be involved. For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to US and Canadian dealers through the GM GlobalConnect Recall Reports, or sent directly to export dealers. Dealers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information Parts required to complete this recall are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Service Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Technical Service Bulletins > Recalls for Exhaust Temperature Sensor: > 11054 > Apr > 11 > Recall - Replace Exhaust Gas Temperature Sensor > Page 3931 1. Remove and replace position 1 and position 2 exhaust gas temperature sensors (1). Refer to Exhaust Temperature Sensor Replacement in SI. 2. CALIFORNIA, CONNECTICUT, MASSACHUSETTS, MAINE, OREGON, VERMONT, & WASHINGTON VEHICLES ONLY: Install a Recall Identification Label. Also, for California vehicles complete a "Proof of Correction" certificate upon recall completion. Recall Identification Label California/Connecticut/Massachusetts/Maine/Oregon/Vermont/Washington Vehicles Only) Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five-digit dealer code of the dealer performing the recall service. This information may be inserted with a ballpoint pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Recall Identification Label, be sure to pull the tab to allow adhesion of the clear protective covering. Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials by ordering on the web from DWD Store, www.gmdealerworld.com, and then click on the DWD Store link. Request Item Number S-1015 when ordering. Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a transaction using the table below. Customer Notification - For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter included with this bulletin). In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper maintenance. The vehicle may fail a state or local emission inspection test if the recall work is not completed. Customer Notification - For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the attached sample letter. In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Technical Service Bulletins > Recalls for Exhaust Temperature Sensor: > 11054 > Apr > 11 > Recall - Replace Exhaust Gas Temperature Sensor > Page 3932 maintenance. The vehicle may fail a state or local emission inspection test if the recall work is not completed. Dealer Recall Responsibility All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. ***THE FOLLOWING 2 PARAGRAPHS ARE NOT FOR CANADA OR EXPORT*** When a California emissions recall is completed by a GM dealer, the dealer must provide the vehicle owner a "Proof of Correction Certificate" which the owner may need to present to the California Department Of Motor Vehicles (DMV) when renewing their vehicle registration. Without this correction certificate, the owner may be unable to renew their vehicle registration. Additional Certificates can be obtained, at no charge, from Dealer Support Materials by ordering on the web from the DWD Store, www.gmdealerworld.com, and then click on the DWD Store link; request GM Item Number 1825 when ordering. Disclaimer Owner Letter Owner Letter Dear General Motors Customer: This notice is sent to inform you that General Motors is conducting a voluntary emission recall that includes your vehicle. Reason For This Recall: General Motors has decided to conduct a Voluntary Emission Recall involving certain 2010 model year Chevrolet Express, Silverado HD; and GMC Savana, Sierra HD vehicles equipped with a 6.6L V8 Duramax diesel engine; and 2007-2009 model year Chevrolet Express, Kodiak, Silverado HD; and GMC Savana, Sierra HD, and TopKick vehicles equipped with a 6.6L V8 Duramax diesel engine that may have been serviced with a suspect Exhaust Gas Temperature (EGT) sensor. The circuit board welds on the EGT sensors in the exhaust system may not be to GM specification. If a weld fails, the Service Engine Soon light will illuminate in the instrument panel, the exhaust gas may not be filtered properly, and the engine power may be reduced. What Will Be Done: Your GM dealer will replace both EGT sensors. This service will be performed for you at no charge. What You Should Do: Please contact your GM dealer as soon as possible to arrange a service date and to assure parts availability. Instructions for making this correction have been sent to your dealer. Please ask your dealer if you wish to know how much time will be needed to schedule, process, and repair your vehicle. If you have any questions or need any assistance, just contact your dealer or the appropriate Customer Assistance Center at the number listed below. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Technical Service Bulletins > Recalls for Exhaust Temperature Sensor: > 11054 > Apr > 11 > Recall - Replace Exhaust Gas Temperature Sensor > Page 3933 Emission Law Information: In order to ensure your full protection under the emission warranty made applicable to your vehicle by State and Federal Law, and your right to participate in future recalls, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could legally be determined to be lack of proper maintenance of your vehicle. Also, your vehicle may fail a state or local emission inspection if this recall is not accomplished. IMPORTANT MESSAGE FOR CALIFORNIA RESIDENTS The California Air Resources Board (CARB) requires vehicle emission recalls be completed prior to California registration renewal. Uncorrected emission recalls will result in the inability to renew your California vehicle registration. At the time of emission recall completion, your California dealer will issue a "Proof of Correction Certificate". Keep this certificate and, if required, present it to the Department of Motor Vehicles when renewing your California registration as proof of recall completion. We are sorry to cause you this inconvenience; however, we have taken this action in the interest of your continued satisfaction with our products. Jim Moloney General Director, Customer and Relationship Services 11054 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exhaust Temperature Sensor: > 11054 > Apr > 11 > Recall - Replace Exhaust Gas Temperature Sensor Technical Service Bulletin # 11054 Date: 110412 Recall - Replace Exhaust Gas Temperature Sensor PRODUCT EMISSION Bulletin No.: 11054 Date: April 12, 2011 Subject: 11054 - Reduced Engine Performance and Emission Control - Replace Exhaust Gas Temperature Sensors Models: 2010 Chevrolet Express, Silverado HD 2010 GMC Savana, Sierra HD With 6.6L V8 Duramax Diesel Engine (LMM) 2007-2009 Chevrolet Express, Kodiak, Silverado HD 2007-2009 GMC Savana, Sierra HD, TopKick With 6.6L V8 Duramax Diesel Engine (LMM) Serviced with a Suspect EGT Sensor Condition General Motors has decided to conduct a Voluntary Emission Recall involving certain 2010 model year Chevrolet Express, Silverado HD; and GMC Savana, Sierra HD vehicles equipped with a 6.6L V8 Duramax diesel engine (LMM); and 2007-2009 model year Chevrolet Express, Kodiak, Silverado HD; and GMC Savana, Sierra HD, and TopKick vehicles equipped with a 6.6L V8 Duramax diesel engine (LMM) that may have been serviced with a suspect Exhaust Gas Temperature (EGT) sensor. On these vehicles, the circuit board welds on the EGT sensors in the exhaust system may not be to GM specification. If a weld fails, the Service Engine Soon light will illuminate in the instrument panel, the exhaust gas may not be filtered properly, and the engine power may be reduced. Correction Dealers are to replace both EGT sensors. Vehicles Involved Involved are certain 2010 model year Chevrolet Express, Silverado HD; and GMC Savana, Sierra HD vehicles equipped with a 6.6L V8 Duramax diesel engine (LMM); and 2007-2009 model year Chevrolet Express, Kodiak, Silverado HD; and GMC Savana, Sierra HD, and TopKick vehicles equipped with a 6.6L V8 Duramax diesel engine (LMM) that may have been serviced with a suspect EGT sensor. Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Required Field Actions section in the Global Warranty system. Not all vehicles may be involved. For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to US and Canadian dealers through the GM GlobalConnect Recall Reports, or sent directly to export dealers. Dealers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information Parts required to complete this recall are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Service Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exhaust Temperature Sensor: > 11054 > Apr > 11 > Recall - Replace Exhaust Gas Temperature Sensor > Page 3939 1. Remove and replace position 1 and position 2 exhaust gas temperature sensors (1). Refer to Exhaust Temperature Sensor Replacement in SI. 2. CALIFORNIA, CONNECTICUT, MASSACHUSETTS, MAINE, OREGON, VERMONT, & WASHINGTON VEHICLES ONLY: Install a Recall Identification Label. Also, for California vehicles complete a "Proof of Correction" certificate upon recall completion. Recall Identification Label California/Connecticut/Massachusetts/Maine/Oregon/Vermont/Washington Vehicles Only) Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five-digit dealer code of the dealer performing the recall service. This information may be inserted with a ballpoint pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Recall Identification Label, be sure to pull the tab to allow adhesion of the clear protective covering. Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials by ordering on the web from DWD Store, www.gmdealerworld.com, and then click on the DWD Store link. Request Item Number S-1015 when ordering. Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a transaction using the table below. Customer Notification - For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter included with this bulletin). In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper maintenance. The vehicle may fail a state or local emission inspection test if the recall work is not completed. Customer Notification - For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the attached sample letter. In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exhaust Temperature Sensor: > 11054 > Apr > 11 > Recall - Replace Exhaust Gas Temperature Sensor > Page 3940 maintenance. The vehicle may fail a state or local emission inspection test if the recall work is not completed. Dealer Recall Responsibility All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. ***THE FOLLOWING 2 PARAGRAPHS ARE NOT FOR CANADA OR EXPORT*** When a California emissions recall is completed by a GM dealer, the dealer must provide the vehicle owner a "Proof of Correction Certificate" which the owner may need to present to the California Department Of Motor Vehicles (DMV) when renewing their vehicle registration. Without this correction certificate, the owner may be unable to renew their vehicle registration. Additional Certificates can be obtained, at no charge, from Dealer Support Materials by ordering on the web from the DWD Store, www.gmdealerworld.com, and then click on the DWD Store link; request GM Item Number 1825 when ordering. Disclaimer Owner Letter Owner Letter Dear General Motors Customer: This notice is sent to inform you that General Motors is conducting a voluntary emission recall that includes your vehicle. Reason For This Recall: General Motors has decided to conduct a Voluntary Emission Recall involving certain 2010 model year Chevrolet Express, Silverado HD; and GMC Savana, Sierra HD vehicles equipped with a 6.6L V8 Duramax diesel engine; and 2007-2009 model year Chevrolet Express, Kodiak, Silverado HD; and GMC Savana, Sierra HD, and TopKick vehicles equipped with a 6.6L V8 Duramax diesel engine that may have been serviced with a suspect Exhaust Gas Temperature (EGT) sensor. The circuit board welds on the EGT sensors in the exhaust system may not be to GM specification. If a weld fails, the Service Engine Soon light will illuminate in the instrument panel, the exhaust gas may not be filtered properly, and the engine power may be reduced. What Will Be Done: Your GM dealer will replace both EGT sensors. This service will be performed for you at no charge. What You Should Do: Please contact your GM dealer as soon as possible to arrange a service date and to assure parts availability. Instructions for making this correction have been sent to your dealer. Please ask your dealer if you wish to know how much time will be needed to schedule, process, and repair your vehicle. If you have any questions or need any assistance, just contact your dealer or the appropriate Customer Assistance Center at the number listed below. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exhaust Temperature Sensor: > 11054 > Apr > 11 > Recall - Replace Exhaust Gas Temperature Sensor > Page 3941 Emission Law Information: In order to ensure your full protection under the emission warranty made applicable to your vehicle by State and Federal Law, and your right to participate in future recalls, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could legally be determined to be lack of proper maintenance of your vehicle. Also, your vehicle may fail a state or local emission inspection if this recall is not accomplished. IMPORTANT MESSAGE FOR CALIFORNIA RESIDENTS The California Air Resources Board (CARB) requires vehicle emission recalls be completed prior to California registration renewal. Uncorrected emission recalls will result in the inability to renew your California vehicle registration. At the time of emission recall completion, your California dealer will issue a "Proof of Correction Certificate". Keep this certificate and, if required, present it to the Department of Motor Vehicles when renewing your California registration as proof of recall completion. We are sorry to cause you this inconvenience; however, we have taken this action in the interest of your continued satisfaction with our products. Jim Moloney General Director, Customer and Relationship Services 11054 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Service and Repair > Exhaust Temperature Sensor Replacement - Position 1 Exhaust Temperature Sensor: Service and Repair Exhaust Temperature Sensor Replacement Position 1 Exhaust Temperature Sensor Replacement - Position 1 Removal Procedure Caution: The exhaust temperature sensor and exhaust pressure differential sensor line fittings may be difficult to remove when the engine exhaust system temperature is below 48°C (120°F). Excessive force may damage the threads in the exhaust manifold or exhaust pipe. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the exhaust temperature sensor electrical connector (1) from the chassis wiring harness electrical connector (2). 3. Remove the exhaust temperature sensor. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Service and Repair > Exhaust Temperature Sensor Replacement - Position 1 > Page 3944 Note: A special anti-seize compound is used in the sensor or line fittings threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor or line fitting easier to remove. New, or service replacement sensors or line fittings already have the compound applied to the threads. If the sensor or line fittings are removed from an exhaust component and if for any reason the sensor or line fitting are reinstalled, the threads must have anti-seize compound applied before reinstallation. 1. If reinstalling the old temperature sensor or differential pressor sensor line fittings, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the exhaust temperature sensor. Tighten the sensor to 45 Nm (33 lb ft). 3. Connect the exhaust temperature sensor electrical connector (1) to the chassis wiring harness electrical connector (2). 4. Lower the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Service and Repair > Exhaust Temperature Sensor Replacement - Position 1 > Page 3945 Exhaust Temperature Sensor: Service and Repair Exhaust Temperature Sensor Replacement Position 2 Exhaust Temperature Sensor Replacement - Position 2 Removal Procedure Caution: The exhaust temperature sensor and exhaust pressure differential sensor line fittings may be difficult to remove when the engine exhaust system temperature is below 48°C (120°F). Excessive force may damage the threads in the exhaust manifold or exhaust pipe. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the exhaust temperature sensor (3) electrical connector from the chassis wiring harness electrical connector (4). 3. Remove the exhaust temperature sensor. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Sensors and Switches - Exhaust System > Exhaust Temperature Sensor > Component Information > Service and Repair > Exhaust Temperature Sensor Replacement - Position 1 > Page 3946 Note: A special anti-seize compound is used in the sensor or line fittings threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor or line fitting easier to remove. New, or service replacement sensors or line fittings already have the compound applied to the threads. If the sensor or line fittings are removed from an exhaust component and if for any reason the sensor or line fitting are reinstalled, the threads must have anti-seize compound applied before reinstallation. 1. If reinstalling the old temperature sensor or differential pressor sensor line fittings, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the exhaust temperature sensor. Tighten the sensor to 45 Nm (33 lb ft). 3. Connect the exhaust temperature sensor (3) electrical connector to the chassis wiring harness electrical connector (4). 4. Lower the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 07-08-42-006E > Nov > 10 > Instruments - Bulb Outage Detection Restoration Body Control Module: Customer Interest Instruments - Bulb Outage Detection Restoration INFORMATION Bulletin No.: 07-08-42-006E Date: November 11, 2010 Subject: Information on BCM Calibrations Available to Restore Bulb Outage Detection on Vehicles Produced by a Second Stage Manufacturer, Turn Signals Flash Fast after Factory Box Removed (Upfitter) Models: 2007-2011 Chevrolet Silverado 2007-2011 GMC Sierra Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 07-08-42-006D (Section 08 - Body and Accessories). The information contained in this bulletin applies to vehicles that are to be completed by a second stage manufacturer (upfitter) and may need to have the Body Control Module (BCM) rear turn signal bulb outage detection capability changed. All production vehicles will be manufactured with one of the following BCM rear turn signal bulb outage detection software options: 1. A standard production vehicle will have BCM software that checks for two bulbs functioning in each rear turn signal bulb circuit. If one or more bulbs are inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 2. Certain 2500 and 3500 models can be ordered with a new option (RPO 9U5) where the BCM checks for one bulb functioning in each rear turn signal bulb circuit. If the bulb goes inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 3. A vehicle built with a pickup box delete or chassis cab option (RPO ZW9) will be produced with a BCM program that has no turn signal bulb outage detection capability (LED compatible). The IPC turn signal indicator will flash at the same rate no matter how many turn signal bulbs are inoperative. In some cases, the upfitter may wish to change the turn signal bulb outage detection capability so that the turn signals work correctly with their upfit or to meet certain requirements. This will require contacting the Techline Customer Support Center (TCSC) to open a case and obtain a Vehicle Configuration Index (VCI) number. Advise the TCSC consultant which turn signal bulb outage detection capability is needed: 1. Factory standard production TWO bulb outage detection. 2. Optional (RPO 9U5) ONE bulb outage detection. NOTE: ONLY AVAILABLE ON CERTAIN 2007-2011 MODEL 2500 AND 3500 VEHICLES. 3. NO bulb outage detection (LED compatible). The BCM can then be reprogrammed with the correct software. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 07-08-42-006E > Nov > 10 > Instruments - Bulb Outage Detection Restoration Body Control Module: All Technical Service Bulletins Instruments - Bulb Outage Detection Restoration INFORMATION Bulletin No.: 07-08-42-006E Date: November 11, 2010 Subject: Information on BCM Calibrations Available to Restore Bulb Outage Detection on Vehicles Produced by a Second Stage Manufacturer, Turn Signals Flash Fast after Factory Box Removed (Upfitter) Models: 2007-2011 Chevrolet Silverado 2007-2011 GMC Sierra Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 07-08-42-006D (Section 08 - Body and Accessories). The information contained in this bulletin applies to vehicles that are to be completed by a second stage manufacturer (upfitter) and may need to have the Body Control Module (BCM) rear turn signal bulb outage detection capability changed. All production vehicles will be manufactured with one of the following BCM rear turn signal bulb outage detection software options: 1. A standard production vehicle will have BCM software that checks for two bulbs functioning in each rear turn signal bulb circuit. If one or more bulbs are inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 2. Certain 2500 and 3500 models can be ordered with a new option (RPO 9U5) where the BCM checks for one bulb functioning in each rear turn signal bulb circuit. If the bulb goes inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 3. A vehicle built with a pickup box delete or chassis cab option (RPO ZW9) will be produced with a BCM program that has no turn signal bulb outage detection capability (LED compatible). The IPC turn signal indicator will flash at the same rate no matter how many turn signal bulbs are inoperative. In some cases, the upfitter may wish to change the turn signal bulb outage detection capability so that the turn signals work correctly with their upfit or to meet certain requirements. This will require contacting the Techline Customer Support Center (TCSC) to open a case and obtain a Vehicle Configuration Index (VCI) number. Advise the TCSC consultant which turn signal bulb outage detection capability is needed: 1. Factory standard production TWO bulb outage detection. 2. Optional (RPO 9U5) ONE bulb outage detection. NOTE: ONLY AVAILABLE ON CERTAIN 2007-2011 MODEL 2500 AND 3500 VEHICLES. 3. NO bulb outage detection (LED compatible). The BCM can then be reprogrammed with the correct software. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 09-08-47-001A > Jun > 10 > Body Controls - Unable To Reprogram Body Control Module Body Control Module: All Technical Service Bulletins Body Controls - Unable To Reprogram Body Control Module INFORMATION Bulletin No.: 09-08-47-001A Date: June 14, 2010 Subject: Unable to Reprogram Body Control Module (BCM), BCM Reprogramming Did Not Complete - Revised Reprogramming Instructions Models: 2006-2010 Buick Lucerne 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX 2008-2010 Cadillac CTS 2010 Cadillac CTS Wagon 2010 Chevrolet Camaro 2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Impala 2007-2010 Chevrolet Avalanche, Equinox, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet Traverse 2007-2010 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2008-2010 GMC Savana 2010 GMC Terrain 2007-2009 Pontiac Torrent 2008-2009 Pontiac G8 2008-2009 HUMMER H2 2007-2009 Saturn OUTLOOK 2008-2009 Saturn VUE Refer to GMVIS Supercede: This bulletin is being revised to update the models and the model years. Please discard Corporate Bulletin Number 09-08-47-001 (Section 08 - Body and Accessories). Some technicians may experience an unsuccessful body control module (BCM) reprogramming event, when choosing the Reprogram ECU selection on the Service Programming System (SPS). The technician may also notice that when attempting to reprogram the BCM again after this incident has occurred, the BCM may not complete the programming event. This condition may be caused by the following: - A reprogramming event that was interrupted due to a lack of communication between the vehicle and the TIS2WEB terminal. - The vehicle experienced low system voltage during the reprogramming event. Important Do not replace the BCM for this condition. SPS Programming Process Selection Perform this procedure first. 1. If reprogramming has failed during the initial reprogramming event, back out of the SPS application completely. 2. Re-select SPS from the TIS2WEB terminal application. 3. When selecting the Programming Process , choose Replace and Program ECU , even though a new BCM is NOT being installed. 4. Reprogram the BCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the SPS procedures in SI. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 09-08-47-001A > Jun > 10 > Body Controls - Unable To Reprogram Body Control Module > Page 3967 During programming, the battery voltage must be maintained within the proper range of 12-15 volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. BCM Still Fails to Reprogram If the BCM still fails to reprogram perform this procedure: 1. Turn OFF the ignition, and remove the key. 2. Remove the fuses that power up the following modules/components for a minimum of 2 minutes: - BCM - EBCM - ECM - IS LPS (located in the left IP fusebox) - TCM 3. Open and close the driver door. Allow enough time for the retained accessory power (RAP) to turn OFF. 4. Reinstall the fuses. 5. When selecting the Programming Process , choose Replace and Program ECU , even though a new BCM is NOT being installed. 6. Reprogram the BCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the SPS procedures in SI. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 09-08-47-001A > Jun > 10 > Body Controls - Unable To Reprogram Body Control Module Body Control Module: All Technical Service Bulletins Body Controls - Unable To Reprogram Body Control Module INFORMATION Bulletin No.: 09-08-47-001A Date: June 14, 2010 Subject: Unable to Reprogram Body Control Module (BCM), BCM Reprogramming Did Not Complete - Revised Reprogramming Instructions Models: 2006-2010 Buick Lucerne 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX 2008-2010 Cadillac CTS 2010 Cadillac CTS Wagon 2010 Chevrolet Camaro 2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Impala 2007-2010 Chevrolet Avalanche, Equinox, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet Traverse 2007-2010 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2008-2010 GMC Savana 2010 GMC Terrain 2007-2009 Pontiac Torrent 2008-2009 Pontiac G8 2008-2009 HUMMER H2 2007-2009 Saturn OUTLOOK 2008-2009 Saturn VUE Refer to GMVIS Supercede: This bulletin is being revised to update the models and the model years. Please discard Corporate Bulletin Number 09-08-47-001 (Section 08 - Body and Accessories). Some technicians may experience an unsuccessful body control module (BCM) reprogramming event, when choosing the Reprogram ECU selection on the Service Programming System (SPS). The technician may also notice that when attempting to reprogram the BCM again after this incident has occurred, the BCM may not complete the programming event. This condition may be caused by the following: - A reprogramming event that was interrupted due to a lack of communication between the vehicle and the TIS2WEB terminal. - The vehicle experienced low system voltage during the reprogramming event. Important Do not replace the BCM for this condition. SPS Programming Process Selection Perform this procedure first. 1. If reprogramming has failed during the initial reprogramming event, back out of the SPS application completely. 2. Re-select SPS from the TIS2WEB terminal application. 3. When selecting the Programming Process , choose Replace and Program ECU , even though a new BCM is NOT being installed. 4. Reprogram the BCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the SPS procedures in SI. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 09-08-47-001A > Jun > 10 > Body Controls - Unable To Reprogram Body Control Module > Page 3973 During programming, the battery voltage must be maintained within the proper range of 12-15 volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. BCM Still Fails to Reprogram If the BCM still fails to reprogram perform this procedure: 1. Turn OFF the ignition, and remove the key. 2. Remove the fuses that power up the following modules/components for a minimum of 2 minutes: - BCM - EBCM - ECM - IS LPS (located in the left IP fusebox) - TCM 3. Open and close the driver door. Allow enough time for the retained accessory power (RAP) to turn OFF. 4. Reinstall the fuses. 5. When selecting the Programming Process , choose Replace and Program ECU , even though a new BCM is NOT being installed. 6. Reprogram the BCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the SPS procedures in SI. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 3974 Body Control Module: Diagrams Component Connector End Views Body Control Module (BCM) X1 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 3975 Body Control Module (BCM) X2 Body Control Module (BCM) X3 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 3976 Body Control Module (BCM) X4 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 3977 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 3978 Body Control Module (BCM) X5 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 3979 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 3980 Body Control Module (BCM) X6 Body Control Module (BCM) X7 (except MEX or A52) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 3981 Auxiliary Body Control Module (XBCM) X1 (EXP) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 3982 Auxiliary Body Control Module (XBCM) X2 (EXP) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 3983 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Auxiliary Body Control Module Replacement Body Control Module: Service and Repair Auxiliary Body Control Module Replacement Auxiliary Body Control Module Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Auxiliary Body Control Module Replacement > Page 3986 Body Control Module: Service and Repair Body Control Module Replacement Body Control Module Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Auxiliary Body Control Module Replacement > Page 3987 Body Control Module: Service and Repair Body Control Module Bracket Replacement Body Control Module Bracket Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Auxiliary Body Control Module Replacement > Page 3988 Body Control Module: Service and Repair Serial Data Gateway Module Replacement Serial Data Gateway Module Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Power-Up/Calibration ID Engine Control Module: Technical Service Bulletins Engine Controls - Aftermarket Power-Up/Calibration ID INFORMATION Bulletin No.: 08-06-04-006H Date: February 07, 2011 Subject: Information on Identifying Non-GM ECM Calibration Usages for Duramax(TM) Diesel Engines RPOs LBZ, LLY, LMM, LML, LGH and Power-up Hardware Detection for Duramax(TM) Diesel Engine RPO LMM - Photograph Tech 2(R) Calibration IDs and Calibration Verification Numbers (CVNs) and Transmission Data Screen Before Removing Engine/Transmission/Drivetrain Components Models: 2006-2011 Chevrolet Express, Kodiak, Silverado 2006-2011 GMC Savana, Sierra, TopKick Equipped With Duramax(TM) Diesel Engine RPOs LBZ, LLY, LMM, LML, LGH Please Refer to GMVIS Attention: In order to process an engine/transmission/drivetrain hard part WARRANTY CLAIM, you MUST photograph the required Tech 2(R) screen information BEFORE disassembly or removing engine/transmission/drivetrain components from the vehicle. Supercede: This bulletin is being revised to update the model years and RPOs. Please discard Corporate Bulletin Number 08-06-04-006G (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission, diesel oxidation catalyst (DOC) and exhaust particulate filter failures that are the result of non-GM (aftermarket Power-up Kits ) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine , transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage to the powertrain and driveline components whenever the presence of a non-GM calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of first sale, or subsequently updated by GM or its dealers with approved calibrations. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different than those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM issued engine control modifications do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines procedures to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine, transmission, transfer case or rear axle components, and before disassembly, repair or replacement of an engine, transmission, transfer case or rear axle assembly under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that the diesel oxidation catalyst (DOC) needs replacement. Note BEFORE authorizing any Duramax(TM) diesel engine or transmission replacement, the PQC will require digital photographs of the following Tech 2(R) screens: - For RPOs LLY and LBZ only: Calibration ID Numbers and Verification Numbers from the Vehicle Information screen - For RPO LMM only: Calibration ID Numbers and Verification Numbers from the Vehicle Information AND the Programming History screen. - For RPO LMM only: Transmission Data screen containing the Max Transmission Calc Engine Torque parameter. Symptoms Caused by Aftermarket Power-up Kit Some customers may have reprogrammed the engine control module (ECM) with a non-GM released calibration. The Power-Up Kit engine calibration changes fueling and timing parameters and likely contributes to the following vehicle conditions: - Poor performance - Driveability concerns - Increased emissions Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Power-Up/Calibration ID > Page 3993 - Black smoke (This symptom is not valid for the Duramax(TM) diesel engine RPO LMM equipped with the exhaust particulate filter. The filter will trap black smoke unless it is cracked, melted or has been removed from the exhaust system.) - Knocking noise - Engine damage (Refer to Corporate Bulletin Number 06-06-01-007C for additional information.) 2005-2007 RPO LLY and LBZ Instructions for Confirming Calibration Verification Numbers (CVNs) - Power-up Kit Detection Important In order to process an engine/transmission/drivetrain WARRANTY CLAIM , you MUST photograph the required Tech 2(R) screen information BEFORE disassembly or removing the engine/transmission/drivetrain components from the vehicle. 1. Go to TIS2WEB 2. Select: Calibration Information (SPS Info) 3. Enter the VIN 4. Select: Get Cal ID 5. Select: ECM Engine Control Module 6. Select: Next 7. Select: Complete History 8. Print 9. Take the printout to the vehicle along with the Tech 2(R) 10. Plug in the Tech 2(R) 11. Go to diagnostics and build the vehicle 12. Select: Powertrain 13. Select: Engine 14. *Select: Engine Control Module 15. *Select: Module ID Information or I/M Information System if Module ID Information selection is not available. 16. *If: I/M Information System was selected in step 15, it may be necessary to select: Vehicle Information in order to display the calibration information. *Steps may vary by engine controller. 17. Compare the Calibration ID and Calibration Verification Number (CVN) to the CVN shown on the TIS2WEB printout. Although the part numbers will be the same for each, it is the CVN that will determine if the calibration is GM issued. The CVNs should be the same. ‹› If the CVN information is displayed as "N/A" , it will be necessary to contact the TCSC to obtain the CVN information. ‹› If the part numbers match and ANY CVNs DO NOT match the printout, it is likely that a non-GM certified calibration has been installed. ‹› If ALL of the CVNs are EXACTLY the same the calibration is GM issued. Vehicle Information Screen 18. Take clear digital picture(s) of the Tech 2(R) Vehicle Information screen(s) showing the VIN, the Calibration IDs and the Verification Numbers. Retain the printout information and the Tech 2(R) screen photographs with the repair order. 1. E-mail copies of the digital pictures to [email protected]. In the subject line of the E-mail include the phrase "Duramax(TM) diesel", the complete VIN and Dealer BAC. In the body of the E-mail include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an email reply after the calibrations have been validated. The email reply will advise the dealer if the calibrations are OEM. 2. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 3. You may call the PQC two hours after submitting the required information for authorization to replace the assembly. This will provide them time to receive, review the information and set up a case on the request. Be prepared to provide all of the usual documentation that is normally Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Power-Up/Calibration ID > Page 3994 required when requesting an assembly authorization from the PQC. 2007-2011 RPO LMM Instructions for Confirming Calibration Verification Numbers (CVNs) Power-up Kit Detection Important In order to process an engine/transmission/drivetrain WARRANTY CLAIM , you MUST photograph the required Tech 2(R) screen information BEFORE disassembly or removing the engine/transmission/drivetrain components from the vehicle. For 2007-2011 applications, an engine control module (ECM) algorithm was implemented that records the engine calibration part number and calibration verification number (CVN) for the last 10 flash programming events. The ECM records the engine calibration part number because it contains the parameters for increasing torque and fueling rates. If a vehicle comes in for service for a driveability/powertrain concern as a result of a Power-Up Kit installation, the dealership technician can read the last 10 engine calibration part numbers and CVN history using a Tech 2(R). The dealership technician will input each ECM calibration part number into the TIS2WEB/SPS CVN database to confirm the CVN history information. Refer to the following Tech 2(R) path table to verify the ECM calibrations. 1. Build the vehicle with the Tech 2(R). 2. Select F0: Engine Control Module. 3. Select F5: Module Identification Information. 4. Select F1: Programming History. 5. Turn On the ignition, with the engine Off. 6. Press the ENTER Key to Continue. Important An original production engine operation part number programmed in the ECM from the supplier, which is the last part number shown, would not be in the TIS2WEB/SPS database. 7. Record the Calibration ID Numbers and Calibration Verification Numbers from the Tech 2(R) Programming History Screen. If the list of Calibration Part Numbers is less than 10, the first Calibration ID Number (bottom of the list) will not be in TIS2WEB/SPS CVN database. In this case, the first Calibration ID Number is programmed at the ECM production factory and is reprogrammed at the vehicle assembly plant. 8. From TIS2WEB/SPS, record the Calibration Part Number into the CVN Database. Get the CVN. ‹› If the CVN DOES NOT MATCH the CVN database, an unauthorized engine calibration part WAS PROGRAMMED into the ECM. ‹› If the CVN MATCHES the CVN database, the calibration/s are GM issued and an unauthorized engine calibration part WAS NOT used. Programming History Screen 9. Take a clear digital picture of the Tech 2(R) Programming History screen showing the VIN, Calibration IDs and the CVNs. Retain the printout information and the Tech 2(R) screen photograph with the repair order. Vehicle Information Screen 1. Take a clear digital picture of the Tech 2(R) Vehicle Information screen. Retain the printout information and the Tech 2(R) screen photograph with the repair order. 2. Take a clear digital picture of the Transmission Data screen that contains the Max Transmission Calc Engine Torque parameter. The path table is outlined in the following Instructions for Tech 2 Transmission Data Path section. Retain the Tech 2(R) Transmission Data screen photograph with the repair order. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Power-Up/Calibration ID > Page 3995 3. E-mail copies of the digital pictures to [email protected]. In the subject line of the E-mail include the phrase "Duramax(TM) diesel", the complete VIN and Dealer BAC. In the body of the E-mail include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an email reply after the calibrations have been validated. The email reply will advise the dealer if the calibrations are OEM. 4. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 5. You may call the PQC two hours after submitting the required information for authorization to replace the assembly. This will provide them time to receive, review the information and set up a case on the request. Be prepared to provide all of the usual documentation that is normally required when requesting an assembly authorization from the PQC. 2007-2011 RPO LMM Instructions for Tech 2 Transmission Data Path - Power-up Hardware Detection Transmission Data ONLY Available With GMC Sierra, TopKick, Chevrolet Kodiak, Silverado An example of this hardware is a propane injection system. A transmission control module (TCM) algorithm has been implemented that records a maximum calculated input torque. This information is available via the Tech 2(R). 1. Build the vehicle with the Tech 2(R). 2. Select F3: Transmission Control Module 3. Select F1: Data Display 4. Select F0: Transmission Data 5. Highlight: Max Transmission Calc Engine Torque Transmission Data Screen (Max. Trans Calc. Engine Torque Parameter) 6. Take a clear digital picture of the Tech 2(R) screen showing the Transmission Data and the Max Transmission Calc Engine Torque parameter. 7. Retain the Tech 2(R) Transmission Data screen photograph with the repair order. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Power-Up/Calibration ID > Page 3996 Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Power-Up/Calibration ID > Page 3997 Engine Control Module: Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Power-Up/Calibration ID > Page 3998 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Power-Up/Calibration ID > Page 3999 Engine Control Module: Technical Service Bulletins Diesel Engine - Damage Due To Power-Up Devices INFORMATION Bulletin No.: 06-06-01-007F Date: March 31, 2010 Subject: Information On Identifying Duramax(TM) Diesel LB7, LLY, LMM, LBZ Overpower Engine Breakdown or Non-Function Due to Aftermarket Power-Up Devices vs. Non Overpower Engine Non-Function of Pistons, Cylinders, Valvetrain Components and/or Turbocharger DTC P003A Set Models: 2001-2010 Chevrolet Silverado 2003-2009 Chevrolet Kodiak 2006-2010 Chevrolet Express 2001-2010 GMC Sierra 2003-2009 GMC TopKick 2006-2010 GMC Savana Equipped With Duramax(TM) Turbocharged Diesel Engine RPOs LB7, LLY, LMM, LBZ Please Refer to GMVIS Supercede: This bulletin is being revised to add text to the end of the Caution statement. Please discard Corporate Bulletin Number 06-06-01-007E (Section 06 - Engine/Propulsion System). Caution Customers should be informed if a hard part failure is observed in the engine, transmission, transfer case and/or other driveline components, it is likely that powertrain components were weakened to the point of premature failure, while subjected to the higher stresses from Aftermarket Power-Up Devices. Failures associated with the installation of Aftermarket Power-Up Devices, which have been verified, are not covered under the terms of the New Vehicle Warranty. In the majority of these cases, the Fixed Operations Manager (FOM) (in Canada, Warranty Manager) should be contacted and the remaining portion of the powertrain portion of the New Vehicle Warranty blocked. GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage. General Motors Position On Aftermarket Power-Up Devices Important General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. Refer to Service Bulletin Number 04-06-04-054A or newer - Warranty Admin. - Non-GM Parts and Accessories (Aftermarket). Important For further information on aftermarket power-up kits, refer to February 2006 Emerging Issues Course Number 10206.02D. In Canada, information on aftermarket power-up kits was covered in the April 2006 TAC TALK program. Aftermarket power-up devices are non-approved by General Motors. These devices are usually piggy-backed in the main engine harness or remain connected to the diagnostic connector to upload the calibration to the ECM. Recent warranty reviews of returned engines show engine breakdown or non-function due to power-up devices that are utilized for increased horsepower and torque. The following information will assist technicians in identifying overpower engine breakdown or non-function due to aftermarket power-up devices vs. non overpower engine breakdown or non-function. Non-GM parts can alter the design of the vehicle. GM dealers need to be aware of the quality of parts being installed on vehicles. If failure occurs as a result of installation of sub-par parts, warranty coverage may be denied. Refer to Service Bulletin Number 04-06-04-054A or newer Warranty Admin. - Non-GM Parts and Accessories (Aftermarket). Installed Power-Up Kit Aftermarket power-up kits have become a very popular add on for performance-minded customers. These devices can add horsepower and torque and can add additional stress to the engine. These aftermarket calibrations take the Duramax(TM) powertrain outside of its design torque and horsepower rating. They do this by altering air/fuel ratios and injector timing, resulting in excessive cylinder pressure and temperature. When these calibrated parameters are altered, it will upset the design balance and can lead to a reduction of engine life expectancy. Generally, in inspection of Duramax(TM) engine failure due to power-up failures, two or more cylinders will be affected. Installed Power-Up Kit - Once installed, the calibration may mask itself with the factory original calibration ID and may remain the same. Refer to Service Bulletin Number 08-06-04-006F or newer - Information on Identifying Non-GM Calibration Usage for LMM Duramax(TM) Diesel Engine. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Power-Up/Calibration ID > Page 4000 - A Tech 2(R) will not positively enable you to identify the use of a power-up device. - Some companies that offer power-up devices claim increases of 150 or more horsepower and 300 or more lb/ft pounds of torque. - A vehicle that is used to the power-up device potential 100% of the time will see earlier engine wear and breakdown. - A vehicle that takes advantage of additional power, but on a less frequent basis, may not see premature engine wear and breakdown until later in the engine's life. - A vehicle not pushed to its limits of the power-up device often may not encounter premature wear and breakdown until after the engine is out of warranty. Duramax(TM) Powertrain Horsepower / Torque Ratings The following horsepower and torque increase over the past years required new internal components to accommodate the increase. - LB7 - 300 hp with 520 ft/lb of torque for model years 2000-2004 - LLY - 310 hp with 605 ft/lb of torque for model years 2004-2008 - LBZ - 360 hp with 650 ft/lb of torque for model year 2006-2008 - LMM - 365 hp with 660 ft/lb of torque for model year 2007-2009 LBZ Improvements To reliably achieve an increase in 50 horsepower with 45 ft/lb torque, the Duramax (TM) diesel had to be revised in many areas. A few of the revisions on the 2006 LBZ were: - New pistons with a revised compression ratio. - Wrist pins that are larger in diameter. - Connecting rods with added material to increase the I section strength. - Engine block and machining changes - Cylinder heads Duramax(TM) Life Expectancy The Duramax(TM) 6.6L V8 Turbo Diesel Engine is sold with a warranty of 100,000 miles/160,000 kilometers. The Duramax(TM) has been tested to survive upwards of 200,000 miles/320,000 kilometers. The Duramax(TM) powertrain is designed for reliability, peak horsepower and torque within its design limits. When a customer installs a power-up device, it drastically reduces the mileage ratings. Important Cylinder Wall Spotting (commonly referred to leopard spots) is from the induction hardening process of the top 1/3 of the cylinder wall. This is normal for the Duramax (TM) Diesel. Identifying Fuel Related Aftermarket Power-Up Devices Aftermarket companies have developed a performance pressure relief fuel valve for Duramax(TM) diesel engines. Refer to above graphic illustration. The performance pressure relief fuel valve attaches to the fuel rail in place of the OEM valve and will not allow any fuel return to the tank, giving 100% of the fuel to be available for additional engine performance. This may cause additional fuel related driveability concerns and may set the following DTCs: - DTC P1093 Fuel Rail Pressure (FRP) Low During Power Enrichment - DTC P0087 Fuel Rail Pressure (FRP) Too Low Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Power-Up/Calibration ID > Page 4001 Aftermarket companies have developed a replacement performance/economy fuel injector nozzle. Refer to above illustration. The performance/economy fuel injector nozzles replace the OEM fuel injector nozzles. The aftermarket companies claim increased horsepower, improved fuel atomization, lower exhaust gas temperatures and increase fuel economy. This may cause additional fuel related driveability concerns and may cause internal engine damage to the pistons and fuel injector nozzles. Identifying Overpower Engine Premature Wear and Breakdown When premature wear and breakdown is encountered due to an aftermarket power-up device, it has some very specific characteristics to the internal engine components. The following list will assist in identifying these characteristics as you tear down the engine. - Pistons will be cracked in the lip area, or a hole in the pistons. - Pistons can also be melted on the lip of the combustion bowl, or the top of the pistons can be melted. - Crosshatch will be polished off the cylinder wall in the major thrust face of cylinder below ring belt travel. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Power-Up/Calibration ID > Page 4002 - Piston pin bore will show signs of scoring, the wrist pins will be discolored, and can have oil coking on them. The connecting rod bushing surface will have accelerated wear. The above illustration shows a connecting rod bushing. - Oil coking on the underside of the piston between the wrist pin bosses. - Signs of bearing fretting will also be noticed on the connecting rod and main bearing caps. Refer to the above illustration for fretting of main bearing cap 1 and back side of connection rod bearing 2. - Excessive heat in engine compartment caused by overpower device. Refer to above illustration (1). Non Overpower Engine Premature Wear and Breakdown The following pictures show results of overheat, overspeed, low/no oil pressure or injector breakdown and how they differ from aftermarket power-up device premature wear and breakdown. Engine Overheat Overheat can be caused by a loss of coolant or a general cooling system failure. Some of the indicators of overheat are: Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Power-Up/Calibration ID > Page 4003 - Melted pistons. - Head gasket breakdown or non-function. - Warped cylinder heads. - Crankshaft and connecting rod discolored. Engine Overspeed Causes If an engine has been run faster than design capability (redline), and has caused damage as a result, it may be a result of one of the following conditions: - Leaking or failed turbocharger (TC) oil seals. - Oil evident in the intake runners and compressor side of the TC. - Starting fluid use or alternative fuel added to the engine such as ether. Engine Overspeed Results The following are indicators that an overspeed event took place: - Valve train damage. - Pushrods that are bent (4). - Broken valve bridge buttons after cylinder head removal (2). - Rocker arm tip damage (1). - Dry or rusted cylinders from the use of ether, propane or nitrous oxide. - Piston to valve contact. - Cam gear pin shear. Lack of Oil Pressure Lack of lubrication causes rapid bearing wear or bearing to seize. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Power-Up/Calibration ID > Page 4004 Bearing failure. Spun main bearings. Engine Premature Wear and Breakdown Due to Improper Function of Fuel Injector A fuel injector may fracture a piston or melt a piston but the damage will be limited to that cylinder only and all other pistons and cylinder walls are OK. In some cases hydraulic lock will occur on the suspected cylinder with an over-fueling fuel injector. Hydraulic lock on the suspected cylinder will cause a bent connecting rod. This can be verified with piston protrusion measurements. 2007-2010 RPO LMM Only Turbocharger DTC P003A Set General Motors has identified a turbocharger (TC) failure mode involving Power-Up Kits that causes soot leakage and DTC P003A to be set. The Power-Up Kits create an overtemperature condition from the increased exhaust gas temperatures that results in a permanent and excessive turbine housing distortion at the TC case halves. 1. A technician may observe one or more of the following conditions: - DTC P003A being set as Current or in History. - An unusual odor emanating from the TC due to an overtemperature condition. - Soot leaking and accumulating at the V-band clamp that secures the TC case halves together. - Limited or unresponsive travel when Commanding the TC Vane Pos. Ctrl. Solenoid ON and OFF with a scan tool. 2. If DTC P003A is found as Current or in History, OR there is evidence of soot leakage (1) in the area of the V-band clamp (1), then technicians MUST verify if the engine control module (ECM) has a Power-Up Kit aftermarket calibration installed or an aftermarket hardware device has been installed. Refer to Service Bulletin Number 08-06-04-006F or newer for the calibration verification information and procedures. How to Handle a Suspect Engine Failure Due to a Power-Up Device Dealers should not automatically decline warranty assistance on engine failures due to the fact that a power-up device or modification is evident or suspected. The technician must identify that the failure is due to a power-up device by teardown analysis and diagnosis of the engine components. The following steps should be taken if an engine failure occurs and it is suspected that the modification or addition of a power-up device maybe the cause of the engine failure. If unclear of this process or direction feel free to contact your Fixed Operations Manager (in Canada, Warranty Manager) for further support. 1. The technician should use proper engine diagnostics to lead him/her to the failed engine components. The Aftermarket Power-Up Kit Check List should be followed and if it is determined that at least three of the Aftermarket Power-Up Kit Check List items match the engine component failures then it can be decided that the failure is not a warrantable claim. 2. Engine failures that meet at least three criteria of the Aftermarket Power-Up Kit Check List are considered failures that are not manufacturer's defects in workmanship or materials. 3. The dealership should contact the PQC, open a case to review the findings and make the final decision on warranty coverage. The Fixed Operations Manager (in Canada, Warranty Manager) should be notified of the PQC decision. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Power-Up/Calibration ID > Page 4005 4. Denied claims should be documented as follows: 1. The Aftermarket Power-Up Kit Check List completed with the technicians detailed written findings of the diagnosis on the repair order and retained in the repair order file. 2. Photographs of the failed parts should be retained in the repair order file. 5. The customer should be advised that the failure of their engine was not due to a manufacturer's defect in workmanship or materials and therefore the warranty claim is denied on this failure. Aftermarket Power-Up Kit Check List Important Print and use this aftermarket power-up kit check list when performing an engine disassembly investigation of overpower engine breakdown or non-function. Retain a copy of this checklist and photographs of the failed parts in the repair order file. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4006 Engine Control Module: Locations Harness Routing Views Engine Harness Routing - Left Front Side (4.8L/5.3L/6.0L/6.2L except LFA/HP2) 1 - Air Intake Duct 2 - X111 3 - Fuse Block - Underhood X2 4 - X109 5 - X110 (NQF/NQG/NQH) 6 Engine Control Module (ECM) X2 7 - Engine Control Module (ECM) X1 8 - G102 9 - J105 Engine Chassis Harness Routing - Top Front (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4007 1 - Battery - Right 2 - Fuse Holder 3 - X127 4 - X108 5 - X107 6 - X123 (PTO) 7 - Fuse Block Underhood 8 - X109 9 - Battery - Left 10 - Engine Control Module (ECM) 11 - Transmission Control Module (TCM) Engine Harness Routing - Top (4.3L) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4008 1 - Mega Fuse Ring Terminal 2 - X175 (M30) 3 - J128 4 - J105 5 - J106 6 - J130 (M30 with NQG/NQH) 7 - Engine Control Module (ECM) X1 8 - Engine Control Module (ECM) X2 9 - G103 10 - X112 11 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Connector Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4009 Engine Control Module: Diagrams Component Connector End Views Engine Control Module (ECM) X1 (LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4010 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4011 Engine Control Module (ECM) X1 (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4012 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4013 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4014 Engine Control Module (ECM) X1 (LY2, LMG, LC9, LY5, LH6, L76 or L9H) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4015 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4016 Engine Control Module (ECM) X1 (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4017 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4018 Engine Control Module (ECM) X1 (LY6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4019 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4020 Engine Control Module (ECM) X2 (LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4021 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4022 Engine Control Module (ECM) X2 (LY2, LY6 or L9H with Y91) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4023 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4024 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4025 Engine Control Module (ECM) X2 (LMG, LC9, LY5, LH6, L76 or L9H without Y91) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4026 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4027 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4028 Engine Control Module (ECM) X2 (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4029 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4030 Engine Control Module (ECM) X2 (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4031 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4032 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4033 Engine Control Module (ECM) X3 (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4034 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4035 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Engine Control Module Description Engine Control Module: Description and Operation Engine Control Module Description Engine Control Module Description The powertrain has electronic controls to reduce exhaust emissions while maintaining excellent driveability and fuel economy. The engine control module (ECM) is the control center of this system. The ECM monitors numerous engine and vehicle functions. The ECM constantly monitors information from various sensors and other inputs, and controls the systems that affect vehicle performance and emissions. The ECM also performs diagnostic tests on various parts of the system. The ECM can recognize operational problems and alert the driver via the malfunction indicator lamp (MIL). When the ECM detects a malfunction, the ECM stores a diagnostic trouble code (DTC). The problem area is identified by the particular DTC that is set. The control module supplies a buffered voltage to various sensors and switches. Review the components and wiring diagrams in order to determine which systems are controlled by the ECM. Malfunction Indicator Lamp (MIL) Operation The malfunction indicator lamp (MIL) is located in the instrument panel cluster. The MIL will display as either SERVICE ENGINE SOON or one of the following symbols when commanded ON: The MIL indicates that an emissions related fault has occurred and vehicle service is required. The following is a list of the modes of operation for the MIL: * The MIL illuminates when the ignition is turned ON, with the engine OFF. This is a bulb test to ensure the MIL is able to illuminate. * The MIL turns OFF after the engine is started if a diagnostic fault is not present. * The MIL remains illuminated after the engine is started if the control module detects a fault. A diagnostic trouble code (DTC) is stored any time the control module illuminates the MIL due to an emissions related fault. The MIL turns OFF after three consecutive ignition cycles in which a Test Passed has been reported for the diagnostic test that originally caused the MIL to illuminate. * The MIL flashes if the control module detects a misfire condition which could damage the catalytic converter. * When the MIL is illuminated and the engine stalls, the MIL will remain illuminated as long as the ignition is ON. * When the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition is cycled OFF and then ON. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Engine Control Module Description > Page 4038 Engine Control Module: Description and Operation Engine Idle Control System Description Engine Idle Control System Description High Idle Switch The high idle switch will slowly increase engine RPM to the calibrated high idle speed when depressed. The high idle speed can be programmed by using a scan tool. Refer to High Idle Switch Programming (See: Fuel Delivery and Air Induction/Idle Speed/Service and Repair). If the High Idle Switch is not operating as desired, refer to High Idle Switch Diagnosis (See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/High Idle Switch Diagnosis). Manual High Idle The diesel engine has a high idle system to improve the warm-up time of the engine in cold weather conditions. This system allows the engine control module (ECM) to increase the idle speed above the normal calibrated value. The ECM increases the idle speed using the following adjustments: * The fuel injection timing is changed * The fuel injection quantity is changed * The turbocharger vane position is commanded closed-The vane position will be farther closed than any other normal operating condition. The instrument panel will indicate the high idle system is active one of two ways: * The driver information center (DIC) will indicate an active high idle system on light duty trucks. * An indicator lamp will flash on medium duty trucks. * The manual high idle feature comes enabled from the factory. The Elevated Idle function in the scan tool will disable or enable this feature. If the engine does not increase to the calibrated high idle speed after the procedure is performed, use the scan tool to verify the Elevated Idle speed feature is enabled. Manual High Idle Speed Enable and Disable To enable or disable the manual high idle system perform the following procedure: 1. Turn the ignition ON, with the engine OFF. 2. Depress the accelerator pedal to the floor and hold down. 3. While the accelerator pedal is depressed, depress the brake pedal 3 times in less than 8 seconds. 4. Release the accelerator pedal. 5. Start the engine. When the procedure is followed the engine idle speed will slowly increased to the calibrated high idle speed. This is 1,200 RPM for light duty, and 1,500 RPM for medium duty trucks. The idle speed will return to normal if any of the following conditions occur: * There is brake, clutch, or throttle input from the driver. * The automatic transmission is shifted out of Park or Neutral. * The air temperature is more than 7°C (45°F). * The engine coolant temperature (ECT) is more than 68°C (154°F). * The vehicle speed exceeds 0 km/h (0 mph). The high idle system will reactivate automatically when the following conditions occur: * The engine has been idling for more than 30 seconds. * The transmission is placed in Park or Neutral. * The vehicle speed is 0 km/h (0 mph). * The ambient air temperature is less than 3°C (37°F). * The ECT is less than 68°C (154°F). * The brake, clutch and throttle pedals are not depressed. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 4039 Engine Control Module: Service and Repair Engine Control Module Replacement Caution: * Turn the ignition OFF when installing or removing the control module connectors and disconnecting or reconnecting the power to the control module (battery cable, powertrain control module (PCM)/engine control module (ECM)/transaxle control module (TCM) pigtail, control module fuse, jumper cables, etc.) in order to prevent internal control module damage. * Control module damage may result when the metal case contacts battery voltage. DO NOT contact the control module metal case with battery voltage when servicing a control module, using battery booster cables, or when charging the vehicle battery. * In order to prevent any possible electrostatic discharge damage to the control module, do no touch the connector pins or the soldered components on the circuit board. * Remove any debris from around the control module connector surfaces before servicing the control module. Inspect the control module connector gaskets when diagnosing or replacing the control module. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant intrusion into the control module. * The replacement control module must be programmed. Note: Before removing the engine control module (ECM), use the scan tool to capture the ECM data. This captured data will then need to be restored into the NEW ECM. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning). Removal Procedure 1. Using a scan tool, capture the ECM data. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 3. Disconnect the ECM electrical connectors (2). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 4040 4. Release the ECM upper retaining tabs. 5. Remove the ECM from the bracket. Installation Procedure 1. Place the bottom edge of the ECM into the bracket lower retainers. 2. Push the ECM towards the bracket until the upper edge of the ECM snaps into place. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 4041 3. Connect the ECM electrical connectors (2). 4. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 5. If a NEW ECM was installed, program the ECM. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 4045 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 4046 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 4047 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 4048 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 4049 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 4050 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 4051 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pressure Control Module > Component Information > Diagrams Fuel Pressure Control Module: Diagrams Component Connector End Views Fuel Pump Flow Control Module (Gas except JL1 and except LU3, LY6 or LY6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pressure Control Module > Component Information > Diagrams > Page 4056 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Fuse Block Underhood Fuel Pump Relay: Locations Fuse Block - Underhood Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Fuse Block Underhood > Page 4061 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Fuse Block Underhood > Page 4062 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Fuse Block Underhood > Page 4063 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Fuse Block Underhood > Page 4064 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Fuse Block Underhood > Page 4065 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Fuse Block Underhood > Page 4066 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Fuse Block Underhood > Page 4067 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Fuse Block Underhood > Page 4068 Fuel Pump Relay: Locations Harness Routing Views Harness Routing Views Chassis Harness - Front Engine Compartment (31 Series) 1 - X102 (JL1) 2 - Fuel Pump Relay - Secondary (LY6 without NQZ) 3 - Fuse Block - Underhood 4 X126 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 4069 Fuel Pump Relay: Diagrams Component Connector End Views Fuel Pump Relay - Secondary (LY6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 4073 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 4074 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 4075 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 4076 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 4077 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 4078 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 4079 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Glow Plug System > Glow Plug Control Module > Component Information > Diagrams Glow Plug Control Module: Diagrams Component Connector End Views Glow Plug Control Module (GPCM) X1 (Diesel) Glow Plug Control Module (GPCM) X2 (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Glow Plug System > Glow Plug Control Module > Component Information > Diagrams > Page 4084 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Glow Plug System > Glow Plug Control Module > Component Information > Diagrams > Page 4085 Glow Plug Control Module: Service and Repair Glow Plug Control Module Replacement Removal Procedure 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 2. Disconnect the positive battery cable (1) from the glow plug control module. 3. Disconnect the engine wiring harness electrical connector (2) from the glow plug control module. 4. Remove the glow plug control module bolts and module. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Glow Plug System > Glow Plug Control Module > Component Information > Diagrams > Page 4086 5. Remove the fuel return pipe clamp bolt (1). 6. Remove the glow plug control module protector bolts and protector (1), if required. 7. Remove the glow plug control module bracket and bolts (2), if required. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Glow Plug System > Glow Plug Control Module > Component Information > Diagrams > Page 4087 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Position the glow plug control module bracket (2) to the lower valve rocker arm cover and install the bolts, if required. Tighten the bolts to 10 Nm (89 lb in). 2. Position the glow plug control module protector (1) and install the bolts, if required. Tighten the bolts to 10 Nm (89 lb in). 3. Install the fuel return pipe clamp bolt (1). Tighten the bolt to 24 Nm (18 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Glow Plug System > Glow Plug Control Module > Component Information > Diagrams > Page 4088 4. Position the glow plug control module onto the bracket and install the bolts. Tighten the bolts to 10 Nm (89 lb in). 5. Connect the engine wiring harness electrical connector (2) to the glow plug control module. 6. Connect the positive battery cable (1) to the glow plug control module. 7. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 8. If a NEW glow plug control module was installed, program the module. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations Accelerator Pedal Position Sensor: Locations Harness Routing Views Brake Clutch Harness Routing 1 - Driver Door Frame 2 - X205 3 - X102 (JL1) 4 - Accelerator Pedal Position (APP) Sensor Connector 5 - Junction Block - Left I/P (except MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 4094 Accelerator Pedal Position Sensor: Diagrams Component Connector End Views Accelerator Pedal Position (APP) Sensor Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 4095 Accelerator Pedal Position Sensor: Description and Operation Accelerator Pedal Position System Description The accelerator pedal position (APP) sensor is mounted inside the accelerator pedal control assembly. The sensor is made up of the two individual sensors within a single housing. Each sensor has a unique functionality to determine pedal position. The accelerator pedal position (APP) system along with the engine control module (ECM) is used to calculate and control the amount of acceleration and deceleration through fuel injector control. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 4096 Accelerator Pedal Position Sensor: Service and Repair Accelerator Pedal Position Sensor Replacement Removal Procedure Caution: Handle the electronic throttle control components carefully. Use cleanliness in order to prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the electronic throttle control components. Do not immerse the electronic throttle control components in cleaning solvents of any type. 1. Remove the connector position assurance (CPA) retainer. 2. Disconnect the accelerator pedal position (APP) sensor electrical connector (1). 3. Remove the accelerator pedal bolts. 4. Remove the accelerator pedal. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 4097 Installation Procedure 1. Position the accelerator pedal to the accelerator pedal bracket. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the accelerator pedal bolts and tighten to 9 Nm (80 lb in).. 3. Connect the APP sensor electrical connector (1). 4. Install the CPA retainer. 5. Connect a scan tool to the diagnostic port in order to test for proper throttle-opening and throttle-closing range. 6. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle, and a wide open throttle (WOT). 7. Verify that the vehicle meets the following conditions: * The vehicle is not in a reduced engine power mode. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 4098 * The ignition is ON. * The engine is OFF. 8. Inspect the carpet fit under the accelerator pedal. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations Air Flow Meter/Sensor: Locations Harness Routing Views Engine Harness Routing - Top (4.3L) 1 - Mega Fuse Ring Terminal 2 - X175 (M30) 3 - J128 4 - J105 5 - J106 6 - J130 (M30 with NQG/NQH) 7 - Engine Control Module (ECM) X1 8 - Engine Control Module (ECM) X2 9 - G103 10 - X112 11 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Connector Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 4102 Air Flow Meter/Sensor: Diagrams Component Connector End Views Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (Diesel) Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (Gas) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 4103 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 4104 Air Flow Meter/Sensor: Service and Repair Mass Airflow Sensor with Intake Air Temperature Sensor Replacement Removal Procedure 1. Disconnect the engine wiring harness electrical connector (1) from the mass air flow (MAF)/intake air temperature (IAT) sensor. 2. Remove the MAF/IAT sensor TORX(R) screws. 3. Remove the MAF/IAT sensor. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 4105 1. Install the MAF/IAT sensor. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the MAF/IAT sensor TORX(R) screws. Tighten the screws to 8 Nm (70 lb in). 3. Connect the engine wiring harness electrical connector (1) to the MAF/IAT sensor. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Current Sensor > Component Information > Diagrams Battery Current Sensor: Diagrams Component Connector End Views Battery Current Sensor (10 Series without MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Current Sensor > Component Information > Diagrams > Page 4109 Battery Current Sensor: Service and Repair Battery Current Sensor Replacement Removal Procedure 1. Remove the negative battery cable. Refer to Battery Negative Cable Replacement (V6) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Replacement (V8) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Replacement (Diesel) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 2. Mark the location of the battery current sensor on the battery cable with tape for reference during installation. 3. Remove the tape securing the battery current sensor to the negative battery cable. 4. Mark the location of the negative battery cable clips (1) and remove the clips from the cable. 5. Squeeze the negative battery cable branches together. Important: Note the orientation of the battery current sensor prior to removal. 6. Slide the battery current sensor (2) off of the negative battery cable. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Current Sensor > Component Information > Diagrams > Page 4110 1. Squeeze the negative battery cable branches together. Important: Ensure the battery current sensor is installed in the correct direction and location on the negative battery cable. 2. Slide the NEW battery current sensor (2) up onto the negative battery cable to the location previously marked during removal. 3. Wrap electrical tape around the battery current sensor leg in order to secure the sensor to the negative battery cable. 4. Install the negative battery cable clips (1) to the cable to the locations previously marked during removal. 5. Install the negative battery cable. Refer to Battery Negative Cable Replacement (V6) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Replacement (V8) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Replacement (Diesel) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Harness Routing Views Camshaft Position Sensor Jumper Harness Routing (4.8L/5.3L/6.0L/6.2L) 1 - X112 2 - Camshaft Position Sensor Jumper Harness Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 4114 Camshaft Position Sensor: Diagrams Component Connector End Views Camshaft Position (CMP) Actuator Solenoid Valve (LZ1, LY6, L96 or L9H) Camshaft Position (CMP) Sensor (LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 4115 Camshaft Position (CMP) Sensor (Gas except LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 4116 Camshaft Position (CMP) Sensor (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 4117 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 4118 Camshaft Position Sensor: Service Precautions Camshaft Position Actuator Removal and Installation Warning Warning Do not push or pull on the reluctor wheel of the camshaft position (CMP) actuator during removal or installation. The reluctor wheel is retained to the front of the CMP actuator by 3 roll pins. Pushing or pulling on the wheel may dislodge the wheel from the front of the actuator. The actuator return spring is under tension and may rotate the dislodged reluctor wheel, causing personal injury. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 4119 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor Replacement Removal Procedure 1. Remove the cooling fan pulley. Refer to Fan Pulley Replacement (See: Engine, Cooling and Exhaust/Cooling System/Radiator Cooling Fan/Service and Repair). 2. Remove the camshaft position (CMP) sensor bolt. 3. Remove the CMP sensor. Installation Procedure 1. Lubricate the CMP sensor O-ring with clean engine oil. 2. Install the CMP sensor. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 4120 3. Install the CMP sensor bolt. Tighten the bolt to 10 Nm (89 lb in). 4. Install the cooling fan pulley. Refer to Fan Pulley Replacement (See: Engine, Cooling and Exhaust/Cooling System/Radiator Cooling Fan/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Clutch Switch, ECM > Component Information > Diagrams Clutch Switch: Diagrams Component Connector End Views Clutch Pedal Position (CPP) Switch (TZ0) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps Coolant Temperature Sensor/Switch (For Computer): Customer Interest Engine - MIL ON P0116/P1400 Set In Very Cold Temps TECHNICAL Bulletin No.: 10-06-04-008A Date: January 24, 2011 Subject: Malfunction Indicator Lamp (MIL) Illuminated at Very Cold Ambient Temperatures When Using Engine Coolant Heater, DTC P0116 and/or P1400 Set (Relocate Engine Coolant Temperature (ECT) Sensor and Engine Coolant Heater Cord) Models: 2006-2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2006-2010 Cadillac Escalade 2006-2007 Chevrolet Monte Carlo 2006-2009 Chevrolet Impala SS, TrailBlazer 2006-2010 Chevrolet Avalanche, Express, Silverado Tahoe 2006-2009 GMC Envoy 2006-2010 GMC Savana, Sierra, Yukon 2006-2008 Pontiac Grand Prix 2006-2009 Saab 9-7X Equipped with V8 Engine RPO LC9, LH6, LH8, LH9, L76, LS2, LS4, LFA, LZ1, L92, L94, L9H or L20, L96, LMF, LMG, LY2, LY5, LY6 Please Refer to GMVIS Attention: To properly correct this condition, you must follow both of the procedures to relocate the ECT sensor and the engine coolant heater cord. Supercede: This bulletin is being revised to add cast iron block engine RPOs and to update the Warranty Information coverage period. Please discard Corporate Bulletin Number 10-06-04-008 (Section 06 - Engine/Propulsion System). Condition Some customers may comment that the malfunction indicator lamp (MIL) illuminates after starting the vehicle when they were using the engine coolant heater in very cold ambient temperatures. This usually occurs in a range of -23 to -40°C (-10 to -40°F) or colder. The technician may observe on a scan tool DTC P0116 and/or P1400 set as Current or in History. Cause This condition may be caused by the engine control module (ECM) determining that the ignition OFF time requirement has been met at start-up and interpreting the temperature difference between the engine coolant temperature (ECT) sensor and the intake air temperature (IAT) sensor as being outside of a calibrated range. Correction Important DO NOT replace the ECM for this condition. Relocating the ECT Sensor 1. Turn ON the ignition with the engine OFF. 2. Perform the diagnostic system check - vehicle. Refer to Diagnostic System Check - Vehicle in SI. ‹› If DTC P0116 and/or P1400 are set and the customer WAS using the engine coolant heater, proceed to Step 3. ‹› If DTC P0116 and/or P1400 are set and the customer WAS NOT using the engine coolant heater, refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. 3. Turn OFF the ignition. Warning To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 4132 under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator are still hot. 4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle. Refer to Cooling System Draining and Filling in SI. 7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor. 10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J 38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle. 13. Disconnect the wiring harness connector from the ECT sensor (2). 14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT sensor in the hole of the cylinder head where the plug was removed. Tighten Tighten to 20 Nm (15 lb ft). 18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was removed Tighten Tighten to 20 Nm (15 lb ft). Important Leave enough wire attached to the ECT sensor harness connector in order to create manageable splices that are at least 40 mm (1.5 in) away from the other splice. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 4133 20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit. Cut off the ECT sensor harness connector and wiring. 21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured TO or WITHIN an existing protective conduit. Note This step is to set up and verify the length of wiring that is required before cutting. 22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the appropriate length. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. 26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit using tie straps. Important You MUST run the engine at the specified RPM and until it reaches normal operating temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool down in order to top off the coolant level as needed. 28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI. 29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan tool to clear any DTCs. Relocating the Engine Coolant Heater Cord Important For reference, the procedure and graphics that are shown are from a Chevrolet Silverado, but are similar for the other vehicles listed above. 1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit from the engine compartment in order to determine the required extension cord length. 3. Obtain an extension cord with the following features: - 120 volt - 14/3 gauge - 15A capacity - Three prong - Polarized plug and receptacle - Chemical resistant - Grounded terminals - Designed for use in a cold outdoor environment - Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight - Maximum length of 2.5-3 m (8-10 ft) 4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N 12345579 (in Canada, use P/N 10953481) or an equivalent. 6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 4134 7. Wrap electrical tape around the connection as shown. 8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to the engine coolant crossover pipe as shown. 9. Continue to route the extension cord to the exit location desired by the customer as shown. 10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the engine coolant heater cord to the vehicle that were released to provide length. Part Information The extension cord may be obtained at any of the following outlets: - Lowes* - Home Depot* - Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number: CWRSJTOW3C14-10 USA: Cords should bear the UL symbol. Canada: Cords should bear the ULc symbol or CSA approval. *We believe these sources and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from these firms or for any such items that may be available from other sources. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 4135 Warranty Information (excluding Saab Models) For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps Coolant Temperature Sensor/Switch (For Computer): All Technical Service Bulletins Engine - MIL ON P0116/P1400 Set In Very Cold Temps TECHNICAL Bulletin No.: 10-06-04-008A Date: January 24, 2011 Subject: Malfunction Indicator Lamp (MIL) Illuminated at Very Cold Ambient Temperatures When Using Engine Coolant Heater, DTC P0116 and/or P1400 Set (Relocate Engine Coolant Temperature (ECT) Sensor and Engine Coolant Heater Cord) Models: 2006-2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2006-2010 Cadillac Escalade 2006-2007 Chevrolet Monte Carlo 2006-2009 Chevrolet Impala SS, TrailBlazer 2006-2010 Chevrolet Avalanche, Express, Silverado Tahoe 2006-2009 GMC Envoy 2006-2010 GMC Savana, Sierra, Yukon 2006-2008 Pontiac Grand Prix 2006-2009 Saab 9-7X Equipped with V8 Engine RPO LC9, LH6, LH8, LH9, L76, LS2, LS4, LFA, LZ1, L92, L94, L9H or L20, L96, LMF, LMG, LY2, LY5, LY6 Please Refer to GMVIS Attention: To properly correct this condition, you must follow both of the procedures to relocate the ECT sensor and the engine coolant heater cord. Supercede: This bulletin is being revised to add cast iron block engine RPOs and to update the Warranty Information coverage period. Please discard Corporate Bulletin Number 10-06-04-008 (Section 06 - Engine/Propulsion System). Condition Some customers may comment that the malfunction indicator lamp (MIL) illuminates after starting the vehicle when they were using the engine coolant heater in very cold ambient temperatures. This usually occurs in a range of -23 to -40°C (-10 to -40°F) or colder. The technician may observe on a scan tool DTC P0116 and/or P1400 set as Current or in History. Cause This condition may be caused by the engine control module (ECM) determining that the ignition OFF time requirement has been met at start-up and interpreting the temperature difference between the engine coolant temperature (ECT) sensor and the intake air temperature (IAT) sensor as being outside of a calibrated range. Correction Important DO NOT replace the ECM for this condition. Relocating the ECT Sensor 1. Turn ON the ignition with the engine OFF. 2. Perform the diagnostic system check - vehicle. Refer to Diagnostic System Check - Vehicle in SI. ‹› If DTC P0116 and/or P1400 are set and the customer WAS using the engine coolant heater, proceed to Step 3. ‹› If DTC P0116 and/or P1400 are set and the customer WAS NOT using the engine coolant heater, refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. 3. Turn OFF the ignition. Warning To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 4141 under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator are still hot. 4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle. Refer to Cooling System Draining and Filling in SI. 7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor. 10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J 38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle. 13. Disconnect the wiring harness connector from the ECT sensor (2). 14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT sensor in the hole of the cylinder head where the plug was removed. Tighten Tighten to 20 Nm (15 lb ft). 18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was removed Tighten Tighten to 20 Nm (15 lb ft). Important Leave enough wire attached to the ECT sensor harness connector in order to create manageable splices that are at least 40 mm (1.5 in) away from the other splice. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 4142 20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit. Cut off the ECT sensor harness connector and wiring. 21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured TO or WITHIN an existing protective conduit. Note This step is to set up and verify the length of wiring that is required before cutting. 22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the appropriate length. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. 26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit using tie straps. Important You MUST run the engine at the specified RPM and until it reaches normal operating temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool down in order to top off the coolant level as needed. 28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI. 29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan tool to clear any DTCs. Relocating the Engine Coolant Heater Cord Important For reference, the procedure and graphics that are shown are from a Chevrolet Silverado, but are similar for the other vehicles listed above. 1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit from the engine compartment in order to determine the required extension cord length. 3. Obtain an extension cord with the following features: - 120 volt - 14/3 gauge - 15A capacity - Three prong - Polarized plug and receptacle - Chemical resistant - Grounded terminals - Designed for use in a cold outdoor environment - Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight - Maximum length of 2.5-3 m (8-10 ft) 4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N 12345579 (in Canada, use P/N 10953481) or an equivalent. 6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 4143 7. Wrap electrical tape around the connection as shown. 8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to the engine coolant crossover pipe as shown. 9. Continue to route the extension cord to the exit location desired by the customer as shown. 10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the engine coolant heater cord to the vehicle that were released to provide length. Part Information The extension cord may be obtained at any of the following outlets: - Lowes* - Home Depot* - Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number: CWRSJTOW3C14-10 USA: Cords should bear the UL symbol. Canada: Cords should bear the ULc symbol or CSA approval. *We believe these sources and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from these firms or for any such items that may be available from other sources. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 4144 Warranty Information (excluding Saab Models) For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 4145 Coolant Temperature Sensor/Switch (For Computer): Diagrams Component Connector End Views Engine Coolant Temperature (ECT) Sensor (Diesel) Engine Coolant Temperature (ECT) Sensor (Gas) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 4146 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Engine Coolant Temperature Sensor Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams Crankshaft Position Sensor: Diagrams Component Connector End Views Crankshaft Position (CKP) Sensor (LU3) Crankshaft Position (CKP) Sensor (Gas except LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 4150 Crankshaft Position (CKP) Sensor (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 4151 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement Crankshaft Position Sensor Replacement Removal Procedure 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 2. Remove the right wheelhouse panel. Refer to Front Wheelhouse Liner Replacement - Right Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side)Front Wheelhouse Liner Replacement - Right Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side). 3. Disconnect the crankshaft position (CKP) sensor electrical connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 4154 4. Remove the CKP sensor bolt. 5. Remove the CKP sensor. 6. If necessary, remove the CKP sensor spacer bolts. 7. If necessary, remove the CKP sensor spacer. Installation Procedure 1. If necessary, lubricate a NEW CKP spacer O-ring with clean engine oil. 2. If necessary, install the NEW O-ring to the CKP sensor spacer. Note: The crankshaft position sensor spacers are machined with different timing positions. However, if the crankshaft position sensor spacer requires replacement, replace with a grade "C" spacer. 3. If necessary, install the CKP sensor spacer. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. If necessary, install the CKP sensor spacer bolts. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 4155 Tighten the bolts to 10 Nm (89 lb in). 5. Lubricate a NEW CKP sensor O-ring with clean engine oil. 6. Install the NEW O-ring to the CKP sensor. 7. Install the CKP sensor. 8. Install the CKP sensor bolt. Tighten the bolt to 10 Nm (89 lb in). 9. Connect the CKP sensor electrical connector. 10. Install the right wheelhouse panel. Refer to Front Wheelhouse Liner Replacement - Right Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side)Front Wheelhouse Liner Replacement - Right Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side). 11. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 4156 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Exciter Ring and Oil Pump Drive Gear Replacement Crankshaft Position Sensor Exciter Ring and Oil Pump Drive Gear Replacement Removal Procedure 1. Remove the engine front cover. Refer to Engine Front Cover Replacement (See: Engine, Cooling and Exhaust/Engine/Timing Components/Timing Cover/Service and Repair). 2. Remove the upper oil pan. Refer to Upper Oil Pan Replacement (See: Engine, Cooling and Exhaust/Engine/Engine Lubrication/Oil Pan/Service and Repair/Upper Oil Pan Replacement). Caution: Do not use an impact driver to remove or install the oil pump driven gear nut. Use of an impact driver may shear the oil pump drive gear pin in the crankshaft. 3. While holding the secondary oil pump shaft with a hex driver, remove the oil pump driven gear nut. 4. Remove the oil pump driven gear. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 4157 5. Remove the oil pump drive gear and crankshaft sensor reluctor. Do not damage the crankshaft reluctor teeth. Note: Do not remove the reluctor from the oil pump drive gear unless replacing the reluctor or the oil pump drive gear. The reluctor is timed to the gear and once removed the correct timing will be lost. 6. Remove the crankshaft reluctor to oil pump drive gear bolts. 7. Inspect the crankshaft reluctor for the damage, bent teeth, being bent or warped. 8. Inspect the oil pump drive gear for damaged or worn teeth. 9. Inspect the oil pump drive gear crankshaft pin for wear. 10. Inspect the groove of the crankshaft pin in the oil pump drive gear for wear. 11. Replace any parts that are damaged or worn. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 4158 Note: The crankshaft reluctor and the oil pump drive gear are timed at the factory. In order to re-establish proper timing, install knock pins in the oil pump drive gear if the crankshaft reluctor was removed from the oil pump drive gear. The knock pins are available through the parts department. 1. Install the knock pins in the oil pump drive gear to a height of 4.5-5.5 mm (0.177-0.217 in) 2. Install the crankshaft reluctor on the oil pump drive gear. Ensure the reluctor is aligned on the knock pins. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the crankshaft reluctor bolts and tighten to 8 Nm (71 lb in). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 4159 Note: Do not damage the teeth on the crankshaft reluctor. 4. Install the oil pump drive gear and reluctor to the crankshaft. 5. Install the oil pump driven gear. Caution: Do not use an impact driver to remove or install the oil pump driven gear nut. Use of an impact driver may shear the oil pump drive gear pin in the crankshaft. 6. While holding the secondary oil pump shaft with a hex driver, install the oil pump driven gear nut and tighten to 100 Nm (74 lb ft). 7. Install the upper oil pan. Refer to Upper Oil Pan Replacement (See: Engine, Cooling and Exhaust/Engine/Engine Lubrication/Oil Pan/Service and Repair/Upper Oil Pan Replacement). 8. Install the engine front cover. Refer to Engine Front Cover Replacement (See: Engine, Cooling and Exhaust/Engine/Timing Components/Timing Cover/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Technical Service Bulletins > Recalls for Exhaust Temperature Sensor: > 11054 > Apr > 11 > Recall - Replace Exhaust Gas Temperature Sensor Technical Service Bulletin # 11054 Date: 110412 Recall - Replace Exhaust Gas Temperature Sensor PRODUCT EMISSION Bulletin No.: 11054 Date: April 12, 2011 Subject: 11054 - Reduced Engine Performance and Emission Control - Replace Exhaust Gas Temperature Sensors Models: 2010 Chevrolet Express, Silverado HD 2010 GMC Savana, Sierra HD With 6.6L V8 Duramax Diesel Engine (LMM) 2007-2009 Chevrolet Express, Kodiak, Silverado HD 2007-2009 GMC Savana, Sierra HD, TopKick With 6.6L V8 Duramax Diesel Engine (LMM) Serviced with a Suspect EGT Sensor Condition General Motors has decided to conduct a Voluntary Emission Recall involving certain 2010 model year Chevrolet Express, Silverado HD; and GMC Savana, Sierra HD vehicles equipped with a 6.6L V8 Duramax diesel engine (LMM); and 2007-2009 model year Chevrolet Express, Kodiak, Silverado HD; and GMC Savana, Sierra HD, and TopKick vehicles equipped with a 6.6L V8 Duramax diesel engine (LMM) that may have been serviced with a suspect Exhaust Gas Temperature (EGT) sensor. On these vehicles, the circuit board welds on the EGT sensors in the exhaust system may not be to GM specification. If a weld fails, the Service Engine Soon light will illuminate in the instrument panel, the exhaust gas may not be filtered properly, and the engine power may be reduced. Correction Dealers are to replace both EGT sensors. Vehicles Involved Involved are certain 2010 model year Chevrolet Express, Silverado HD; and GMC Savana, Sierra HD vehicles equipped with a 6.6L V8 Duramax diesel engine (LMM); and 2007-2009 model year Chevrolet Express, Kodiak, Silverado HD; and GMC Savana, Sierra HD, and TopKick vehicles equipped with a 6.6L V8 Duramax diesel engine (LMM) that may have been serviced with a suspect EGT sensor. Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Required Field Actions section in the Global Warranty system. Not all vehicles may be involved. For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to US and Canadian dealers through the GM GlobalConnect Recall Reports, or sent directly to export dealers. Dealers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information Parts required to complete this recall are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Service Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Technical Service Bulletins > Recalls for Exhaust Temperature Sensor: > 11054 > Apr > 11 > Recall - Replace Exhaust Gas Temperature Sensor > Page 4168 1. Remove and replace position 1 and position 2 exhaust gas temperature sensors (1). Refer to Exhaust Temperature Sensor Replacement in SI. 2. CALIFORNIA, CONNECTICUT, MASSACHUSETTS, MAINE, OREGON, VERMONT, & WASHINGTON VEHICLES ONLY: Install a Recall Identification Label. Also, for California vehicles complete a "Proof of Correction" certificate upon recall completion. Recall Identification Label California/Connecticut/Massachusetts/Maine/Oregon/Vermont/Washington Vehicles Only) Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five-digit dealer code of the dealer performing the recall service. This information may be inserted with a ballpoint pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Recall Identification Label, be sure to pull the tab to allow adhesion of the clear protective covering. Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials by ordering on the web from DWD Store, www.gmdealerworld.com, and then click on the DWD Store link. Request Item Number S-1015 when ordering. Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a transaction using the table below. Customer Notification - For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter included with this bulletin). In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper maintenance. The vehicle may fail a state or local emission inspection test if the recall work is not completed. Customer Notification - For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the attached sample letter. In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Technical Service Bulletins > Recalls for Exhaust Temperature Sensor: > 11054 > Apr > 11 > Recall - Replace Exhaust Gas Temperature Sensor > Page 4169 maintenance. The vehicle may fail a state or local emission inspection test if the recall work is not completed. Dealer Recall Responsibility All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. ***THE FOLLOWING 2 PARAGRAPHS ARE NOT FOR CANADA OR EXPORT*** When a California emissions recall is completed by a GM dealer, the dealer must provide the vehicle owner a "Proof of Correction Certificate" which the owner may need to present to the California Department Of Motor Vehicles (DMV) when renewing their vehicle registration. Without this correction certificate, the owner may be unable to renew their vehicle registration. Additional Certificates can be obtained, at no charge, from Dealer Support Materials by ordering on the web from the DWD Store, www.gmdealerworld.com, and then click on the DWD Store link; request GM Item Number 1825 when ordering. Disclaimer Owner Letter Owner Letter Dear General Motors Customer: This notice is sent to inform you that General Motors is conducting a voluntary emission recall that includes your vehicle. Reason For This Recall: General Motors has decided to conduct a Voluntary Emission Recall involving certain 2010 model year Chevrolet Express, Silverado HD; and GMC Savana, Sierra HD vehicles equipped with a 6.6L V8 Duramax diesel engine; and 2007-2009 model year Chevrolet Express, Kodiak, Silverado HD; and GMC Savana, Sierra HD, and TopKick vehicles equipped with a 6.6L V8 Duramax diesel engine that may have been serviced with a suspect Exhaust Gas Temperature (EGT) sensor. The circuit board welds on the EGT sensors in the exhaust system may not be to GM specification. If a weld fails, the Service Engine Soon light will illuminate in the instrument panel, the exhaust gas may not be filtered properly, and the engine power may be reduced. What Will Be Done: Your GM dealer will replace both EGT sensors. This service will be performed for you at no charge. What You Should Do: Please contact your GM dealer as soon as possible to arrange a service date and to assure parts availability. Instructions for making this correction have been sent to your dealer. Please ask your dealer if you wish to know how much time will be needed to schedule, process, and repair your vehicle. If you have any questions or need any assistance, just contact your dealer or the appropriate Customer Assistance Center at the number listed below. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Technical Service Bulletins > Recalls for Exhaust Temperature Sensor: > 11054 > Apr > 11 > Recall - Replace Exhaust Gas Temperature Sensor > Page 4170 Emission Law Information: In order to ensure your full protection under the emission warranty made applicable to your vehicle by State and Federal Law, and your right to participate in future recalls, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could legally be determined to be lack of proper maintenance of your vehicle. Also, your vehicle may fail a state or local emission inspection if this recall is not accomplished. IMPORTANT MESSAGE FOR CALIFORNIA RESIDENTS The California Air Resources Board (CARB) requires vehicle emission recalls be completed prior to California registration renewal. Uncorrected emission recalls will result in the inability to renew your California vehicle registration. At the time of emission recall completion, your California dealer will issue a "Proof of Correction Certificate". Keep this certificate and, if required, present it to the Department of Motor Vehicles when renewing your California registration as proof of recall completion. We are sorry to cause you this inconvenience; however, we have taken this action in the interest of your continued satisfaction with our products. Jim Moloney General Director, Customer and Relationship Services 11054 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exhaust Temperature Sensor: > 11054 > Apr > 11 > Recall - Replace Exhaust Gas Temperature Sensor Technical Service Bulletin # 11054 Date: 110412 Recall - Replace Exhaust Gas Temperature Sensor PRODUCT EMISSION Bulletin No.: 11054 Date: April 12, 2011 Subject: 11054 - Reduced Engine Performance and Emission Control - Replace Exhaust Gas Temperature Sensors Models: 2010 Chevrolet Express, Silverado HD 2010 GMC Savana, Sierra HD With 6.6L V8 Duramax Diesel Engine (LMM) 2007-2009 Chevrolet Express, Kodiak, Silverado HD 2007-2009 GMC Savana, Sierra HD, TopKick With 6.6L V8 Duramax Diesel Engine (LMM) Serviced with a Suspect EGT Sensor Condition General Motors has decided to conduct a Voluntary Emission Recall involving certain 2010 model year Chevrolet Express, Silverado HD; and GMC Savana, Sierra HD vehicles equipped with a 6.6L V8 Duramax diesel engine (LMM); and 2007-2009 model year Chevrolet Express, Kodiak, Silverado HD; and GMC Savana, Sierra HD, and TopKick vehicles equipped with a 6.6L V8 Duramax diesel engine (LMM) that may have been serviced with a suspect Exhaust Gas Temperature (EGT) sensor. On these vehicles, the circuit board welds on the EGT sensors in the exhaust system may not be to GM specification. If a weld fails, the Service Engine Soon light will illuminate in the instrument panel, the exhaust gas may not be filtered properly, and the engine power may be reduced. Correction Dealers are to replace both EGT sensors. Vehicles Involved Involved are certain 2010 model year Chevrolet Express, Silverado HD; and GMC Savana, Sierra HD vehicles equipped with a 6.6L V8 Duramax diesel engine (LMM); and 2007-2009 model year Chevrolet Express, Kodiak, Silverado HD; and GMC Savana, Sierra HD, and TopKick vehicles equipped with a 6.6L V8 Duramax diesel engine (LMM) that may have been serviced with a suspect EGT sensor. Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Required Field Actions section in the Global Warranty system. Not all vehicles may be involved. For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to US and Canadian dealers through the GM GlobalConnect Recall Reports, or sent directly to export dealers. Dealers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information Parts required to complete this recall are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Service Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exhaust Temperature Sensor: > 11054 > Apr > 11 > Recall - Replace Exhaust Gas Temperature Sensor > Page 4176 1. Remove and replace position 1 and position 2 exhaust gas temperature sensors (1). Refer to Exhaust Temperature Sensor Replacement in SI. 2. CALIFORNIA, CONNECTICUT, MASSACHUSETTS, MAINE, OREGON, VERMONT, & WASHINGTON VEHICLES ONLY: Install a Recall Identification Label. Also, for California vehicles complete a "Proof of Correction" certificate upon recall completion. Recall Identification Label California/Connecticut/Massachusetts/Maine/Oregon/Vermont/Washington Vehicles Only) Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five-digit dealer code of the dealer performing the recall service. This information may be inserted with a ballpoint pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Recall Identification Label, be sure to pull the tab to allow adhesion of the clear protective covering. Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials by ordering on the web from DWD Store, www.gmdealerworld.com, and then click on the DWD Store link. Request Item Number S-1015 when ordering. Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a transaction using the table below. Customer Notification - For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter included with this bulletin). In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper maintenance. The vehicle may fail a state or local emission inspection test if the recall work is not completed. Customer Notification - For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the attached sample letter. In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exhaust Temperature Sensor: > 11054 > Apr > 11 > Recall - Replace Exhaust Gas Temperature Sensor > Page 4177 maintenance. The vehicle may fail a state or local emission inspection test if the recall work is not completed. Dealer Recall Responsibility All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. ***THE FOLLOWING 2 PARAGRAPHS ARE NOT FOR CANADA OR EXPORT*** When a California emissions recall is completed by a GM dealer, the dealer must provide the vehicle owner a "Proof of Correction Certificate" which the owner may need to present to the California Department Of Motor Vehicles (DMV) when renewing their vehicle registration. Without this correction certificate, the owner may be unable to renew their vehicle registration. Additional Certificates can be obtained, at no charge, from Dealer Support Materials by ordering on the web from the DWD Store, www.gmdealerworld.com, and then click on the DWD Store link; request GM Item Number 1825 when ordering. Disclaimer Owner Letter Owner Letter Dear General Motors Customer: This notice is sent to inform you that General Motors is conducting a voluntary emission recall that includes your vehicle. Reason For This Recall: General Motors has decided to conduct a Voluntary Emission Recall involving certain 2010 model year Chevrolet Express, Silverado HD; and GMC Savana, Sierra HD vehicles equipped with a 6.6L V8 Duramax diesel engine; and 2007-2009 model year Chevrolet Express, Kodiak, Silverado HD; and GMC Savana, Sierra HD, and TopKick vehicles equipped with a 6.6L V8 Duramax diesel engine that may have been serviced with a suspect Exhaust Gas Temperature (EGT) sensor. The circuit board welds on the EGT sensors in the exhaust system may not be to GM specification. If a weld fails, the Service Engine Soon light will illuminate in the instrument panel, the exhaust gas may not be filtered properly, and the engine power may be reduced. What Will Be Done: Your GM dealer will replace both EGT sensors. This service will be performed for you at no charge. What You Should Do: Please contact your GM dealer as soon as possible to arrange a service date and to assure parts availability. Instructions for making this correction have been sent to your dealer. Please ask your dealer if you wish to know how much time will be needed to schedule, process, and repair your vehicle. If you have any questions or need any assistance, just contact your dealer or the appropriate Customer Assistance Center at the number listed below. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exhaust Temperature Sensor: > 11054 > Apr > 11 > Recall - Replace Exhaust Gas Temperature Sensor > Page 4178 Emission Law Information: In order to ensure your full protection under the emission warranty made applicable to your vehicle by State and Federal Law, and your right to participate in future recalls, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could legally be determined to be lack of proper maintenance of your vehicle. Also, your vehicle may fail a state or local emission inspection if this recall is not accomplished. IMPORTANT MESSAGE FOR CALIFORNIA RESIDENTS The California Air Resources Board (CARB) requires vehicle emission recalls be completed prior to California registration renewal. Uncorrected emission recalls will result in the inability to renew your California vehicle registration. At the time of emission recall completion, your California dealer will issue a "Proof of Correction Certificate". Keep this certificate and, if required, present it to the Department of Motor Vehicles when renewing your California registration as proof of recall completion. We are sorry to cause you this inconvenience; however, we have taken this action in the interest of your continued satisfaction with our products. Jim Moloney General Director, Customer and Relationship Services 11054 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Exhaust Temperature Sensor Replacement - Position 1 Exhaust Temperature Sensor: Service and Repair Exhaust Temperature Sensor Replacement Position 1 Exhaust Temperature Sensor Replacement - Position 1 Removal Procedure Caution: The exhaust temperature sensor and exhaust pressure differential sensor line fittings may be difficult to remove when the engine exhaust system temperature is below 48°C (120°F). Excessive force may damage the threads in the exhaust manifold or exhaust pipe. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the exhaust temperature sensor electrical connector (1) from the chassis wiring harness electrical connector (2). 3. Remove the exhaust temperature sensor. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Exhaust Temperature Sensor Replacement - Position 1 > Page 4181 Note: A special anti-seize compound is used in the sensor or line fittings threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor or line fitting easier to remove. New, or service replacement sensors or line fittings already have the compound applied to the threads. If the sensor or line fittings are removed from an exhaust component and if for any reason the sensor or line fitting are reinstalled, the threads must have anti-seize compound applied before reinstallation. 1. If reinstalling the old temperature sensor or differential pressor sensor line fittings, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the exhaust temperature sensor. Tighten the sensor to 45 Nm (33 lb ft). 3. Connect the exhaust temperature sensor electrical connector (1) to the chassis wiring harness electrical connector (2). 4. Lower the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Exhaust Temperature Sensor Replacement - Position 1 > Page 4182 Exhaust Temperature Sensor: Service and Repair Exhaust Temperature Sensor Replacement Position 2 Exhaust Temperature Sensor Replacement - Position 2 Removal Procedure Caution: The exhaust temperature sensor and exhaust pressure differential sensor line fittings may be difficult to remove when the engine exhaust system temperature is below 48°C (120°F). Excessive force may damage the threads in the exhaust manifold or exhaust pipe. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the exhaust temperature sensor (3) electrical connector from the chassis wiring harness electrical connector (4). 3. Remove the exhaust temperature sensor. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Exhaust Temperature Sensor Replacement - Position 1 > Page 4183 Note: A special anti-seize compound is used in the sensor or line fittings threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor or line fitting easier to remove. New, or service replacement sensors or line fittings already have the compound applied to the threads. If the sensor or line fittings are removed from an exhaust component and if for any reason the sensor or line fitting are reinstalled, the threads must have anti-seize compound applied before reinstallation. 1. If reinstalling the old temperature sensor or differential pressor sensor line fittings, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the exhaust temperature sensor. Tighten the sensor to 45 Nm (33 lb ft). 3. Connect the exhaust temperature sensor (3) electrical connector to the chassis wiring harness electrical connector (4). 4. Lower the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Diagrams Fuel Level Sensor: Diagrams Component Connector End Views Fuel Level Sensor - Primary (Diesel) Fuel Level Sensor - Secondary (Diesel with 31 Series without NQZ) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Diagrams > Page 4187 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor (Cab/Chassis - Rear Tank) Fuel Level Sensor: Service and Repair Fuel Level Sensor (Cab/Chassis - Rear Tank) Fuel Level Sensor Replacement (Cab/Chassis - Rear Tank) Removal Procedure 1. Remove the sending unit. Refer to Fuel Sender Assembly Replacement (See: Fuel Delivery and Air Induction/Fuel Tank/Fuel Gauge Sender/Service and Repair). 2. Disconnect the fuel level sensor electrical connector (1). 3. Remove the sensor retaining clip (3). 4. Squeeze the locking tangs (2) and remove the fuel level sensor. Installation Procedure 1. Install the fuel level sensor. 2. Install the sensor retaining clip (3). 3. Connect the sensor electrical connector (1). 4. Install the sending unit. Refer to Fuel Sender Assembly Replacement (See: Fuel Delivery and Air Induction/Fuel Tank/Fuel Gauge Sender/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor (Cab/Chassis - Rear Tank) > Page 4190 Fuel Level Sensor: Service and Repair Fuel Level Sensor Replacement (35 Reg/Ext/Crew Cab With 34 gal Tank) Fuel Level Sensor Replacement (35 Reg/Ext/Crew Cab With 34 gal Tank) Removal Procedure 1. Remove the fuel tank module. Refer to Fuel Tank Fuel Pump Module Replacement (25 Ext/Crew Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15/25 Reg/Ext/Crw Cab With 34 Gal Tnk) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Ext/Crew Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Reg Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (35 Reg/Ext/Crew Cab With 34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair). 2. Disconnect the fuel level sensor wiring pigtail electrical connector (1) from the module cover. 3. Remove the fuel level sensor wiring pigtail from under the module clip (2). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor (Cab/Chassis - Rear Tank) > Page 4191 4. Gently push in the fuel level sensor retainers (1), disengaging them from the module reservoir. 5. Slide the fuel level sensor up, in order to remove the sensor from the module slot. Installation Procedure 1. Position the fuel level sensor over the slot in the reservoir and slide the sensor down into the slot. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor (Cab/Chassis - Rear Tank) > Page 4192 2. Ensure that the fuel level sensor retainers (1) engage the module reservoir. 3. Install the fuel level sensor wiring pigtail under the module clip (2) behind the fuel pump wires. 4. Connect the fuel level sensor wiring pigtail electrical connector (1) to the module cover. 5. Install the fuel tank module. Refer to Fuel Tank Fuel Pump Module Replacement (25 Ext/Crew Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15/25 Reg/Ext/Crw Cab With 34 Gal Tnk) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Ext/Crew Cab With 26 Gal Tank) ( See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Reg Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (35 Reg/Ext/Crew Cab With 34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor (Cab/Chassis - Rear Tank) > Page 4193 Fuel Level Sensor: Service and Repair Fuel Sender Assembly Replacement Fuel Sender Assembly Replacement Special Tools J 45722 Fuel Sender Lock Ring Wrench Removal Procedure 1. Remove the fuel tank. Refer to Fuel Tank Replacement (Pickup) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (Cab/Chassis - Front) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (Cab/Chassis - Rear) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement). 2. Disconnect the fuel lines from the sending unit. Refer to Metal Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Metal Collar Quick Connect Fitting Service) or Plastic Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). Caution: Avoid damaging the lock ring. Use only J-45722 to prevent damage to the lock ring. Caution: Do Not handle the fuel sender assembly by the fuel pipes. The amount of leverage generated by handling the fuel pipes could damage the joints. Note: Do NOT use impact tools. Significant force will be required to release the lock ring. The use of a hammer and screwdriver is not recommended. Secure the fuel tank in order to prevent fuel tank rotation. 3. Use the J 45722 and a long breaker-bar in order to unlock the fuel sender lock ring. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor (Cab/Chassis - Rear Tank) > Page 4194 4. Remove the sending unit and seal. Discard the seal. 5. Clean the sending unit sealing surfaces. Note: Some lock rings were manufactured with "DO NOT REUSE" stamped into them. These lock rings may be reused if they are not damaged or warped. Note: Inspect the lock ring for damage due to improper removal or installation procedures. If damage is found, install a NEW lock ring. Note: Check the lock ring for flatness. 6. Place the lock ring on a flat surface. Measure the clearance between the lock ring and the flat surface using a feeler gauge at 7 points. 7. If warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement. 8. If warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor (Cab/Chassis - Rear Tank) > Page 4195 1. Install the sending unit and a NEW seal. Note: Always replace the fuel sender seal when installing the fuel sender assembly. Replace the lock ring if necessary. DO NOT apply any type of lubrication in the seal groove. Ensure the lock ring is installed with the correct side facing upward. A correctly installed lock ring will only turn in a clockwise direction. 2. Use the J 45722 in order to install the fuel sender lock ring. Turn the fuel sender lock ring in a clockwise direction. 3. Connect the fuel lines to the sending unit. Refer to Metal Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Metal Collar Quick Connect Fitting Service) or Plastic Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). 4. Install the fuel tank. Refer to Fuel Tank Replacement (Pickup) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (Cab/Chassis - Front) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (Cab/Chassis - Rear) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Diagrams Fuel Tank Pressure Sensor: Diagrams Component Connector End Views Fuel Tank Pressure (FTP) Sensor (Gas) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Diagrams > Page 4199 Fuel Tank Pressure Sensor: Service and Repair Fuel Tank Pressure Sensor Replacement (35 Reg/Ext/Crew Cab With 34 Gal Tank) Removal Procedure 1. Remove the fuel tank. Refer to Fuel Tank Replacement (35 Reg/Ext/Crew Cab With 34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15 Ext/Crew Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15/25 Reg/Ext/Crw Cab With 34 Gal Tnk) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15 Rec Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (25 Ext/Crew Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement). 2. Remove the fuel tank pressure sensor by pulling straight up using a slight rocking motion. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Diagrams > Page 4200 1. Install the fuel tank pressure sensor. 2. Install the fuel tank pressure sensor cover. 3. Install the fuel tank. Refer to Fuel Tank Replacement (35 Reg/Ext/Crew Cab With 34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15 Ext/Crew Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15/25 Reg/Ext/Crw Cab With 34 Gal Tnk) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15 Rec Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (25 Ext/Crew Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > High Idle Switch > Component Information > Testing and Inspection High Idle Switch: Testing and Inspection High Idle Switch Diagnosis Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions )provide an overview of each diagnostic category. Diagnostic Fault Information Reference Information Schematic Reference Engine Controls Schematics (See: Diagrams/Electrical Diagrams) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning)for scan tool information Circuit/System Verification Ignition ON, observe the scan tool High Idle switch parameter while exercising the switch. The reading should change between ON/OFF. Circuit/System Testing 1. Ignition OFF, disconnect the harness connector at the high idle switch. 2. Test for less than 5 ohms between the ground circuit terminal A and ground. ‹› If greater than 5 ohms, test the ground circuit for an open/high resistance. 3. Ignition ON, verify the scan tool High Idle switch parameter is OFF. ‹› If not OFF, test the signal circuit for a short to ground. If the circuit tests normal, replace the ECM. 4. Install a 3A fused jumper wire between the signal circuit terminal C and ground. Verify the scan tool High Idle switch parameter is ON. ‹› If not ON, test the signal circuit for a short to voltage or an open/high resistance. If the circuit tests normal, replace the ECM. 5. If all circuits test normal, test or replace the high idle switch. Component Testing Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > High Idle Switch > Component Information > Testing and Inspection > Page 4204 1. Ignition OFF, disconnect the harness connector at the high idle switch. 2. Test for infinite resistance between the signal terminal C and the ground circuit terminal A with the switch in the open position. ‹› If less than infinite resistance, replace the high idle switch. 3. Test for less than 1 ohm between the signal terminal C and the ground terminal A with the switch in the closed position. ‹› If greater than 1 ohm, replace the high idle switch. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams Intake Air Temperature Sensor: Diagrams Component Connector End Views Intake Air Temperature (IAT) Sensor 2 (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Intake Air Temperature (IAT) Sensor 2 Replacement Intake Air Temperature Sensor: Service and Repair Intake Air Temperature (IAT) Sensor 2 Replacement Intake Air Temperature (IAT) Sensor 2 Replacement Removal Procedure 1. Remove the air intake pipe. Refer to Air Intake Pipe Replacement (See: Fuel Delivery and Air Induction/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair/Air Intake Pipe Replacement). 2. Disconnect the engine wiring harness electrical connector (1) from the intake air temperature (IAT) sensor pigtail. 3. Remove the IAT sensor (2) from the center intake manifold. Installation Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Intake Air Temperature (IAT) Sensor 2 Replacement > Page 4210 1. Install the IAT sensor (2) to the center intake manifold. Tighten the sensor to 25 Nm (18 lb ft). 2. Connect the engine wiring harness electrical connector (1) to the IAT sensor pigtail. 3. Install the air intake pipe. Refer to Air Intake Pipe Replacement (See: Fuel Delivery and Air Induction/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair/Air Intake Pipe Replacement). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Intake Air Temperature (IAT) Sensor 2 Replacement > Page 4211 Intake Air Temperature Sensor: Service and Repair Mass Airflow Sensor with Intake Air Temperature Sensor Replacement Mass Airflow Sensor with Intake Air Temperature Sensor Replacement Removal Procedure 1. Disconnect the engine wiring harness electrical connector (1) from the mass air flow (MAF)/intake air temperature (IAT) sensor. 2. Remove the MAF/IAT sensor TORX(R) screws. 3. Remove the MAF/IAT sensor. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Intake Air Temperature (IAT) Sensor 2 Replacement > Page 4212 1. Install the MAF/IAT sensor. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the MAF/IAT sensor TORX(R) screws. Tighten the screws to 8 Nm (70 lb in). 3. Connect the engine wiring harness electrical connector (1) to the MAF/IAT sensor. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams Knock Sensor: Diagrams Component Connector End Views Knock Sensor (KS) 1 (Gas) Knock Sensor (KS) 2 (Gas) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 4216 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams Manifold Pressure/Vacuum Sensor: Diagrams Component Connector End Views Manifold Absolute Pressure (MAP) Sensor (LU3) Manifold Absolute Pressure (MAP) Sensor (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Page 4220 Manifold Absolute Pressure (MAP) Sensor (Gas except LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Page 4221 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Page 4222 Manifold Pressure/Vacuum Sensor: Service and Repair Manifold Absolute Pressure Sensor Replacement Removal Procedure 1. Disconnect the engine wiring harness electrical connector (2) from the manifold absolute pressure (MAP) sensor. 2. Remove the MAP sensor bolt. 3. Remove the MAP sensor bracket and sensor. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Page 4223 1. Install the MAP sensor and bracket. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the MAP sensor bolt. Tighten the bolt to 10 Nm (89 lb in). 3. Connect the engine wiring harness electrical connector (2) to the MAP sensor. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams Oil Pressure Sensor: Diagrams Component Connector End Views Engine Oil Pressure (EOP) Sensor (Diesel) Engine Oil Pressure (EOP) Sensor (Gas except LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Page 4227 Engine Oil Pressure (EOP) Sensor (LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Page 4228 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Page 4229 Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement Special Tools DT-48827 Skip Shift Socket Removal Procedure 1. Remove the left wheelhouse inner panel. Refer to Front Wheelhouse Liner Replacement - Left Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Left Side)Front Wheelhouse Liner Replacement - Left Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Left Side). Note: Clean the area around the sensor. Do not allow debris to enter the engine. 2. Disconnect the oil pressure sensor electrical connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Page 4230 3. Using DT-48827 , remove the oil pressure sensor (1). Installation Procedure 1. Apply sealant to the threads of the oil pressure sensor. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Engine, Cooling and Exhaust/Engine/Specifications/Adhesives, Fluids, Lubricants, and Sealers) for the correct part number. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Using DT-48827 , install the oil pressure sensor (1). Tighten the sensor to 49 Nm (36 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Page 4231 3. Connect the oil pressure sensor electrical connector. 4. Install the left wheelhouse inner panel. Refer to Front Wheelhouse Liner Replacement - Left Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Left Side)Front Wheelhouse Liner Replacement - Left Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Left Side). 5. Check and add engine oil if necessary. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations Oxygen Sensor: Locations Harness Routing Views Heated Oxygen Sensor (HO2S) Jumper Harness Routing (LY6) 1 - X125 2 - Heated Oxygen Sensor (HO2S) Bank 2 Sensor 2 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 4235 Oxygen Sensor: Diagrams Component Connector End Views Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 (LU3) Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 (Gas except LU3 and except ZW9) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 4236 Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 (LY6 or L96 with ZW9) Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 2 (LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 4237 Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 2 (Gas except LU3) Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 (LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 4238 Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 (Gas except LU3 and except ZW9) Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 (LY6 or L96 with ZW9) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 4239 Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 2 (LU3) Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 2 (Gas except LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 4240 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service Precautions > Excessive Force and Oxygen Sensor Caution Oxygen Sensor: Service Precautions Excessive Force and Oxygen Sensor Caution Excessive Force and Oxygen Sensor Caution Caution: The oxygen sensor may be difficult to remove when the engine temperature is below 48°C (120°F). Excessive force may damage threads in the exhaust manifold or the exhaust pipe. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service Precautions > Excessive Force and Oxygen Sensor Caution > Page 4243 Oxygen Sensor: Service Precautions Heated Oxygen and Oxygen Sensor Caution Heated Oxygen and Oxygen Sensor Caution Caution: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen sensor (O2S). Removing the pigtail or the connector will affect sensor operation. Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical connector and the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of any type. Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring, connector, or terminal is damaged. This external clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air reference and degraded sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. * Do not damage the sensor pigtail and harness wires in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp bends or kinks could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire, where applicable. Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will cause poor engine performance. * Ensure that the peripheral seal remains intact on the vehicle harness connector in order to prevent damage due to water intrusion. The engine harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service Precautions > Excessive Force and Oxygen Sensor Caution > Page 4244 Oxygen Sensor: Service Precautions Heated Oxygen Sensor Resistance Learn Reset Caution Heated Oxygen Sensor Resistance Learn Reset Caution Caution: When replacing the HO2S perform the following: * A code clear with a scan tool, regardless of whether or not a DTC is set * HO2S heater resistance learn reset with a scan tool, where available Perform the above in order to reset the HO2S resistance learned value and avoid possible HO2S failure. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service Precautions > Excessive Force and Oxygen Sensor Caution > Page 4245 Oxygen Sensor: Service Precautions Silicon Contamination of Heated Oxygen Sensors Caution Silicon Contamination of Heated Oxygen Sensors Caution Caution: Contamination of the oxygen sensor can result from the use of an inappropriate RTV sealant (not oxygen sensor safe) or excessive engine coolant or oil consumption. Remove the HO2S and visually inspect the portion of the sensor exposed to the exhaust stream in order to check for contamination. If contaminated, the portion of the sensor exposed to the exhaust stream will have a white powdery coating. Silicon contamination causes a high but false HO2S signal voltage (rich exhaust indication). The control module will then reduce the amount of fuel delivered to the engine, causing a severe driveability problem. Eliminate the source of contamination before replacing the oxygen sensor. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Diagrams Pressure Feedback Exhaust Sensor: Diagrams Component Connector End Views Exhaust Pressure Differential Sensor (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams Transmission Position Switch/Sensor: Diagrams Component Connector End Views Park/Neutral Position (PNP) Switch (M30) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 4252 Transmission Position Switch/Sensor: Service and Repair Manual Shift Shaft, Detent Lever, and Position Switch Assembly Replacement Removal Procedure 1. Remove the control valve assembly from the transmission. Refer to Control Valve Body Replacement (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Valve Body/Service and Repair). Note: The detent lever/IMS retaining bolt contains patch lock material on the threads. Do not reuse the retaining bolt. 2. Remove the detent lever/IMS retaining bolt (1) using a T27 TORX(R) bit and discard the retaining bolt. Caution: DO NOT mar the transmission case surface around the spherical pin when removing or installing the spherical pin. An unmarred surface is required to maintain the seal between the control valve assembly and the transmission case. Caution: DO NOT twist the spherical pin when removing the pin from the transmission case. Damage to the transmission case can occur. 3. Place a protective plate on the transmission case surface around the spherical pin (3). Remove the spherical pin (3) from the transmission case. 4. Slide the manual shift shaft (5) through the detent lever/IMS assembly (4) and through the manual shift shaft seal. 5. Rotate the detent lever/IMS assembly to disengage the park pawl apply assembly (2). Remove the detent lever/IMS assembly (4). Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 4253 1. Place the new detent lever/IMS assembly (4) in position in the transmission case. Rotate the detent lever/IMS assembly to engage the park pawl apply assembly (2). Reinstall the manual shift shaft (5) through the manual shift shaft seal and through the detent lever/IMS assembly (4). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Push the manual shift shaft (5) into the final position in the transmission case. 3. Install the spherical pin (3) into the transmission case that retains the manual shift shaft. 4. Install the detent lever/IMS retaining bolt (1) using a T27 TORX(R) bit. Tighten the bolt (1) to 10 Nm (92 lb in). 5. Install the control valve assembly. Refer to Control Valve Body Replacement (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Valve Body/Service and Repair). Note: The FastLearn, adapt, procedure must be performed. This can be done in 1 step using a scan tool. If this procedure is not done, the TCM adaptive values will be at the settings that it learned for the old components and will be in slow adaptive mode. Under these conditions, it will take an unacceptably long time for the adaptive values to converge to levels suitable for the new transmission. 6. Perform the FastLearn procedure. Refer to FastLearn Procedure (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Testing and Inspection/Programming and Relearning). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Turbocharger Vane Position Sensor > Component Information > Technical Service Bulletins > Engine - Info on Duramax Turbo Vane Position Sensor Turbocharger Vane Position Sensor: Technical Service Bulletins Engine - Info on Duramax Turbo Vane Position Sensor INFORMATION Bulletin No.: 10-06-04-014 Date: November 03, 2010 Subject: Information on Duramax Turbo Vane Position Sensor Models: 2010-2011 Chevrolet Express Vans, Silverado 2010-2011 GMC Savana Vans, Sierra Equipped with Duramax(TM) Diesel Engine (RPOs LGH, LML) An improvement has been implemented to the turbocharger vane position sensor. Some turbochargers existing in inventory have the old style vane position sensor. If turbochargers, GM P/N 12635325 or 12635167 are being replaced, the original turbo vane sensor should be removed and replaced with the new style sensor, GM P/N 12643471. Turbochargers that are supersessions to these part numbers will have the new style vane position sensor and no action is necessary. Parts Information Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Turbocharger Vane Position Sensor > Component Information > Technical Service Bulletins > Page 4258 Turbocharger Vane Position Sensor: Diagrams Component Connector End Views Turbocharger Vane Position Sensor (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > A/T - Shifting/Poor Performance Vehicle Speed Sensor: Technical Service Bulletins A/T - Shifting/Poor Performance INFORMATION Bulletin No.: 01-03-10-010G Date: July 22, 2009 Subject: Inspection of Tire and Wheel Size Prior to Diagnosis of Transmission Shifts, Poor Performance, Speedometer, Cruise Control Concerns Models: 2001-2007 Chevrolet Silverado Pickup (Classic) Models Equipped with Allison(R) Automatic Transmission Only 2001-2007 GMC Sierra Pickup (Classic) Models Equipped with Allison(R) Automatic Transmission Only 2007-2010 Chevrolet Silverado Pickup HD Models 2007-2010 GMC Sierra Pickup HD Models Supercede: This bulletin is being revised to add the 2008-2010 model years, update the tire size information and reference the vehicle tire information label locations. Please discard Corporate Bulletin Number 01-03-10-010F (Section 03 - Suspension). GM has developed and matched specific tires for your vehicle. The original equipment tires and their respective size installed on the vehicle when it was new, were designed to meet General Motors Tire Performance Criteria Specification (TPC Spec) system rating. GM's exclusive TPC Spec system considers over a dozen critical specifications that impact the overall performance of the vehicle. A truck that has different tires and wheels from the original equipment designed for that vehicle will have engine power/performance concerns, transmission shift concerns, speedometer registered speed concerns, cruise control concerns and increased steering effort, especially during parking lot maneuvers at slow speeds. The engine control module (ECM) and transmission control module (TCM) use engine speed (RPM) and vehicle speed sensor (VSS) inputs as operational parameters for engine torque, transmission shifting, cruise control operation and speedometer indicated vehicle speed. Calibrations for different tire/wheel combinations are not available. Therefore, changing of tire and/or wheel size should not be undertaken by dealerships or truck owners. Proper diagnosis of engine, transmission, speedometer and cruise control concerns MUST begin with an inspection of tire/wheel size. Important A vehicle specific Tire and Loading Information label is attached to the center pillar (B-pillar) of the vehicle. With the driver's door open, you will find the label attached below the door lock post (striker). The label shows the size of the original equipment tires and the recommended cold tire inflation pressures.A vehicle specific Certification/Tire label is found on the rear edge of the driver's door. The label shows the size of the original equipment tires and the recommended cold tire inflation pressures. 2001-2007 Pickups (Classic) Equipped with Allison(R) Automatic Transmission Only Inspect the vehicle for the proper tire size as indicated in the following information. - The 2500 series trucks have LT245/75R16E tires as standard equipment. - The 3500 series trucks with single rear wheels have LT265/75R16E tires as standard equipment. - The 3500 series trucks with dual rear wheels have LT215/85R16D tires as standard equipment. 2007 Pickups HD Models (New Design Pickups) Inspect the vehicle for the proper tire size as indicated in the following information. - The 2500 series trucks have LT245/75R16E tires as standard equipment. - The 3500 series trucks with single rear wheels have LT265/75R16E tires as standard equipment. - The 3500 series trucks with dual rear wheels have LT215/85R16E tires as standard equipment. 2008-2010 Pickups HD Models (New Design Pickups) Inspect the vehicle for the proper tire size as indicated in the following information. - The 2500 series trucks have LT245/75R16E tires as standard equipment. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > A/T - Shifting/Poor Performance > Page 4263 - The 3500 series trucks with single rear wheels have LT265/75R16E tires as standard equipment. - The 3500 series trucks with dual rear wheels have LT225/75R17E tires as standard equipment. If a truck is found to have other than the above listed tire sizes, no further diagnosis should be undertaken until the original size tires and wheels are reinstalled on the truck. Warranty Information Reinstalling the proper wheels and tires on the vehicle, prior to performing any type of diagnosis of the truck, would be considered truck owner responsibility and not a warranty repair. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Page 4264 Vehicle Speed Sensor: Locations Harness Routing Views Engine Chassis Harness Routing - Rear (Diesel) 1 - X300 2 - G300 3 - Automatic Transmission Turbine Speed Sensor (MW7) 4 - Automatic Transmission (MW7) 5 - Vehicle Speed Sensor (VSS) (MW7) 6 - X124 (PTO) 7 - Power Take Off (PTO) Module (PTO) 8 - X175 (MW7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Page 4265 Vehicle Speed Sensor: Diagrams Component Connector End Views Vehicle Speed Sensor (VSS) (M30, TZ0, MYC and MW7or M99 with NQG or NQF) Vehicle Speed Sensor (VSS) (MW7 except NQG or NQF) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Page 4266 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Tremec 5-Speed (M96) - Manual Transmission Vehicle Speed Sensor: Service and Repair Tremec 5-Speed (M96) - Manual Transmission Vehicle Speed Sensor Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Tremec 5-Speed (M96) - Manual Transmission > Page 4269 Vehicle Speed Sensor: Service and Repair Tremec 5-Speed (TZ0) - Manual Transmission Vehicle Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the vehicle speed sensor (VSS) electrical connector (1). 3. Remove the VSS and O-ring seal. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Tremec 5-Speed (M96) - Manual Transmission > Page 4270 1. Coat a NEW O-ring seal with a thin film of Synchro-mesh transmission fluid GM P/N 12345349 (Canadian P/N 10953465), or equivalent. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the VSS and O-ring seal. Tighten the VSS to 16 Nm (12 lb ft). 3. Connect the VSS electrical connector (1). 4. Lower the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Tremec 5-Speed (M96) - Manual Transmission > Page 4271 Vehicle Speed Sensor: Service and Repair MP 1222/1225/1226-NQG - Transfer Case Vehicle Speed Sensor Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Tremec 5-Speed (M96) - Manual Transmission > Page 4272 Vehicle Speed Sensor: Service and Repair MP 1625/1626-NQF - Transfer Case Vehicle Speed Sensor Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Tremec 5-Speed (M96) - Manual Transmission > Page 4273 Vehicle Speed Sensor: Service and Repair MP 3023/3024-NQH - Transfer Case Vehicle Speed Sensor Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Technical Service Bulletins > Recalls: > 11054 > Apr > 11 > Recall - Replace Exhaust Gas Temperature Sensor Technical Service Bulletin # 11054 Date: 110412 Recall - Replace Exhaust Gas Temperature Sensor PRODUCT EMISSION Bulletin No.: 11054 Date: April 12, 2011 Subject: 11054 - Reduced Engine Performance and Emission Control - Replace Exhaust Gas Temperature Sensors Models: 2010 Chevrolet Express, Silverado HD 2010 GMC Savana, Sierra HD With 6.6L V8 Duramax Diesel Engine (LMM) 2007-2009 Chevrolet Express, Kodiak, Silverado HD 2007-2009 GMC Savana, Sierra HD, TopKick With 6.6L V8 Duramax Diesel Engine (LMM) Serviced with a Suspect EGT Sensor Condition General Motors has decided to conduct a Voluntary Emission Recall involving certain 2010 model year Chevrolet Express, Silverado HD; and GMC Savana, Sierra HD vehicles equipped with a 6.6L V8 Duramax diesel engine (LMM); and 2007-2009 model year Chevrolet Express, Kodiak, Silverado HD; and GMC Savana, Sierra HD, and TopKick vehicles equipped with a 6.6L V8 Duramax diesel engine (LMM) that may have been serviced with a suspect Exhaust Gas Temperature (EGT) sensor. On these vehicles, the circuit board welds on the EGT sensors in the exhaust system may not be to GM specification. If a weld fails, the Service Engine Soon light will illuminate in the instrument panel, the exhaust gas may not be filtered properly, and the engine power may be reduced. Correction Dealers are to replace both EGT sensors. Vehicles Involved Involved are certain 2010 model year Chevrolet Express, Silverado HD; and GMC Savana, Sierra HD vehicles equipped with a 6.6L V8 Duramax diesel engine (LMM); and 2007-2009 model year Chevrolet Express, Kodiak, Silverado HD; and GMC Savana, Sierra HD, and TopKick vehicles equipped with a 6.6L V8 Duramax diesel engine (LMM) that may have been serviced with a suspect EGT sensor. Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Required Field Actions section in the Global Warranty system. Not all vehicles may be involved. For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to US and Canadian dealers through the GM GlobalConnect Recall Reports, or sent directly to export dealers. Dealers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information Parts required to complete this recall are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Service Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Technical Service Bulletins > Recalls: > 11054 > Apr > 11 > Recall - Replace Exhaust Gas Temperature Sensor > Page 4283 1. Remove and replace position 1 and position 2 exhaust gas temperature sensors (1). Refer to Exhaust Temperature Sensor Replacement in SI. 2. CALIFORNIA, CONNECTICUT, MASSACHUSETTS, MAINE, OREGON, VERMONT, & WASHINGTON VEHICLES ONLY: Install a Recall Identification Label. Also, for California vehicles complete a "Proof of Correction" certificate upon recall completion. Recall Identification Label California/Connecticut/Massachusetts/Maine/Oregon/Vermont/Washington Vehicles Only) Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five-digit dealer code of the dealer performing the recall service. This information may be inserted with a ballpoint pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Recall Identification Label, be sure to pull the tab to allow adhesion of the clear protective covering. Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials by ordering on the web from DWD Store, www.gmdealerworld.com, and then click on the DWD Store link. Request Item Number S-1015 when ordering. Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a transaction using the table below. Customer Notification - For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter included with this bulletin). In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper maintenance. The vehicle may fail a state or local emission inspection test if the recall work is not completed. Customer Notification - For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the attached sample letter. In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Technical Service Bulletins > Recalls: > 11054 > Apr > 11 > Recall - Replace Exhaust Gas Temperature Sensor > Page 4284 maintenance. The vehicle may fail a state or local emission inspection test if the recall work is not completed. Dealer Recall Responsibility All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. ***THE FOLLOWING 2 PARAGRAPHS ARE NOT FOR CANADA OR EXPORT*** When a California emissions recall is completed by a GM dealer, the dealer must provide the vehicle owner a "Proof of Correction Certificate" which the owner may need to present to the California Department Of Motor Vehicles (DMV) when renewing their vehicle registration. Without this correction certificate, the owner may be unable to renew their vehicle registration. Additional Certificates can be obtained, at no charge, from Dealer Support Materials by ordering on the web from the DWD Store, www.gmdealerworld.com, and then click on the DWD Store link; request GM Item Number 1825 when ordering. Disclaimer Owner Letter Owner Letter Dear General Motors Customer: This notice is sent to inform you that General Motors is conducting a voluntary emission recall that includes your vehicle. Reason For This Recall: General Motors has decided to conduct a Voluntary Emission Recall involving certain 2010 model year Chevrolet Express, Silverado HD; and GMC Savana, Sierra HD vehicles equipped with a 6.6L V8 Duramax diesel engine; and 2007-2009 model year Chevrolet Express, Kodiak, Silverado HD; and GMC Savana, Sierra HD, and TopKick vehicles equipped with a 6.6L V8 Duramax diesel engine that may have been serviced with a suspect Exhaust Gas Temperature (EGT) sensor. The circuit board welds on the EGT sensors in the exhaust system may not be to GM specification. If a weld fails, the Service Engine Soon light will illuminate in the instrument panel, the exhaust gas may not be filtered properly, and the engine power may be reduced. What Will Be Done: Your GM dealer will replace both EGT sensors. This service will be performed for you at no charge. What You Should Do: Please contact your GM dealer as soon as possible to arrange a service date and to assure parts availability. Instructions for making this correction have been sent to your dealer. Please ask your dealer if you wish to know how much time will be needed to schedule, process, and repair your vehicle. If you have any questions or need any assistance, just contact your dealer or the appropriate Customer Assistance Center at the number listed below. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Technical Service Bulletins > Recalls: > 11054 > Apr > 11 > Recall - Replace Exhaust Gas Temperature Sensor > Page 4285 Emission Law Information: In order to ensure your full protection under the emission warranty made applicable to your vehicle by State and Federal Law, and your right to participate in future recalls, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could legally be determined to be lack of proper maintenance of your vehicle. Also, your vehicle may fail a state or local emission inspection if this recall is not accomplished. IMPORTANT MESSAGE FOR CALIFORNIA RESIDENTS The California Air Resources Board (CARB) requires vehicle emission recalls be completed prior to California registration renewal. Uncorrected emission recalls will result in the inability to renew your California vehicle registration. At the time of emission recall completion, your California dealer will issue a "Proof of Correction Certificate". Keep this certificate and, if required, present it to the Department of Motor Vehicles when renewing your California registration as proof of recall completion. We are sorry to cause you this inconvenience; however, we have taken this action in the interest of your continued satisfaction with our products. Jim Moloney General Director, Customer and Relationship Services 11054 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON Control Module: All Technical Service Bulletins A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 4291 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 4292 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 4293 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Exhaust Temperature Sensor: > 08-07-30-020E > Mar > 10 > Recalls for Exhaust Temperature Sensor: > 11054 > Apr > 11 > Recall - Replace Exhaust Gas Temperature Sensor Technical Service Bulletin # 11054 Date: 110412 Recall - Replace Exhaust Gas Temperature Sensor PRODUCT EMISSION Bulletin No.: 11054 Date: April 12, 2011 Subject: 11054 - Reduced Engine Performance and Emission Control - Replace Exhaust Gas Temperature Sensors Models: 2010 Chevrolet Express, Silverado HD 2010 GMC Savana, Sierra HD With 6.6L V8 Duramax Diesel Engine (LMM) 2007-2009 Chevrolet Express, Kodiak, Silverado HD 2007-2009 GMC Savana, Sierra HD, TopKick With 6.6L V8 Duramax Diesel Engine (LMM) Serviced with a Suspect EGT Sensor Condition General Motors has decided to conduct a Voluntary Emission Recall involving certain 2010 model year Chevrolet Express, Silverado HD; and GMC Savana, Sierra HD vehicles equipped with a 6.6L V8 Duramax diesel engine (LMM); and 2007-2009 model year Chevrolet Express, Kodiak, Silverado HD; and GMC Savana, Sierra HD, and TopKick vehicles equipped with a 6.6L V8 Duramax diesel engine (LMM) that may have been serviced with a suspect Exhaust Gas Temperature (EGT) sensor. On these vehicles, the circuit board welds on the EGT sensors in the exhaust system may not be to GM specification. If a weld fails, the Service Engine Soon light will illuminate in the instrument panel, the exhaust gas may not be filtered properly, and the engine power may be reduced. Correction Dealers are to replace both EGT sensors. Vehicles Involved Involved are certain 2010 model year Chevrolet Express, Silverado HD; and GMC Savana, Sierra HD vehicles equipped with a 6.6L V8 Duramax diesel engine (LMM); and 2007-2009 model year Chevrolet Express, Kodiak, Silverado HD; and GMC Savana, Sierra HD, and TopKick vehicles equipped with a 6.6L V8 Duramax diesel engine (LMM) that may have been serviced with a suspect EGT sensor. Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Required Field Actions section in the Global Warranty system. Not all vehicles may be involved. For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to US and Canadian dealers through the GM GlobalConnect Recall Reports, or sent directly to export dealers. Dealers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information Parts required to complete this recall are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Service Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Exhaust Temperature Sensor: > 08-07-30-020E > Mar > 10 > Recalls for Exhaust Temperature Sensor: > 11054 > Apr > 11 > Recall - Replace Exhaust Gas Temperature Sensor > Page 4303 1. Remove and replace position 1 and position 2 exhaust gas temperature sensors (1). Refer to Exhaust Temperature Sensor Replacement in SI. 2. CALIFORNIA, CONNECTICUT, MASSACHUSETTS, MAINE, OREGON, VERMONT, & WASHINGTON VEHICLES ONLY: Install a Recall Identification Label. Also, for California vehicles complete a "Proof of Correction" certificate upon recall completion. Recall Identification Label California/Connecticut/Massachusetts/Maine/Oregon/Vermont/Washington Vehicles Only) Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five-digit dealer code of the dealer performing the recall service. This information may be inserted with a ballpoint pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Recall Identification Label, be sure to pull the tab to allow adhesion of the clear protective covering. Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials by ordering on the web from DWD Store, www.gmdealerworld.com, and then click on the DWD Store link. Request Item Number S-1015 when ordering. Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a transaction using the table below. Customer Notification - For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter included with this bulletin). In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper maintenance. The vehicle may fail a state or local emission inspection test if the recall work is not completed. Customer Notification - For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the attached sample letter. In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Exhaust Temperature Sensor: > 08-07-30-020E > Mar > 10 > Recalls for Exhaust Temperature Sensor: > 11054 > Apr > 11 > Recall - Replace Exhaust Gas Temperature Sensor > Page 4304 maintenance. The vehicle may fail a state or local emission inspection test if the recall work is not completed. Dealer Recall Responsibility All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. ***THE FOLLOWING 2 PARAGRAPHS ARE NOT FOR CANADA OR EXPORT*** When a California emissions recall is completed by a GM dealer, the dealer must provide the vehicle owner a "Proof of Correction Certificate" which the owner may need to present to the California Department Of Motor Vehicles (DMV) when renewing their vehicle registration. Without this correction certificate, the owner may be unable to renew their vehicle registration. Additional Certificates can be obtained, at no charge, from Dealer Support Materials by ordering on the web from the DWD Store, www.gmdealerworld.com, and then click on the DWD Store link; request GM Item Number 1825 when ordering. Disclaimer Owner Letter Owner Letter Dear General Motors Customer: This notice is sent to inform you that General Motors is conducting a voluntary emission recall that includes your vehicle. Reason For This Recall: General Motors has decided to conduct a Voluntary Emission Recall involving certain 2010 model year Chevrolet Express, Silverado HD; and GMC Savana, Sierra HD vehicles equipped with a 6.6L V8 Duramax diesel engine; and 2007-2009 model year Chevrolet Express, Kodiak, Silverado HD; and GMC Savana, Sierra HD, and TopKick vehicles equipped with a 6.6L V8 Duramax diesel engine that may have been serviced with a suspect Exhaust Gas Temperature (EGT) sensor. The circuit board welds on the EGT sensors in the exhaust system may not be to GM specification. If a weld fails, the Service Engine Soon light will illuminate in the instrument panel, the exhaust gas may not be filtered properly, and the engine power may be reduced. What Will Be Done: Your GM dealer will replace both EGT sensors. This service will be performed for you at no charge. What You Should Do: Please contact your GM dealer as soon as possible to arrange a service date and to assure parts availability. Instructions for making this correction have been sent to your dealer. Please ask your dealer if you wish to know how much time will be needed to schedule, process, and repair your vehicle. If you have any questions or need any assistance, just contact your dealer or the appropriate Customer Assistance Center at the number listed below. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Exhaust Temperature Sensor: > 08-07-30-020E > Mar > 10 > Recalls for Exhaust Temperature Sensor: > 11054 > Apr > 11 > Recall - Replace Exhaust Gas Temperature Sensor > Page 4305 Emission Law Information: In order to ensure your full protection under the emission warranty made applicable to your vehicle by State and Federal Law, and your right to participate in future recalls, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could legally be determined to be lack of proper maintenance of your vehicle. Also, your vehicle may fail a state or local emission inspection if this recall is not accomplished. IMPORTANT MESSAGE FOR CALIFORNIA RESIDENTS The California Air Resources Board (CARB) requires vehicle emission recalls be completed prior to California registration renewal. Uncorrected emission recalls will result in the inability to renew your California vehicle registration. At the time of emission recall completion, your California dealer will issue a "Proof of Correction Certificate". Keep this certificate and, if required, present it to the Department of Motor Vehicles when renewing your California registration as proof of recall completion. We are sorry to cause you this inconvenience; however, we have taken this action in the interest of your continued satisfaction with our products. Jim Moloney General Director, Customer and Relationship Services 11054 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module: > 11054 > Apr > 11 > Recall - Replace Exhaust Gas Temperature Sensor Technical Service Bulletin # 11054 Date: 110412 Recall - Replace Exhaust Gas Temperature Sensor PRODUCT EMISSION Bulletin No.: 11054 Date: April 12, 2011 Subject: 11054 - Reduced Engine Performance and Emission Control - Replace Exhaust Gas Temperature Sensors Models: 2010 Chevrolet Express, Silverado HD 2010 GMC Savana, Sierra HD With 6.6L V8 Duramax Diesel Engine (LMM) 2007-2009 Chevrolet Express, Kodiak, Silverado HD 2007-2009 GMC Savana, Sierra HD, TopKick With 6.6L V8 Duramax Diesel Engine (LMM) Serviced with a Suspect EGT Sensor Condition General Motors has decided to conduct a Voluntary Emission Recall involving certain 2010 model year Chevrolet Express, Silverado HD; and GMC Savana, Sierra HD vehicles equipped with a 6.6L V8 Duramax diesel engine (LMM); and 2007-2009 model year Chevrolet Express, Kodiak, Silverado HD; and GMC Savana, Sierra HD, and TopKick vehicles equipped with a 6.6L V8 Duramax diesel engine (LMM) that may have been serviced with a suspect Exhaust Gas Temperature (EGT) sensor. On these vehicles, the circuit board welds on the EGT sensors in the exhaust system may not be to GM specification. If a weld fails, the Service Engine Soon light will illuminate in the instrument panel, the exhaust gas may not be filtered properly, and the engine power may be reduced. Correction Dealers are to replace both EGT sensors. Vehicles Involved Involved are certain 2010 model year Chevrolet Express, Silverado HD; and GMC Savana, Sierra HD vehicles equipped with a 6.6L V8 Duramax diesel engine (LMM); and 2007-2009 model year Chevrolet Express, Kodiak, Silverado HD; and GMC Savana, Sierra HD, and TopKick vehicles equipped with a 6.6L V8 Duramax diesel engine (LMM) that may have been serviced with a suspect EGT sensor. Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Required Field Actions section in the Global Warranty system. Not all vehicles may be involved. For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to US and Canadian dealers through the GM GlobalConnect Recall Reports, or sent directly to export dealers. Dealers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information Parts required to complete this recall are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Service Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module: > 11054 > Apr > 11 > Recall - Replace Exhaust Gas Temperature Sensor > Page 4311 1. Remove and replace position 1 and position 2 exhaust gas temperature sensors (1). Refer to Exhaust Temperature Sensor Replacement in SI. 2. CALIFORNIA, CONNECTICUT, MASSACHUSETTS, MAINE, OREGON, VERMONT, & WASHINGTON VEHICLES ONLY: Install a Recall Identification Label. Also, for California vehicles complete a "Proof of Correction" certificate upon recall completion. Recall Identification Label California/Connecticut/Massachusetts/Maine/Oregon/Vermont/Washington Vehicles Only) Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five-digit dealer code of the dealer performing the recall service. This information may be inserted with a ballpoint pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Recall Identification Label, be sure to pull the tab to allow adhesion of the clear protective covering. Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials by ordering on the web from DWD Store, www.gmdealerworld.com, and then click on the DWD Store link. Request Item Number S-1015 when ordering. Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a transaction using the table below. Customer Notification - For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter included with this bulletin). In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper maintenance. The vehicle may fail a state or local emission inspection test if the recall work is not completed. Customer Notification - For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the attached sample letter. In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module: > 11054 > Apr > 11 > Recall - Replace Exhaust Gas Temperature Sensor > Page 4312 maintenance. The vehicle may fail a state or local emission inspection test if the recall work is not completed. Dealer Recall Responsibility All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. ***THE FOLLOWING 2 PARAGRAPHS ARE NOT FOR CANADA OR EXPORT*** When a California emissions recall is completed by a GM dealer, the dealer must provide the vehicle owner a "Proof of Correction Certificate" which the owner may need to present to the California Department Of Motor Vehicles (DMV) when renewing their vehicle registration. Without this correction certificate, the owner may be unable to renew their vehicle registration. Additional Certificates can be obtained, at no charge, from Dealer Support Materials by ordering on the web from the DWD Store, www.gmdealerworld.com, and then click on the DWD Store link; request GM Item Number 1825 when ordering. Disclaimer Owner Letter Owner Letter Dear General Motors Customer: This notice is sent to inform you that General Motors is conducting a voluntary emission recall that includes your vehicle. Reason For This Recall: General Motors has decided to conduct a Voluntary Emission Recall involving certain 2010 model year Chevrolet Express, Silverado HD; and GMC Savana, Sierra HD vehicles equipped with a 6.6L V8 Duramax diesel engine; and 2007-2009 model year Chevrolet Express, Kodiak, Silverado HD; and GMC Savana, Sierra HD, and TopKick vehicles equipped with a 6.6L V8 Duramax diesel engine that may have been serviced with a suspect Exhaust Gas Temperature (EGT) sensor. The circuit board welds on the EGT sensors in the exhaust system may not be to GM specification. If a weld fails, the Service Engine Soon light will illuminate in the instrument panel, the exhaust gas may not be filtered properly, and the engine power may be reduced. What Will Be Done: Your GM dealer will replace both EGT sensors. This service will be performed for you at no charge. What You Should Do: Please contact your GM dealer as soon as possible to arrange a service date and to assure parts availability. Instructions for making this correction have been sent to your dealer. Please ask your dealer if you wish to know how much time will be needed to schedule, process, and repair your vehicle. If you have any questions or need any assistance, just contact your dealer or the appropriate Customer Assistance Center at the number listed below. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module: > 11054 > Apr > 11 > Recall - Replace Exhaust Gas Temperature Sensor > Page 4313 Emission Law Information: In order to ensure your full protection under the emission warranty made applicable to your vehicle by State and Federal Law, and your right to participate in future recalls, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could legally be determined to be lack of proper maintenance of your vehicle. Also, your vehicle may fail a state or local emission inspection if this recall is not accomplished. IMPORTANT MESSAGE FOR CALIFORNIA RESIDENTS The California Air Resources Board (CARB) requires vehicle emission recalls be completed prior to California registration renewal. Uncorrected emission recalls will result in the inability to renew your California vehicle registration. At the time of emission recall completion, your California dealer will issue a "Proof of Correction Certificate". Keep this certificate and, if required, present it to the Department of Motor Vehicles when renewing your California registration as proof of recall completion. We are sorry to cause you this inconvenience; however, we have taken this action in the interest of your continued satisfaction with our products. Jim Moloney General Director, Customer and Relationship Services 11054 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON Control Module: Customer Interest A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 4322 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 4323 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 4324 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON Control Module: All Technical Service Bulletins A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 4330 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 4331 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 4332 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Component Information > Technical Service Bulletins > Page 4333 Control Module: Locations Harness Routing Views Engine Chassis Harness Routing - Top Front (Diesel) 1 - Battery - Right 2 - Fuse Holder 3 - X127 4 - X108 5 - X107 6 - X123 (PTO) 7 - Fuse Block Underhood 8 - X109 9 - Battery - Left 10 - Engine Control Module (ECM) 11 - Transmission Control Module (TCM) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Component Information > Technical Service Bulletins > Page 4334 Control Module: Diagrams Component Connector End Views Transmission Control Module (TCM) (M30) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Component Information > Technical Service Bulletins > Page 4335 Transmission Control Module (TCM) (MW7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Component Information > Technical Service Bulletins > Page 4336 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Component Information > Technical Service Bulletins > Page 4337 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Component Information > Technical Service Bulletins > Page 4338 Control Module: Service and Repair Transmission Control Module Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Component Information > Service and Repair Keyless Entry Module: Service and Repair Remote Control Door Lock Receiver Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Temperature Sensor > Component Information > Diagrams EGR Temperature Sensor: Diagrams Component Connector End Views Exhaust Gas Recirculation (EGR) Temperature Sensor 1 (Diesel) Exhaust Gas Recirculation (EGR) Temperature Sensor 2 (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Temperature Sensor > Component Information > Diagrams > Page 4344 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Temperature Sensor > Component Information > Service and Repair > Exhaust Gas Recirculation Valve Temperature Sensor Replacement - Position 1 EGR Temperature Sensor: Service and Repair Exhaust Gas Recirculation Valve Temperature Sensor Replacement - Position 1 Exhaust Gas Recirculation Valve Temperature Sensor Replacement - Position 1 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Temperature Sensor > Component Information > Service and Repair > Exhaust Gas Recirculation Valve Temperature Sensor Replacement - Position 1 > Page 4347 EGR Temperature Sensor: Service and Repair Exhaust Gas Recirculation Valve Temperature Sensor Replacement - Position 2 Exhaust Gas Recirculation Valve Temperature Sensor Replacement - Position 2 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Exhaust Pressure Differential Sensor Replacement (Pickup) Exhaust Pressure Differential Sensor: Service and Repair Exhaust Pressure Differential Sensor Replacement (Pickup) Exhaust Pressure Differential Sensor Replacement (Pickup) Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the chassis wiring harness electrical connector (1) from the exhaust differential pressure sensor (2). 3. Reposition the exhaust differential pressure sensor pipe assembly hose clamps (3). 4. Remove the exhaust differential pressure sensor pipe assembly hoses from the sensor. 5. Remove the exhaust differential pressure sensor bracket bolts (1). 6. Remove the exhaust differential pressure sensor (2). Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Exhaust Pressure Differential Sensor Replacement (Pickup) > Page 4352 1. Position the exhaust differential pressure sensor (2) to the bracket. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the exhaust differential pressure sensor bracket bolts (1). Tighten the bolts to 9 Nm (80 lb in). 3. Install the exhaust differential pressure sensor pipe assembly hoses to the sensor. 4. Position the exhaust differential pressure sensor pipe assembly hose clamps (3). 5. Connect the chassis wiring harness electrical connector (1) to the exhaust differential pressure sensor (2). 6. Lower the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Exhaust Pressure Differential Sensor Replacement (Pickup) > Page 4353 Exhaust Pressure Differential Sensor: Service and Repair Exhaust Pressure Differential Sensor Replacement (Cab/Chassis) Exhaust Pressure Differential Sensor Replacement (Cab/Chassis) Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the chassis wiring harness electrical connector (1) from the exhaust differential pressure sensor (2). 3. Reposition the exhaust differential pressure sensor pipe assembly hose clamps (3). 4. Remove the exhaust differential pressure sensor pipe assembly hoses from the sensor. 5. Remove the exhaust differential pressure sensor bracket bolts (1). 6. Remove the exhaust differential pressure sensor (2). Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Exhaust Pressure Differential Sensor Replacement (Pickup) > Page 4354 1. Position the exhaust differential pressure sensor (2) to the bracket. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the exhaust differential pressure sensor bracket bolts (1). Tighten the bolts to 9 Nm (80 lb in). 3. Install the exhaust differential pressure sensor pipe assembly hoses to the sensor. 4. Position the exhaust differential pressure sensor pipe assembly hose clamps (3). 5. Connect the chassis wiring harness electrical connector (1) to the exhaust differential pressure sensor (2). 6. Lower the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Exhaust Pressure Differential Sensor Replacement (Pickup) > Page 4355 Exhaust Pressure Differential Sensor: Service and Repair Exhaust Pressure Differential Sensor Pipe Replacement (Pickup) Exhaust Pressure Differential Sensor Pipe Replacement (Pickup) Removal Procedure Caution: The exhaust temperature sensor and exhaust pressure differential sensor line fittings may be difficult to remove when the engine exhaust system temperature is below 48°C (120°F). Excessive force may damage the threads in the exhaust manifold or exhaust pipe. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Reposition the exhaust differential pressure sensor pipe assembly hose clamps (3). 3. Remove the exhaust differential pressure sensor pipe assembly hoses from the sensor. 4. Remove the exhaust differential pressure sensor pipe bracket bolt and nut. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Exhaust Pressure Differential Sensor Replacement (Pickup) > Page 4356 5. Loosen the exhaust differential pressure sensor pipe assembly fittings (1). 6. Remove the exhaust differential pressure sensor pipe assembly. Installation Procedure Note: A special anti-seize compound is used in the sensor or line fittings threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor or line fitting easier to remove. New, or service replacement sensors or line fittings already have the compound applied to the threads. If the sensor or line fittings are removed from an exhaust component and if for any reason the sensor or line fitting are reinstalled, the threads must have anti-seize compound applied before reinstallation. 1. If reinstalling the old temperature sensor or differential pressor sensor line fittings, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Exhaust Pressure Differential Sensor Replacement (Pickup) > Page 4357 Note: Ensure to route the pipe assembly over the frame crossmember. 2. Position and install the exhaust differential pressure sensor pipe assembly to the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Tighten the exhaust differential pressure sensor pipe assembly fittings (1). Tighten the fittings to 45 Nm (33 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Exhaust Pressure Differential Sensor Replacement (Pickup) > Page 4358 4. Position the exhaust differential pressure sensor pipe bracket to the exhaust hanger and install the bolt and nut. Tighten the bracket bolt/nut to 9 Nm (80 lb in). 5. Install the exhaust differential pressure sensor pipe assembly hoses to the sensor. 6. Position the exhaust differential pressure sensor pipe assembly hose clamps (3). 7. Lower the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Exhaust Pressure Differential Sensor Replacement (Pickup) > Page 4359 Exhaust Pressure Differential Sensor: Service and Repair Exhaust Pressure Differential Sensor Pipe Replacement (Cab/Chassis) Exhaust Pressure Differential Sensor Pipe Replacement (Cab/Chassis) Removal Procedure Caution: The exhaust temperature sensor and exhaust pressure differential sensor line fittings may be difficult to remove when the engine exhaust system temperature is below 48°C (120°F). Excessive force may damage the threads in the exhaust manifold or exhaust pipe. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Reposition the exhaust differential pressure sensor pipe assembly hose clamps (3). 3. Remove the exhaust differential pressure sensor pipe assembly hoses from the sensor. 4. Remove the exhaust differential pressure sensor pipe bracket bolt and nut. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Exhaust Pressure Differential Sensor Replacement (Pickup) > Page 4360 5. Loosen the exhaust differential pressure sensor pipe assembly fittings (1). 6. Remove the exhaust differential pressure sensor pipe assembly. Installation Procedure Note: A special anti-seize compound is used in the sensor or line fittings threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor or line fitting easier to remove. New, or service replacement sensors or line fittings already have the compound applied to the threads. If the sensor or line fittings are removed from an exhaust component and if for any reason the sensor or line fitting are reinstalled, the threads must have anti-seize compound applied before reinstallation. 1. If reinstalling the old temperature sensor or differential pressor sensor line fittings, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Exhaust Pressure Differential Sensor Replacement (Pickup) > Page 4361 Note: Ensure to route the pipe assembly over the frame crossmember. 2. Position and install the exhaust differential pressure sensor pipe assembly to the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Tighten the exhaust differential pressure sensor pipe assembly fittings (1). Tighten the fittings to 45 Nm (33 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Exhaust Pressure Differential Sensor Replacement (Pickup) > Page 4362 4. Position the exhaust differential pressure sensor pipe bracket to the exhaust hanger and install the bolt and nut. Tighten the bracket bolt/nut to 9 Nm (80 lb in). 5. Install the exhaust differential pressure sensor pipe assembly hoses to the sensor. 6. Position the exhaust differential pressure sensor pipe assembly hose clamps (3). 7. Lower the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Diagrams Pressure Feedback Exhaust Sensor: Diagrams Component Connector End Views Exhaust Pressure Differential Sensor (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations Accelerator Pedal Position Sensor: Locations Harness Routing Views Brake Clutch Harness Routing 1 - Driver Door Frame 2 - X205 3 - X102 (JL1) 4 - Accelerator Pedal Position (APP) Sensor Connector 5 - Junction Block - Left I/P (except MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 4370 Accelerator Pedal Position Sensor: Diagrams Component Connector End Views Accelerator Pedal Position (APP) Sensor Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 4371 Accelerator Pedal Position Sensor: Description and Operation Accelerator Pedal Position System Description The accelerator pedal position (APP) sensor is mounted inside the accelerator pedal control assembly. The sensor is made up of the two individual sensors within a single housing. Each sensor has a unique functionality to determine pedal position. The accelerator pedal position (APP) system along with the engine control module (ECM) is used to calculate and control the amount of acceleration and deceleration through fuel injector control. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 4372 Accelerator Pedal Position Sensor: Service and Repair Accelerator Pedal Position Sensor Replacement Removal Procedure Caution: Handle the electronic throttle control components carefully. Use cleanliness in order to prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the electronic throttle control components. Do not immerse the electronic throttle control components in cleaning solvents of any type. 1. Remove the connector position assurance (CPA) retainer. 2. Disconnect the accelerator pedal position (APP) sensor electrical connector (1). 3. Remove the accelerator pedal bolts. 4. Remove the accelerator pedal. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 4373 Installation Procedure 1. Position the accelerator pedal to the accelerator pedal bracket. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the accelerator pedal bolts and tighten to 9 Nm (80 lb in).. 3. Connect the APP sensor electrical connector (1). 4. Install the CPA retainer. 5. Connect a scan tool to the diagnostic port in order to test for proper throttle-opening and throttle-closing range. 6. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle, and a wide open throttle (WOT). 7. Verify that the vehicle meets the following conditions: * The vehicle is not in a reduced engine power mode. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 4374 * The ignition is ON. * The engine is OFF. 8. Inspect the carpet fit under the accelerator pedal. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations Air Flow Meter/Sensor: Locations Harness Routing Views Engine Harness Routing - Top (4.3L) 1 - Mega Fuse Ring Terminal 2 - X175 (M30) 3 - J128 4 - J105 5 - J106 6 - J130 (M30 with NQG/NQH) 7 - Engine Control Module (ECM) X1 8 - Engine Control Module (ECM) X2 9 - G103 10 - X112 11 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Connector Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 4378 Air Flow Meter/Sensor: Diagrams Component Connector End Views Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (Diesel) Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (Gas) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 4379 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 4380 Air Flow Meter/Sensor: Service and Repair Mass Airflow Sensor with Intake Air Temperature Sensor Replacement Removal Procedure 1. Disconnect the engine wiring harness electrical connector (1) from the mass air flow (MAF)/intake air temperature (IAT) sensor. 2. Remove the MAF/IAT sensor TORX(R) screws. 3. Remove the MAF/IAT sensor. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 4381 1. Install the MAF/IAT sensor. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the MAF/IAT sensor TORX(R) screws. Tighten the screws to 8 Nm (70 lb in). 3. Connect the engine wiring harness electrical connector (1) to the MAF/IAT sensor. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Diagrams Fuel Pressure Sensor/Switch: Diagrams Component Connector End Views Fuel Rail Pressure (FRP) Sensor (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Diagrams > Page 4385 Fuel Pressure Sensor/Switch: Service and Repair Fuel Injection Fuel Rail Fuel Pressure Sensor Replacement Removal Procedure 1. Remove the exhaust gas recirculation (EGR) valve cooler. Refer to Exhaust Gas Recirculation Valve Cooler Replacement (See: Emission Control Systems/Exhaust Gas Recirculation/EGR Cooler/Service and Repair/Exhaust Gas Recirculation Valve Cooler Replacement). 2. Disconnect the engine wiring harness electrical connector (1) from the fuel rail fuel pressure sensor wiring harness extension electrical connector. 3. Remove the fuel rail fuel pressure sensor wiring harness extension clip (3) from the wiring harness bracket. 4. Remove the EGR valve cooler rear bracket bolts and bracket. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Diagrams > Page 4386 5. Disconnect the fuel rail fuel pressure sensor wiring harness extension (1) from the fuel rail fuel pressure sensor. 6. Prior to removal, clean the fuel rail fuel pressure sensor and surrounding area thoroughly with solvent, such as GM P/N 12377981 (Canadian P/N 10953463) or equivalent. 7. Using compressed air, thoroughly blow dry the sensor and surrounding area. 8. Remove the fuel rail fuel pressure sensor (2). Installation Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the fuel rail fuel pressure sensor (2). Tighten the sensor to 70 Nm (52 lb ft). 2. Connect the fuel rail fuel pressure sensor wiring harness extension (1) to the fuel rail fuel pressure sensor. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Diagrams > Page 4387 3. Position the EGR valve cooler rear bracket to the cylinder head and install the bolts. Tighten the bolts to 25 Nm (18 lb ft). 4. Connect the engine wiring harness electrical connector (1) to the fuel rail fuel pressure sensor wiring harness extension electrical connector. 5. Install the fuel rail fuel pressure sensor wiring harness extension clip (3) to the wiring harness bracket. 6. Install the EGR valve cooler. Refer to Exhaust Gas Recirculation Valve Cooler Replacement (See: Emission Control Systems/Exhaust Gas Recirculation/EGR Cooler/Service and Repair/Exhaust Gas Recirculation Valve Cooler Replacement). 7. Prime the fuel system. Refer to Fuel System Priming (See: Fuel Delivery and Air Induction/Service and Repair/Fuel System Priming). 8. Start the engine. If the engine stalls, repeat the above step. 9. Once the engine starts, inspect for fuel leaks. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Diagrams Fuel Temperature Sensor: Diagrams Component Connector End Views Fuel Temperature Sensor (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Diagrams > Page 4391 Fuel Temperature Sensor: Service and Repair Fuel Temperature Sensor Replacement Removal Procedure 1. Remove the charge air cooler inlet pipe. Refer to Charge Air Cooler Inlet Pipe Replacement (See: Fuel Delivery and Air Induction/Turbocharger/Intercooler/Intercooler Duct/Service and Repair/Charge Air Cooler Inlet Pipe Replacement). 2. Disconnect the engine wiring harness electrical connector from the fuel temperature sensor. 3. Remove the fuel temperature sensor (1) from the fuel return pipe. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Diagrams > Page 4392 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the fuel temperature sensor (1) to the fuel return pipe. Tighten the sensor to 22 Nm (16 lb ft). 2. Connect the engine wiring harness electrical connector to the fuel temperature sensor. 3. Prime the fuel system. Refer to Fuel System Priming (See: Fuel Delivery and Air Induction/Service and Repair/Fuel System Priming). 4. Start the engine. If the engine stalls, repeat the above step. 5. Once the engine starts, inspect for fuel leaks. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > High Idle Switch > Component Information > Testing and Inspection High Idle Switch: Testing and Inspection High Idle Switch Diagnosis Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions )provide an overview of each diagnostic category. Diagnostic Fault Information Reference Information Schematic Reference Engine Controls Schematics (See: Diagrams/Electrical Diagrams) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning)for scan tool information Circuit/System Verification Ignition ON, observe the scan tool High Idle switch parameter while exercising the switch. The reading should change between ON/OFF. Circuit/System Testing 1. Ignition OFF, disconnect the harness connector at the high idle switch. 2. Test for less than 5 ohms between the ground circuit terminal A and ground. ‹› If greater than 5 ohms, test the ground circuit for an open/high resistance. 3. Ignition ON, verify the scan tool High Idle switch parameter is OFF. ‹› If not OFF, test the signal circuit for a short to ground. If the circuit tests normal, replace the ECM. 4. Install a 3A fused jumper wire between the signal circuit terminal C and ground. Verify the scan tool High Idle switch parameter is ON. ‹› If not ON, test the signal circuit for a short to voltage or an open/high resistance. If the circuit tests normal, replace the ECM. 5. If all circuits test normal, test or replace the high idle switch. Component Testing Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > High Idle Switch > Component Information > Testing and Inspection > Page 4396 1. Ignition OFF, disconnect the harness connector at the high idle switch. 2. Test for infinite resistance between the signal terminal C and the ground circuit terminal A with the switch in the open position. ‹› If less than infinite resistance, replace the high idle switch. 3. Test for less than 1 ohm between the signal terminal C and the ground terminal A with the switch in the closed position. ‹› If greater than 1 ohm, replace the high idle switch. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Turbocharger Vane Position Sensor > Component Information > Technical Service Bulletins > Engine - Info on Duramax Turbo Vane Position Sensor Turbocharger Vane Position Sensor: Technical Service Bulletins Engine - Info on Duramax Turbo Vane Position Sensor INFORMATION Bulletin No.: 10-06-04-014 Date: November 03, 2010 Subject: Information on Duramax Turbo Vane Position Sensor Models: 2010-2011 Chevrolet Express Vans, Silverado 2010-2011 GMC Savana Vans, Sierra Equipped with Duramax(TM) Diesel Engine (RPOs LGH, LML) An improvement has been implemented to the turbocharger vane position sensor. Some turbochargers existing in inventory have the old style vane position sensor. If turbochargers, GM P/N 12635325 or 12635167 are being replaced, the original turbo vane sensor should be removed and replaced with the new style sensor, GM P/N 12643471. Turbochargers that are supersessions to these part numbers will have the new style vane position sensor and no action is necessary. Parts Information Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Turbocharger Vane Position Sensor > Component Information > Technical Service Bulletins > Page 4401 Turbocharger Vane Position Sensor: Diagrams Component Connector End Views Turbocharger Vane Position Sensor (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Harness Routing Views Camshaft Position Sensor Jumper Harness Routing (4.8L/5.3L/6.0L/6.2L) 1 - X112 2 - Camshaft Position Sensor Jumper Harness Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 4406 Camshaft Position Sensor: Diagrams Component Connector End Views Camshaft Position (CMP) Actuator Solenoid Valve (LZ1, LY6, L96 or L9H) Camshaft Position (CMP) Sensor (LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 4407 Camshaft Position (CMP) Sensor (Gas except LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 4408 Camshaft Position (CMP) Sensor (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 4409 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 4410 Camshaft Position Sensor: Service Precautions Camshaft Position Actuator Removal and Installation Warning Warning Do not push or pull on the reluctor wheel of the camshaft position (CMP) actuator during removal or installation. The reluctor wheel is retained to the front of the CMP actuator by 3 roll pins. Pushing or pulling on the wheel may dislodge the wheel from the front of the actuator. The actuator return spring is under tension and may rotate the dislodged reluctor wheel, causing personal injury. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 4411 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor Replacement Removal Procedure 1. Remove the cooling fan pulley. Refer to Fan Pulley Replacement (See: Engine, Cooling and Exhaust/Cooling System/Radiator Cooling Fan/Service and Repair). 2. Remove the camshaft position (CMP) sensor bolt. 3. Remove the CMP sensor. Installation Procedure 1. Lubricate the CMP sensor O-ring with clean engine oil. 2. Install the CMP sensor. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 4412 3. Install the CMP sensor bolt. Tighten the bolt to 10 Nm (89 lb in). 4. Install the cooling fan pulley. Refer to Fan Pulley Replacement (See: Engine, Cooling and Exhaust/Cooling System/Radiator Cooling Fan/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams Crankshaft Position Sensor: Diagrams Component Connector End Views Crankshaft Position (CKP) Sensor (LU3) Crankshaft Position (CKP) Sensor (Gas except LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 4416 Crankshaft Position (CKP) Sensor (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 4417 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement Crankshaft Position Sensor Replacement Removal Procedure 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 2. Remove the right wheelhouse panel. Refer to Front Wheelhouse Liner Replacement - Right Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side)Front Wheelhouse Liner Replacement - Right Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side). 3. Disconnect the crankshaft position (CKP) sensor electrical connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 4420 4. Remove the CKP sensor bolt. 5. Remove the CKP sensor. 6. If necessary, remove the CKP sensor spacer bolts. 7. If necessary, remove the CKP sensor spacer. Installation Procedure 1. If necessary, lubricate a NEW CKP spacer O-ring with clean engine oil. 2. If necessary, install the NEW O-ring to the CKP sensor spacer. Note: The crankshaft position sensor spacers are machined with different timing positions. However, if the crankshaft position sensor spacer requires replacement, replace with a grade "C" spacer. 3. If necessary, install the CKP sensor spacer. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. If necessary, install the CKP sensor spacer bolts. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 4421 Tighten the bolts to 10 Nm (89 lb in). 5. Lubricate a NEW CKP sensor O-ring with clean engine oil. 6. Install the NEW O-ring to the CKP sensor. 7. Install the CKP sensor. 8. Install the CKP sensor bolt. Tighten the bolt to 10 Nm (89 lb in). 9. Connect the CKP sensor electrical connector. 10. Install the right wheelhouse panel. Refer to Front Wheelhouse Liner Replacement - Right Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side)Front Wheelhouse Liner Replacement - Right Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side). 11. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 4422 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Exciter Ring and Oil Pump Drive Gear Replacement Crankshaft Position Sensor Exciter Ring and Oil Pump Drive Gear Replacement Removal Procedure 1. Remove the engine front cover. Refer to Engine Front Cover Replacement (See: Engine, Cooling and Exhaust/Engine/Timing Components/Timing Cover/Service and Repair). 2. Remove the upper oil pan. Refer to Upper Oil Pan Replacement (See: Engine, Cooling and Exhaust/Engine/Engine Lubrication/Oil Pan/Service and Repair/Upper Oil Pan Replacement). Caution: Do not use an impact driver to remove or install the oil pump driven gear nut. Use of an impact driver may shear the oil pump drive gear pin in the crankshaft. 3. While holding the secondary oil pump shaft with a hex driver, remove the oil pump driven gear nut. 4. Remove the oil pump driven gear. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 4423 5. Remove the oil pump drive gear and crankshaft sensor reluctor. Do not damage the crankshaft reluctor teeth. Note: Do not remove the reluctor from the oil pump drive gear unless replacing the reluctor or the oil pump drive gear. The reluctor is timed to the gear and once removed the correct timing will be lost. 6. Remove the crankshaft reluctor to oil pump drive gear bolts. 7. Inspect the crankshaft reluctor for the damage, bent teeth, being bent or warped. 8. Inspect the oil pump drive gear for damaged or worn teeth. 9. Inspect the oil pump drive gear crankshaft pin for wear. 10. Inspect the groove of the crankshaft pin in the oil pump drive gear for wear. 11. Replace any parts that are damaged or worn. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 4424 Note: The crankshaft reluctor and the oil pump drive gear are timed at the factory. In order to re-establish proper timing, install knock pins in the oil pump drive gear if the crankshaft reluctor was removed from the oil pump drive gear. The knock pins are available through the parts department. 1. Install the knock pins in the oil pump drive gear to a height of 4.5-5.5 mm (0.177-0.217 in) 2. Install the crankshaft reluctor on the oil pump drive gear. Ensure the reluctor is aligned on the knock pins. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the crankshaft reluctor bolts and tighten to 8 Nm (71 lb in). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 4425 Note: Do not damage the teeth on the crankshaft reluctor. 4. Install the oil pump drive gear and reluctor to the crankshaft. 5. Install the oil pump driven gear. Caution: Do not use an impact driver to remove or install the oil pump driven gear nut. Use of an impact driver may shear the oil pump drive gear pin in the crankshaft. 6. While holding the secondary oil pump shaft with a hex driver, install the oil pump driven gear nut and tighten to 100 Nm (74 lb ft). 7. Install the upper oil pan. Refer to Upper Oil Pan Replacement (See: Engine, Cooling and Exhaust/Engine/Engine Lubrication/Oil Pan/Service and Repair/Upper Oil Pan Replacement). 8. Install the engine front cover. Refer to Engine Front Cover Replacement (See: Engine, Cooling and Exhaust/Engine/Timing Components/Timing Cover/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder Case Replacement Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder Case Replacement Ignition Lock Cylinder Case Replacement Removal Procedure Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). 1. Remove the inflatable restraint steering wheel module coil. Refer to Steering Wheel Inflatable Restraint Module Coil Replacement (See: Restraint Systems/Air Bag Systems/Clockspring Assembly / Spiral Cable/Service and Repair/Removal and Replacement). 2. Remove the ignition/start switch. Refer to Ignition and Start Switch Replacement (See: Service and Repair). 3. Disconnect the park lock cable from the ignition lock cylinder case. 4. Disconnect the passlock and key buzzer from the ignition lock cylinder case. 5. Remove the 3 ignition lock cylinder case screws (2). 6. Remove the ignition lock cylinder case (1) from the vehicle. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder Case Replacement > Page 4431 1. Install the ignition lock cylinder case (1) to the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the 3 ignition lock cylinder case screws (2). Tighten the screws to 7 Nm (62 lb in). 3. Install the park lock cable into the lock cylinder housing. 4. Connect the passlock and key buzzer to the ignition lock cylinder case. 5. Install the ignition/start switch. Refer to Ignition and Start Switch Replacement (See: Service and Repair). 6. Install the inflatable restraint steering wheel module coil. Refer to Steering Wheel Inflatable Restraint Module Coil Replacement (See: Restraint Systems/Air Bag Systems/Clockspring Assembly / Spiral Cable/Service and Repair/Removal and Replacement). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder Case Replacement > Page 4432 Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder Replacement Ignition Lock Cylinder Replacement Removal Procedure Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). 1. Disable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair). 2. Remove the steering column shroud. Refer to Steering Column Shroud Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Column Shroud Replacement). 3. With the key installed hold it in the START position. 4. Install an allen wrench into the hole on top of the ignition lock cylinder case. Push down on the allen wrench to release the tab on the ignition lock cylinder inside the ignition lock cylinder case. 5. Slide the ignition lock cylinder out of the ignition lock cylinder case. Installation Procedure Note: The gears between the ignition/start switch and the ignition lock cylinder case must be in the correct position. Failure to do so will cause a misalignment of the gears in the ignition/start switch and the ignition lock cylinder case, which may result in a NO START or BATTERY DRAIN. 1. Use a screwdriver to rotate the ignition lock cylinder case gear clockwise to the start position allowing it to spring return into the RUN position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder Case Replacement > Page 4433 2. Install the key into the ignition lock cylinder. 3. Align the ignition lock cylinder and install it into the ignition lock cylinder case. 4. Install the steering column shroud. Refer to Steering Column Shroud Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Column Shroud Replacement). 5. Enable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams Knock Sensor: Diagrams Component Connector End Views Knock Sensor (KS) 1 (Gas) Knock Sensor (KS) 2 (Gas) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 4437 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications During engine cranking, the pressure should be at least 10 MPa. With the engine running at idle the pressure should be close to the Desired Fuel Rail Pressure. As the engine speed increase, the Desired Fuel Rail Pressure and the Actual Fuel Rail Pressure should be within 2 MPa of each other. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 4442 Fuel Pressure: Service Precautions Relieving Fuel Pressure Warning Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis Fuel Pressure: Testing and Inspection Fuel System Diagnosis Fuel System Diagnosis Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Circuit/System Description Fuel is drawn by the fuel injection pump from the tank to the engine through the fuel supply lines. Fuel flows to the fuel filter/heater element housing , which combines a water separator, a prime pump, fuel heater element and a filter element. A mechanical fuel injection pump at the front of the engine valley includes the fuel supply pump and the high-pressure pump. The small section of the fuel pump assembly is the supply pump, which creates a vacuum to pull fuel from the fuel tank to the high-pressure pump. The vacuum varies with engine load and speed as indicated by the table below. The pump is engine-driven by the camshaft gear. From the high-pressure pump, the pressurized fuel flows to the left fuel rail. A balance pipe from the center of the left rail then feeds the right fuel rail. Each fuel rail supplies one bank of 4 fuel injectors. The fuel rail pressure sensor is mounted in the end of the right fuel rail. Fuel is used to cool and lubricate the fuel injectors and fuel injection pump. The fuel return system is designed to return this fuel to the fuel tank. If the high side fuel pressure becomes excessive, the fuel rail pressure relief valve releases the fuel into the fuel return system. The return fuel travels through the fuel cooler and then to the fuel tank. Diagnostic Aids An Engine Cranks but Will Not Run or Hard Start symptom may exist if air is being drawn into the fuel injection system due to the following conditions: * Fuel contamination-Refer to Contaminants-in-Fuel Diagnosis (See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Contaminants-in-Fuel Diagnosis). * Deformed or cut O-rings at the fuel supply line connections * Improperly seated fuel supply line fittings * Porous or weathered rubber fuel supply lines * Fuel filter vent screw not tighten or cross threaded * Fuel filter not tighten properly Reference Information Special Tools * J-23738-A MityVac * EN-47969 Fuel Supply Diagnostic Hose * CH-48027 Digital Pressure Gauge * J 44581 Fuel Line Disconnect Tool Circuit/System Verification Observe the Actual Fuel Rail Pressure parameter with a scan tool. During engine cranking, the pressure should be at least 10 MPa. With the engine running at idle the pressure should be close to the Desired Fuel Rail Pressure. As the engine speed increase, the Desired Fuel Rail Pressure and the Actual Fuel Rail Pressure should be within 2 MPa of each other. Circuit/System Testing Note: Ensure that a sufficient amount of fuel is in the fuel tank to run the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis > Page 4445 1. Install the CH-48027 to the fuel system service port on the right front side of the engine. 2. Prime the fuel system until 10 psi is indicated on the CH-48027 . Fuel pressure should not drop below 2 psi in less than one minute. ‹› If fuel pressure drops below 2 psi in less than one minute, go to step 4. Note: It may be necessary to remove engine components for the visual inspections. 3. Attempt to start and idle the engine. Observe the CH-48027 during idle. The vacuum should be between 1-3 in Hg. ‹› If more than 3 in Hg is observed at idle, visually inspect the following items: * Fuel filter element for a restriction * Hoses and lines that are flattening when the engine is running, or have kinks that would restrict the flow of fuel ‹› If engine did not start and no vacuum was observed, refer to Fuel Injection Pump Replacement (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair). 4. Disconnect the fuel supply line at the engine and install a J-23738-A using the J 44581 to the engine side of the fuel supply line. 5. Apply vacuum to the fuel supply pipe until 25 in Hg has been reached. Wait for at least one minute to allow the fuel system to stabilize. Vacuum should not drop below 8 in Hg within 10 minutes. ‹› If vacuum cannot be obtained or the vacuum drops below 8 in Hg within 10 minutes, repair the air leak at fuel filter/heater element housing connections or at the fuel hoses/pipes on the engine supply line. 6. Remove both hoses from the fuel filter/heater element housing assembly. Cap the suction side port of the fuel filter/heater element housing assembly. Apply 25 in Hg to the discharge port of the fuel filter/heater element housing assembly. Vacuum should not drop below 8 in Hg within 10 minutes. ‹› If vacuum drops below 8 in Hg within 10 minutes, replace the fuel filter/heater element housing assembly. Note: The engine may start and then stall after briefly running. 7. Remove the J-23738-A from the fuel filter/heater element housing assembly. Install the removed fuel filter/heater element housing assembly, and cap off the fuel supply pipe on the engine. Crank the engine in 15-second intervals while observing the CH-48027 . More than 5 in Hg vacuum should be observed during cranking. ‹› If less than 5 in Hg was observed on the vacuum gauge during cranking, replace the fuel injection pump. Note: The engine may start, and then stall after briefly running. 8. Install the fuel supply line at the engine, and disconnect the chassis fuel supply line at the fuel tank. Install a J-23738-A to the supply hose at the fuel tank using the J 44581 . 9. Apply vacuum to the supply hose at the fuel tank until 25 in Hg has been reached. Wait for a least one minute for the fuel system to stabilize. Vacuum should not drop below 8 in Hg within 10 minutes. ‹› If vacuum cannot be obtained, or the vacuum drops below 8 in Hg within 10 minutes, repair the air leak in the fuel supply line between the engine and fuel tank, or the connection of the supply line to the engine. 10. Install all components and lines that were previously removed or disconnected. 11. Install the EN-47969 on the fuel supply line at the engine. Create a vertical loop in the hose to observe the incoming fuel for air bubbles. 12. Open the bleed screw on top of the fuel filter/heater element housing. Prime the system until fuel appears at the bleed screw. Continue to prime the fuel system until the engine starts and runs. 13. Run the engine for at least 10 minutes to allow the fuel system to stabilize, and purge any air from the system. Note: Changes in engine speed can cause an increase of air bubbles that enter the EN-47969 . An air pocket at the top of the EN-47969 loop is considered a normal condition. 14. At a stabilized idle, observe the fuel entering the EN-47969 for air bubbles. ‹› If air bubbles were observed entering the transparent hose, test the fuel sender for leaks. Refer to Fuel Sender Assembly Replacement (See: Fuel Delivery and Air Induction/Fuel Tank/Fuel Gauge Sender/Service and Repair). 15. Install the fuel sender, fuel tank, and all fuel system connections and components that were previously disconnected. Leave the EN-47969 connected to the fuel supply line. Prime the fuel system 30 times to remove the air from the fuel hoses. Continue to prime the fuel system until the engine starts and runs. Observe the fuel entering the transparent hose. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis > Page 4446 ‹› If air bubbles are still present, refer to Diagnostic Aids. ‹› If no air bubbles are present , remove the EN-47969 and run the engine to ensure no fuel leaks exist. Repair Instructions Perform the Diagnostic Repair Verification (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. * Fuel Injection Pump Replacement (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair) * Fuel Sender Assembly Replacement (See: Fuel Delivery and Air Induction/Fuel Tank/Fuel Gauge Sender/Service and Repair) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis > Page 4447 Fuel Pressure: Testing and Inspection Fuel System Diagnosis - High Pressure Side Fuel System Diagnosis - High Pressure Side Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Circuit/System Description High Pressure System The fuel injection pump at the front of the engine valley includes a fuel supply pump and a high-pressure pump. Fuel is drawn by the fuel supply pump from the primary fuel tank and delivered to the high-pressure pump. The pump is engine-driven by the camshaft gear. High pressure fuel is regulated by the fuel pressure regulator mounted on the fuel injection pump. From the high-pressure pump, the fuel moves to the left and right fuel rails through high pressure metal lines. Each fuel rail distributes high pressure fuel to one bank of 4 fuel injectors. The fuel pressure relief valve is location on the left rail, and relieves excessive fuel pressure which returns to the fuel tank. Return System The fuel return system routes fuel from the fuel injectors, the pressure relief valve, and the fuel injection pump. The return fuel travels to the fuel cooler and then to the fuel tank. This fuel is used to cool and lubricate the injection pump and the injectors. Diagnostic Aids * The fuel return volumes vary based on the American Petroleum Institute (API) rating of the diesel fuel. * A fuel injector may have high fuel return flow only at higher engine temperatures. Reference Information Special Tools * J 45873 Fuel Return Volume Test Kit * J-45873-30 Injector Flow Test Adapter Circuit/System Verification With the engine running at idle the Actual Fuel Pressure should be close to the Desired Fuel Rail Pressure. During engine cranking the Actual Fuel Pressure should be at least 10 MPa. Inspect the fuel return hoses and lines for external leaks or damage. Circuit/System Testing Important: If you were not referred to this test from another diagnostic, do not perform this procedure. Only perform this test when the fuel is more than 18°C (65°F). Important: Before replacing the fuel pressure relief valve, ensure that the break-away torque is within specifications. Refer to Fastener Tightening Specifications (See: Specifications). 1. Remove the fuel pressure relief valve return hose and plug the hose to prevent fuel leakage. 2. Install a section of rubber fuel hose on the fuel pressure relief valve connection and place loose end of hose into a clean fuel container. Important: Fuel that is contaminated with gasoline may cause permanent damage to the fuel pressure relief valve. Refer to Contaminants-in-Fuel Diagnosis (See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Contaminants-in-Fuel Diagnosis). * If the engine cranks but does not start, crank engine for 15 seconds. Observe for fuel leaking from fuel pressure relief valve. ‹› If fuel leaks from the fuel pressure relief valve, replace the pressure relief valve. Refer to Fuel Pressure Relief Valve Replacement (See: Fuel Filter/Fuel Pressure Release/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis > Page 4448 * If the engine starts and runs, idle the engine while commanding the fuel rail pressure to 180 MPa with a scan tool. Observe for fuel leaking from fuel pressure relief valve. ‹› If fuel leaks from the fuel pressure relief valve, replace the pressure relief valve. Refer to Fuel Pressure Relief Valve Replacement (See: Fuel Filter/Fuel Pressure Release/Service and Repair). Important: Always replace the fuel return hose retaining clips on the fuel injectors with new clips after removing. 3. Remove the fuel return hose from the fuel injectors of the right cylinder bank. Refer to Fuel Injection Fuel Return Pipe Replacement - Right Side (See: Fuel Delivery and Air Induction/Fuel Return Line/Service and Repair/Fuel Injection Fuel Return Pipe Replacement - Right Side). 4. Connect the yellow hoses from the J 45873 to the J-45873-30 . 5. Connect the J-45873-30 with yellow hoses to each fuel injector return port of the right cylinder bank, and install the retaining clips. 6. Install the 4 yellow hoses in the J 45873 graduated cylinders in numerical order. 7. Connect the fuel return hoses to the J-45873-30 to prevent leakage. ‹› If the engine starts and runs, idle the engine until fuel start dripping into all the graduated cylinders and yellow hoses are full of fuel. Important: The engine cranking speed must be more than 150 RPM during the cranking portion of this test. ‹› If the engine does not start, crank the engine in 15-second intervals, with 1 minute cooling time between intervals, until fuel starts to flow into all of the graduated cylinders. 8. Elevate the 4 yellow hoses to retain the fuel in the hoses, and empty the 4 graduated cylinders into a suitable container. 9. Install the 4 yellow hoses in the J 45873 graduated cylinders in numerical order. ‹› If the engine starts and runs, idle the engine for 15 seconds. ‹› If the engine does not start, crank the engine for 15 seconds. Important: During replacement of the injectors, inspect the inlet and outlet fittings for corrosion or contamination. Refer to Contaminants-in-Fuel Diagnosis (See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Contaminants-in-Fuel Diagnosis). 10. Measure the quantity of fuel in each of the graduated cylinders. Refer to Fuel System Specifications (See: Fuel Delivery and Air Induction/Specifications) for the desired quantities. ‹› If high return flows were recorded, replace those fuel injectors that had high return flow and retest the fuel return flow, referring to Fuel System Specifications (See: Fuel Delivery and Air Induction/Specifications). Replace any additional high return flow injectors and proceed to the next number step. 11. Install and connect all fuel system components that were previously removed or disconnected. 12. Remove the fuel return pipes from the fuel injectors of the left cylinder bank and repeat the fuel return flow test previously preformed on the right cylinder bank. ‹› If high return flows were recorded, replace those fuel injectors that had high return flow and retest the fuel return flow, referring to Fuel System Specifications (See: Fuel Delivery and Air Induction/Specifications). Replace any additional high return flow injectors and proceed to the next number step. 13. Install and connect all fuel system components that were previously removed or disconnected. 14. Start and idle the engine. You may have to prime the fuel system before the engine will start. Command the fuel pressure control to 180 MPa with a scan tool. The actual fuel pressure should be the same as the commanded pressure. ‹› If the engine does not start or the fuel pressure is less than 145 MPa when commanded, replace the fuel injection pump. 15. Command the fuel pressure control to 180 MPa with a scan tool. The fuel pressure should be able to reach 145 MPa when commanded. ‹› If the fuel pressure is less than the specified value, refer to Fuel System Diagnosis (See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Fuel System Diagnosis). 16. Operate the vehicle in order to verify the repairs. Repair Instructions Perform the Diagnostic Repair Verification (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis > Page 4449 * Fuel Injection Pump Replacement (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair) * Fuel Pressure Relief Valve Replacement (See: Fuel Filter/Fuel Pressure Release/Service and Repair) * Fuel Injector Replacement (Right) (See: Fuel Delivery and Air Induction/Fuel Injector/Service and Repair/Removal and Replacement/Fuel Injector Replacement (Right))Fuel Injector Replacement (Left) (See: Fuel Delivery and Air Induction/Fuel Injector/Service and Repair/Removal and Replacement/Fuel Injector Replacement (Left)) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Idle Speed............................................................................................................................................ ......................................................................680 RPM Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 4453 Idle Speed: Service and Repair High Idle Switch Programming Before Programming a Control Module Important: DO NOT program a control module unless you are directed by a service procedure or you are directed by a General Motors Corporation service bulletin. Programming a control module at any other time will not permanently correct a customer's concern. Ensure the following conditions are met before programming a control module: * Vehicle system voltage - There is no charging system concern. All charging system concerns must be repaired before programming a control module. - Battery voltage is greater than 12 volts but less than 16 volts. The battery must be charged before programming the control module if the battery voltage is low. - A battery charger is NOT connected to the vehicle's battery. Incorrect system voltage or voltage fluctuations from a battery charger, may cause programming failure or control module damage. - Turn OFF or disable any system that may put a load on the vehicle's battery. * Twilight sentinel * Interior lights * Daytime running lights (DRL)-Applying the parking brake, on most vehicles, disables the DRL system. Refer to the Owner's Manual. * HVAC systems * Engine cooling fans, etc. * The ignition switch is in the proper position. The scan tool prompts you to turn ON the ignition, with the engine OFF. DO NOT change the position of the ignition switch during the programming procedure, unless instructed to do so. * All tool connections are secure. - The connection at the data link connector (DLC) - Voltage supply circuits * DO NOT disturb the tool harnesses while programming. If an interruption occurs during the programming procedure, programming failure or control module damage may occur. High Idle Switch Programming * Using the Tech 2, select Module Setup/PTO Options * Use soft keys to select desired settings. * When setting selections are complete, select Reprogram. Important: The ECM will not operate under the new value until the it has powered down once. * Turn OFF the ignition until communication with the ECM is lost, as indicated on the scan tool. * Start the vehicle and confirm the new settings by operating the high idle switch. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > Customer Interest for Air Cleaner Fresh Air Duct/Hose: > 08-06-04-054B > Jan > 11 > Diesel Engine - Low Power/MIL ON/DTC P0101 Air Cleaner Fresh Air Duct/Hose: Customer Interest Diesel Engine - Low Power/MIL ON/DTC P0101 TECHNICAL Bulletin No.: 08-06-04-054B Date: January 24, 2011 Subject: Snow or Ice Ingestion into Air Cleaner Element, Malfunction Indicator Lamp (MIL) Illuminated, Engine Power is Reduced Message Displayed, DTC P0101 Set (Perform Repair as Outlined) Models: 2007-2010 Chevrolet Silverado 2500/3500 Series 2007-2010 GMC Sierra 2500/3500 Series Equipped with Duramax(TM) Diesel Engine (RPO LMM) Supercede: This bulletin is being revised to provide a procedure to relocate the OAT sensor, if equipped with RPO CJ2. Please discard Corporate Bulletin 08-06-04-054A (Section 06 - Engine / Propulsion System). Condition Some customers may comment on the malfunction indicator lamp (MIL) being illuminated and an Engine Power is Reduced message being displayed. The technician may observe DTC P0101 set as current or in history. Cause This condition may be caused by snow being ingested into the air cleaner housing and accumulating in the air cleaner element, resulting in restricted airflow into the engine. Correction 1. Verify the condition by questioning the customer as to when the condition occurs (such as during or right after a snow storm). ‹› If the condition occurs as described above, proceed to Step 2. ‹› If the condition does not occur as described above, refer to Diagnostic Trouble Code (DTC) List Vehicle in SI. 2. Remove the air cleaner element. Refer to Air Cleaner Element Replacement in SI. 3. Inspect the air cleaner element for the following conditions: 1. Packed snow 2. Frozen ice 3. A soaking wet condition that would indicate previous snow ingestion 4. Excessive debris and contamination as a result of the ingestion ‹› If any of the above conditions are observed, replace the air cleaner element. Remove any snow or ice that may have accumulated in the air intake duct. Note Winter covers for trucks that are equipped with the Duramax(TM) Diesel Engine are included with vehicle orders that ship to the following areas: All of Canada, and the following states: Alaska, Colorado, Idaho, Maine, Michigan, Minnesota, Montana, New Hampshire, New York, North Dakota, South Dakota, Vermont, Wisconsin, Wyoming. These vehicles should not need a new cover. 4. Install the grille opening section ONLY (if using the 2 piece cover) of the winter front cover following the usage guidelines provided in the Owners Manual for the appropriate type winter cover. ‹› If the customer does not have a cover, obtain and install the grille opening section ONLY , GM P/N 25822811 (GMC) or GM P/N 25822812 (Chevrolet). 5. The grille opening cover MUST BE installed to ensure a complete repair, BEFORE ENCOUNTERING SNOW. This repair allows warm air to be circulated into the air cleaner. Additional Information to Advise Customer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > Customer Interest for Air Cleaner Fresh Air Duct/Hose: > 08-06-04-054B > Jan > 11 > Diesel Engine - Low Power/MIL ON/DTC P0101 > Page 4463 Important If the vehicle is driven in a snow storm before installing the winter cover and the customer chooses to resolve the issue, they must follow this procedure using the following steps: 1. Remove ANY ice or snow that may have accumulated in the air intake duct, BEFORE REPLACING the air cleaner element. 2. INSTALL the winter cover BEFORE continuing to drive the truck. 3. Turn OFF the ignition, and all electrical accessories and components. 4. Remove the key from the vehicle, THEN open and close the door. 5. WAIT for 2 minutes to allow the engine control module (ECM) to power down. This can be verified by watching for the instrument panel cluster (IPC) gage needles to drop slightly. 1. Allowing the ECM to power down will let DTC P0101 revert to a History DTC and the vehicle should return to full power if the issue has been eliminated. 2. Advise the customer to take the vehicle to the dealer as soon as possible to verify the condition has been eliminated. Ambient (Outside) Air Temperature Sensor Relocation For vehicles equipped with Automatic Temperature Control HVAC (RPO CJ2), the ambient (outside) air temperature sensor needs to be relocated using the following procedure: 1. Remove the radiator grille. Refer to the Radiator Grille Replacement procedure in SI. 2. Remove the ambient air sensor from its current location by carefully lifting the sensor from the radiator support cross bar. 3. Remove the harness clip nearest to the sensor. 4. Reinstall the ambient air sensor to the new location using the existing hole (1) in the lower section of the radiator support. 5. Reinstall the harness clip to the existing hole (2) in the radiator support. 6. Reinstall the radiator grille. Parts Information Warranty Information Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > Customer Interest for Air Cleaner Fresh Air Duct/Hose: > 08-06-04-054B > Jan > 11 > Diesel Engine - Low Power/MIL ON/DTC P0101 > Page 4464 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > Customer Interest for Air Cleaner Fresh Air Duct/Hose: > 08-06-04-054A > Jan > 10 > Engine - Reduced Power/MIL ON/DTC P0101 Air Cleaner Fresh Air Duct/Hose: Customer Interest Engine - Reduced Power/MIL ON/DTC P0101 TECHNICAL Bulletin No.: 08-06-04-054A Date: January 07, 2010 Subject: Snow or Ice Ingestion into Air Cleaner Element, Malfunction Indicator Lamp (MIL) Illuminated, Engine Power is Reduced Message Displayed, DTC P0101 Set (Perform Repair as Outlined) Models: 2007-2010 Chevrolet Silverado 2500/3500 Series 2007-2010 GMC Sierra 2500/3500 Series Equipped with Duramax(TM) Diesel Engine (RPO LMM) Please Refer to GMVIS Supercede: This bulletin is being revised to remove the graphic, update the Parts and Correction information and add information to advise a customer. Please discard Corporate Bulletin 08-06-04-054 (Section 06 - Engine / Propulsion System). Condition Some customers may comment on the malfunction indicator lamp (MIL) being illuminated and an Engine Power is Reduced message being displayed. The technician may observe DTC P0101 set as current or in history. Cause This condition may be caused by snow being ingested into the air cleaner housing and accumulating in the air cleaner element, resulting in restricted airflow into the engine. Correction 1. Verify the condition by questioning the customer as to when the condition occurs (such as during or right after a snow storm). ‹› If the condition occurs as described above, proceed to Step 2. ‹› If the condition does not occur as described above, refer to Diagnostic Trouble Code (DTC) List Vehicle in SI. 2. Remove the air cleaner element. Refer to Air Cleaner Element Replacement in SI. 3. Inspect the air cleaner element for the following conditions: 1. Packed snow 2. Frozen ice 3. A soaking wet condition that would indicate previous snow ingestion 4. Excessive debris and contamination as a result of the ingestion ‹› If any of the above conditions are observed, replace the air cleaner element. Remove any snow or ice that may have accumulated in the air intake duct. Note Winter covers for trucks that are equipped with the Duramax(TM) Diesel Engine are included with vehicle orders that ship to the following areas: All of Canada, and the following states: Alaska, Colorado, Idaho, Maine, Michigan, Minnesota, Montana, New Hampshire, New York, North Dakota, South Dakota, Vermont, Wisconsin, Wyoming. These vehicles should not need a new cover. 4. Install the grille opening section ONLY (if using the 2 piece cover) of the winter front cover following the usage guidelines provided in the Owners Manual for the appropriate type winter cover. ‹› If the customer does not have a cover, obtain and install the grille opening section ONLY, GM P/N 25822811 (GMC) or GM P/N 25822812 (Chevrolet). 5. The grille opening cover MUST BE installed to ensure a complete repair, BEFORE ENCOUNTERING SNOW. This repair allows warm air to be circulated into the air cleaner. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > Customer Interest for Air Cleaner Fresh Air Duct/Hose: > 08-06-04-054A > Jan > 10 > Engine - Reduced Power/MIL ON/DTC P0101 > Page 4469 Additional Information to Advise Customer Important If the vehicle is driven in a snow storm before installing the winter cover and the customer chooses to resolve the issue, they must follow this procedure using the following steps: 1. Remove ANY ice or snow that may have accumulated in the air intake duct, BEFORE REPLACING the air cleaner element. 2. INSTALL the winter cover BEFORE continuing to drive the truck. 3. Turn OFF the ignition, and all electrical accessories and components. 4. Remove the key from the vehicle, THEN open and close the door. 5. WAIT for 2 minutes to allow the engine control module (ECM) to power down. This can be verified by watching for the instrument panel cluster (IPC) gage needles to drop slightly. 1. Allowing the ECM to power down will let DTC P0101 revert to a History DTC and the vehicle should return to full power if the issue has been eliminated. 2. Advise the customer to take the vehicle to the dealer as soon as possible to verify the condition has been eliminated. Parts Information Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Cleaner Fresh Air Duct/Hose: > 08-06-04-054B > Jan > 11 > Diesel Engine - Low Power/MIL ON/DTC P0101 Air Cleaner Fresh Air Duct/Hose: All Technical Service Bulletins Diesel Engine - Low Power/MIL ON/DTC P0101 TECHNICAL Bulletin No.: 08-06-04-054B Date: January 24, 2011 Subject: Snow or Ice Ingestion into Air Cleaner Element, Malfunction Indicator Lamp (MIL) Illuminated, Engine Power is Reduced Message Displayed, DTC P0101 Set (Perform Repair as Outlined) Models: 2007-2010 Chevrolet Silverado 2500/3500 Series 2007-2010 GMC Sierra 2500/3500 Series Equipped with Duramax(TM) Diesel Engine (RPO LMM) Supercede: This bulletin is being revised to provide a procedure to relocate the OAT sensor, if equipped with RPO CJ2. Please discard Corporate Bulletin 08-06-04-054A (Section 06 - Engine / Propulsion System). Condition Some customers may comment on the malfunction indicator lamp (MIL) being illuminated and an Engine Power is Reduced message being displayed. The technician may observe DTC P0101 set as current or in history. Cause This condition may be caused by snow being ingested into the air cleaner housing and accumulating in the air cleaner element, resulting in restricted airflow into the engine. Correction 1. Verify the condition by questioning the customer as to when the condition occurs (such as during or right after a snow storm). ‹› If the condition occurs as described above, proceed to Step 2. ‹› If the condition does not occur as described above, refer to Diagnostic Trouble Code (DTC) List Vehicle in SI. 2. Remove the air cleaner element. Refer to Air Cleaner Element Replacement in SI. 3. Inspect the air cleaner element for the following conditions: 1. Packed snow 2. Frozen ice 3. A soaking wet condition that would indicate previous snow ingestion 4. Excessive debris and contamination as a result of the ingestion ‹› If any of the above conditions are observed, replace the air cleaner element. Remove any snow or ice that may have accumulated in the air intake duct. Note Winter covers for trucks that are equipped with the Duramax(TM) Diesel Engine are included with vehicle orders that ship to the following areas: All of Canada, and the following states: Alaska, Colorado, Idaho, Maine, Michigan, Minnesota, Montana, New Hampshire, New York, North Dakota, South Dakota, Vermont, Wisconsin, Wyoming. These vehicles should not need a new cover. 4. Install the grille opening section ONLY (if using the 2 piece cover) of the winter front cover following the usage guidelines provided in the Owners Manual for the appropriate type winter cover. ‹› If the customer does not have a cover, obtain and install the grille opening section ONLY , GM P/N 25822811 (GMC) or GM P/N 25822812 (Chevrolet). 5. The grille opening cover MUST BE installed to ensure a complete repair, BEFORE ENCOUNTERING SNOW. This repair allows warm air to be circulated into the air cleaner. Additional Information to Advise Customer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Cleaner Fresh Air Duct/Hose: > 08-06-04-054B > Jan > 11 > Diesel Engine - Low Power/MIL ON/DTC P0101 > Page 4475 Important If the vehicle is driven in a snow storm before installing the winter cover and the customer chooses to resolve the issue, they must follow this procedure using the following steps: 1. Remove ANY ice or snow that may have accumulated in the air intake duct, BEFORE REPLACING the air cleaner element. 2. INSTALL the winter cover BEFORE continuing to drive the truck. 3. Turn OFF the ignition, and all electrical accessories and components. 4. Remove the key from the vehicle, THEN open and close the door. 5. WAIT for 2 minutes to allow the engine control module (ECM) to power down. This can be verified by watching for the instrument panel cluster (IPC) gage needles to drop slightly. 1. Allowing the ECM to power down will let DTC P0101 revert to a History DTC and the vehicle should return to full power if the issue has been eliminated. 2. Advise the customer to take the vehicle to the dealer as soon as possible to verify the condition has been eliminated. Ambient (Outside) Air Temperature Sensor Relocation For vehicles equipped with Automatic Temperature Control HVAC (RPO CJ2), the ambient (outside) air temperature sensor needs to be relocated using the following procedure: 1. Remove the radiator grille. Refer to the Radiator Grille Replacement procedure in SI. 2. Remove the ambient air sensor from its current location by carefully lifting the sensor from the radiator support cross bar. 3. Remove the harness clip nearest to the sensor. 4. Reinstall the ambient air sensor to the new location using the existing hole (1) in the lower section of the radiator support. 5. Reinstall the harness clip to the existing hole (2) in the radiator support. 6. Reinstall the radiator grille. Parts Information Warranty Information Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Cleaner Fresh Air Duct/Hose: > 08-06-04-054B > Jan > 11 > Diesel Engine - Low Power/MIL ON/DTC P0101 > Page 4476 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Cleaner Fresh Air Duct/Hose: > 08-06-04-054A > Jan > 10 > Engine - Reduced Power/MIL ON/DTC P0101 Air Cleaner Fresh Air Duct/Hose: All Technical Service Bulletins Engine - Reduced Power/MIL ON/DTC P0101 TECHNICAL Bulletin No.: 08-06-04-054A Date: January 07, 2010 Subject: Snow or Ice Ingestion into Air Cleaner Element, Malfunction Indicator Lamp (MIL) Illuminated, Engine Power is Reduced Message Displayed, DTC P0101 Set (Perform Repair as Outlined) Models: 2007-2010 Chevrolet Silverado 2500/3500 Series 2007-2010 GMC Sierra 2500/3500 Series Equipped with Duramax(TM) Diesel Engine (RPO LMM) Please Refer to GMVIS Supercede: This bulletin is being revised to remove the graphic, update the Parts and Correction information and add information to advise a customer. Please discard Corporate Bulletin 08-06-04-054 (Section 06 - Engine / Propulsion System). Condition Some customers may comment on the malfunction indicator lamp (MIL) being illuminated and an Engine Power is Reduced message being displayed. The technician may observe DTC P0101 set as current or in history. Cause This condition may be caused by snow being ingested into the air cleaner housing and accumulating in the air cleaner element, resulting in restricted airflow into the engine. Correction 1. Verify the condition by questioning the customer as to when the condition occurs (such as during or right after a snow storm). ‹› If the condition occurs as described above, proceed to Step 2. ‹› If the condition does not occur as described above, refer to Diagnostic Trouble Code (DTC) List Vehicle in SI. 2. Remove the air cleaner element. Refer to Air Cleaner Element Replacement in SI. 3. Inspect the air cleaner element for the following conditions: 1. Packed snow 2. Frozen ice 3. A soaking wet condition that would indicate previous snow ingestion 4. Excessive debris and contamination as a result of the ingestion ‹› If any of the above conditions are observed, replace the air cleaner element. Remove any snow or ice that may have accumulated in the air intake duct. Note Winter covers for trucks that are equipped with the Duramax(TM) Diesel Engine are included with vehicle orders that ship to the following areas: All of Canada, and the following states: Alaska, Colorado, Idaho, Maine, Michigan, Minnesota, Montana, New Hampshire, New York, North Dakota, South Dakota, Vermont, Wisconsin, Wyoming. These vehicles should not need a new cover. 4. Install the grille opening section ONLY (if using the 2 piece cover) of the winter front cover following the usage guidelines provided in the Owners Manual for the appropriate type winter cover. ‹› If the customer does not have a cover, obtain and install the grille opening section ONLY, GM P/N 25822811 (GMC) or GM P/N 25822812 (Chevrolet). 5. The grille opening cover MUST BE installed to ensure a complete repair, BEFORE ENCOUNTERING SNOW. This repair allows warm air to be circulated into the air cleaner. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Cleaner Fresh Air Duct/Hose: > 08-06-04-054A > Jan > 10 > Engine - Reduced Power/MIL ON/DTC P0101 > Page 4481 Additional Information to Advise Customer Important If the vehicle is driven in a snow storm before installing the winter cover and the customer chooses to resolve the issue, they must follow this procedure using the following steps: 1. Remove ANY ice or snow that may have accumulated in the air intake duct, BEFORE REPLACING the air cleaner element. 2. INSTALL the winter cover BEFORE continuing to drive the truck. 3. Turn OFF the ignition, and all electrical accessories and components. 4. Remove the key from the vehicle, THEN open and close the door. 5. WAIT for 2 minutes to allow the engine control module (ECM) to power down. This can be verified by watching for the instrument panel cluster (IPC) gage needles to drop slightly. 1. Allowing the ECM to power down will let DTC P0101 revert to a History DTC and the vehicle should return to full power if the issue has been eliminated. 2. Advise the customer to take the vehicle to the dealer as soon as possible to verify the condition has been eliminated. Parts Information Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Air Cleaner Outlet Duct Replacement Air Cleaner Fresh Air Duct/Hose: Service and Repair Air Cleaner Outlet Duct Replacement Air Cleaner Outlet Duct Replacement Removal Procedure 1. Loosen the outlet duct clamps at the air cleaner assembly and the turbocharger. 2. Remove the air cleaner outlet duct. Installation Procedure Note: The air cleaner outlet duct must be fully seated against the positive stop feature on the turbocharger inlet and also must be fully seated against the positive stop features on both sides of the air cleaner assembly. 1. Install the air cleaner outlet duct. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Air Cleaner Outlet Duct Replacement > Page 4484 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Tighten the outlet duct clamps at the turbocharger and the air cleaner assembly. Tighten the clamps to 4 Nm (35 lb in). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Air Cleaner Outlet Duct Replacement > Page 4485 Air Cleaner Fresh Air Duct/Hose: Service and Repair Air Intake Pipe Replacement Air Intake Pipe Replacement Removal Procedure 1. Remove the water outlet tube. Refer to Water Outlet Tube Replacement (LU3) (See: Engine, Cooling and Exhaust/Cooling System/Coolant Outlet/Service and Repair)Water Outlet Tube Replacement (LMM) (See: Engine, Cooling and Exhaust/Cooling System/Coolant Outlet/Service and Repair). 2. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (See: Air Cleaner Outlet Duct Replacement). Note: It is not necessary to completely remove the PCV hose/pipe from the engine when removing the air intake pipe. 3. Remove the positive crankcase ventilation (PCV) hose/pipe from the air intake pipe. Refer to Positive Crankcase Ventilation Hose/Pipe/Tube Replacement (See: Emission Control Systems/Positive Crankcase Ventilation/PCV Valve Hose/Service and Repair). 4. Disconnect the engine wiring harness electrical connector from the turbocharger control solenoid valve. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Air Cleaner Outlet Duct Replacement > Page 4486 5. Remove the engine wiring harness clip (1) from the bracket on the turbocharger. 6. Reposition the turbocharger control solenoid valve wiring harness extension out of the way. Note: The clamp for the air intake pipe uses reverse threads. 7. Loosen the air intake pipe to turbocharger clamp (1). 8. Remove the air intake pipe (2) from the turbocharger. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Air Cleaner Outlet Duct Replacement > Page 4487 1. Clean the mating surfaces on the air intake pipe and the turbocharger. 2. Align the arrow (2) on the air intake pipe to the arrow (1) on the turbocharger. 3. Install the air intake pipe (2) into the turbocharger. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Note: The clamp for the air intake pipe uses reverse threads. 4. Tighten the air intake pipe to turbocharger clamp (1). Tighten the clamp to 4.6 Nm (41 lb in). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Air Cleaner Outlet Duct Replacement > Page 4488 5. Route the turbocharger control solenoid valve wiring harness extension into position. 6. Install the engine wiring harness clip (1) to the bracket on the turbocharger. 7. Connect the engine wiring harness electrical connector to the turbocharger control solenoid valve. 8. Install the PCV hose/pipe to the air intake pipe. Refer to Positive Crankcase Ventilation Hose/Pipe/Tube Replacement (See: Emission Control Systems/Positive Crankcase Ventilation/PCV Valve Hose/Service and Repair). 9. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (See: Air Cleaner Outlet Duct Replacement). 10. Install the water outlet tube. Refer to Water Outlet Tube Replacement (LU3) (See: Engine, Cooling and Exhaust/Cooling System/Coolant Outlet/Service and Repair)Water Outlet Tube Replacement (LMM) (See: Engine, Cooling and Exhaust/Cooling System/Coolant Outlet/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 08-06-04-054B > Jan > 11 > Diesel Engine - Low Power/MIL ON/DTC P0101 Air Filter Element: Customer Interest Diesel Engine - Low Power/MIL ON/DTC P0101 TECHNICAL Bulletin No.: 08-06-04-054B Date: January 24, 2011 Subject: Snow or Ice Ingestion into Air Cleaner Element, Malfunction Indicator Lamp (MIL) Illuminated, Engine Power is Reduced Message Displayed, DTC P0101 Set (Perform Repair as Outlined) Models: 2007-2010 Chevrolet Silverado 2500/3500 Series 2007-2010 GMC Sierra 2500/3500 Series Equipped with Duramax(TM) Diesel Engine (RPO LMM) Supercede: This bulletin is being revised to provide a procedure to relocate the OAT sensor, if equipped with RPO CJ2. Please discard Corporate Bulletin 08-06-04-054A (Section 06 - Engine / Propulsion System). Condition Some customers may comment on the malfunction indicator lamp (MIL) being illuminated and an Engine Power is Reduced message being displayed. The technician may observe DTC P0101 set as current or in history. Cause This condition may be caused by snow being ingested into the air cleaner housing and accumulating in the air cleaner element, resulting in restricted airflow into the engine. Correction 1. Verify the condition by questioning the customer as to when the condition occurs (such as during or right after a snow storm). ‹› If the condition occurs as described above, proceed to Step 2. ‹› If the condition does not occur as described above, refer to Diagnostic Trouble Code (DTC) List Vehicle in SI. 2. Remove the air cleaner element. Refer to Air Cleaner Element Replacement in SI. 3. Inspect the air cleaner element for the following conditions: 1. Packed snow 2. Frozen ice 3. A soaking wet condition that would indicate previous snow ingestion 4. Excessive debris and contamination as a result of the ingestion ‹› If any of the above conditions are observed, replace the air cleaner element. Remove any snow or ice that may have accumulated in the air intake duct. Note Winter covers for trucks that are equipped with the Duramax(TM) Diesel Engine are included with vehicle orders that ship to the following areas: All of Canada, and the following states: Alaska, Colorado, Idaho, Maine, Michigan, Minnesota, Montana, New Hampshire, New York, North Dakota, South Dakota, Vermont, Wisconsin, Wyoming. These vehicles should not need a new cover. 4. Install the grille opening section ONLY (if using the 2 piece cover) of the winter front cover following the usage guidelines provided in the Owners Manual for the appropriate type winter cover. ‹› If the customer does not have a cover, obtain and install the grille opening section ONLY , GM P/N 25822811 (GMC) or GM P/N 25822812 (Chevrolet). 5. The grille opening cover MUST BE installed to ensure a complete repair, BEFORE ENCOUNTERING SNOW. This repair allows warm air to be circulated into the air cleaner. Additional Information to Advise Customer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 08-06-04-054B > Jan > 11 > Diesel Engine - Low Power/MIL ON/DTC P0101 > Page 4497 Important If the vehicle is driven in a snow storm before installing the winter cover and the customer chooses to resolve the issue, they must follow this procedure using the following steps: 1. Remove ANY ice or snow that may have accumulated in the air intake duct, BEFORE REPLACING the air cleaner element. 2. INSTALL the winter cover BEFORE continuing to drive the truck. 3. Turn OFF the ignition, and all electrical accessories and components. 4. Remove the key from the vehicle, THEN open and close the door. 5. WAIT for 2 minutes to allow the engine control module (ECM) to power down. This can be verified by watching for the instrument panel cluster (IPC) gage needles to drop slightly. 1. Allowing the ECM to power down will let DTC P0101 revert to a History DTC and the vehicle should return to full power if the issue has been eliminated. 2. Advise the customer to take the vehicle to the dealer as soon as possible to verify the condition has been eliminated. Ambient (Outside) Air Temperature Sensor Relocation For vehicles equipped with Automatic Temperature Control HVAC (RPO CJ2), the ambient (outside) air temperature sensor needs to be relocated using the following procedure: 1. Remove the radiator grille. Refer to the Radiator Grille Replacement procedure in SI. 2. Remove the ambient air sensor from its current location by carefully lifting the sensor from the radiator support cross bar. 3. Remove the harness clip nearest to the sensor. 4. Reinstall the ambient air sensor to the new location using the existing hole (1) in the lower section of the radiator support. 5. Reinstall the harness clip to the existing hole (2) in the radiator support. 6. Reinstall the radiator grille. Parts Information Warranty Information Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 08-06-04-054B > Jan > 11 > Diesel Engine - Low Power/MIL ON/DTC P0101 > Page 4498 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 08-06-04-054A > Jan > 10 > Engine - Reduced Power/MIL ON/DTC P0101 Air Filter Element: Customer Interest Engine - Reduced Power/MIL ON/DTC P0101 TECHNICAL Bulletin No.: 08-06-04-054A Date: January 07, 2010 Subject: Snow or Ice Ingestion into Air Cleaner Element, Malfunction Indicator Lamp (MIL) Illuminated, Engine Power is Reduced Message Displayed, DTC P0101 Set (Perform Repair as Outlined) Models: 2007-2010 Chevrolet Silverado 2500/3500 Series 2007-2010 GMC Sierra 2500/3500 Series Equipped with Duramax(TM) Diesel Engine (RPO LMM) Please Refer to GMVIS Supercede: This bulletin is being revised to remove the graphic, update the Parts and Correction information and add information to advise a customer. Please discard Corporate Bulletin 08-06-04-054 (Section 06 - Engine / Propulsion System). Condition Some customers may comment on the malfunction indicator lamp (MIL) being illuminated and an Engine Power is Reduced message being displayed. The technician may observe DTC P0101 set as current or in history. Cause This condition may be caused by snow being ingested into the air cleaner housing and accumulating in the air cleaner element, resulting in restricted airflow into the engine. Correction 1. Verify the condition by questioning the customer as to when the condition occurs (such as during or right after a snow storm). ‹› If the condition occurs as described above, proceed to Step 2. ‹› If the condition does not occur as described above, refer to Diagnostic Trouble Code (DTC) List Vehicle in SI. 2. Remove the air cleaner element. Refer to Air Cleaner Element Replacement in SI. 3. Inspect the air cleaner element for the following conditions: 1. Packed snow 2. Frozen ice 3. A soaking wet condition that would indicate previous snow ingestion 4. Excessive debris and contamination as a result of the ingestion ‹› If any of the above conditions are observed, replace the air cleaner element. Remove any snow or ice that may have accumulated in the air intake duct. Note Winter covers for trucks that are equipped with the Duramax(TM) Diesel Engine are included with vehicle orders that ship to the following areas: All of Canada, and the following states: Alaska, Colorado, Idaho, Maine, Michigan, Minnesota, Montana, New Hampshire, New York, North Dakota, South Dakota, Vermont, Wisconsin, Wyoming. These vehicles should not need a new cover. 4. Install the grille opening section ONLY (if using the 2 piece cover) of the winter front cover following the usage guidelines provided in the Owners Manual for the appropriate type winter cover. ‹› If the customer does not have a cover, obtain and install the grille opening section ONLY, GM P/N 25822811 (GMC) or GM P/N 25822812 (Chevrolet). 5. The grille opening cover MUST BE installed to ensure a complete repair, BEFORE ENCOUNTERING SNOW. This repair allows warm air to be circulated into the air cleaner. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 08-06-04-054A > Jan > 10 > Engine - Reduced Power/MIL ON/DTC P0101 > Page 4503 Additional Information to Advise Customer Important If the vehicle is driven in a snow storm before installing the winter cover and the customer chooses to resolve the issue, they must follow this procedure using the following steps: 1. Remove ANY ice or snow that may have accumulated in the air intake duct, BEFORE REPLACING the air cleaner element. 2. INSTALL the winter cover BEFORE continuing to drive the truck. 3. Turn OFF the ignition, and all electrical accessories and components. 4. Remove the key from the vehicle, THEN open and close the door. 5. WAIT for 2 minutes to allow the engine control module (ECM) to power down. This can be verified by watching for the instrument panel cluster (IPC) gage needles to drop slightly. 1. Allowing the ECM to power down will let DTC P0101 revert to a History DTC and the vehicle should return to full power if the issue has been eliminated. 2. Advise the customer to take the vehicle to the dealer as soon as possible to verify the condition has been eliminated. Parts Information Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 08-06-04-054B > Jan > 11 > Diesel Engine - Low Power/MIL ON/DTC P0101 Air Filter Element: All Technical Service Bulletins Diesel Engine - Low Power/MIL ON/DTC P0101 TECHNICAL Bulletin No.: 08-06-04-054B Date: January 24, 2011 Subject: Snow or Ice Ingestion into Air Cleaner Element, Malfunction Indicator Lamp (MIL) Illuminated, Engine Power is Reduced Message Displayed, DTC P0101 Set (Perform Repair as Outlined) Models: 2007-2010 Chevrolet Silverado 2500/3500 Series 2007-2010 GMC Sierra 2500/3500 Series Equipped with Duramax(TM) Diesel Engine (RPO LMM) Supercede: This bulletin is being revised to provide a procedure to relocate the OAT sensor, if equipped with RPO CJ2. Please discard Corporate Bulletin 08-06-04-054A (Section 06 - Engine / Propulsion System). Condition Some customers may comment on the malfunction indicator lamp (MIL) being illuminated and an Engine Power is Reduced message being displayed. The technician may observe DTC P0101 set as current or in history. Cause This condition may be caused by snow being ingested into the air cleaner housing and accumulating in the air cleaner element, resulting in restricted airflow into the engine. Correction 1. Verify the condition by questioning the customer as to when the condition occurs (such as during or right after a snow storm). ‹› If the condition occurs as described above, proceed to Step 2. ‹› If the condition does not occur as described above, refer to Diagnostic Trouble Code (DTC) List Vehicle in SI. 2. Remove the air cleaner element. Refer to Air Cleaner Element Replacement in SI. 3. Inspect the air cleaner element for the following conditions: 1. Packed snow 2. Frozen ice 3. A soaking wet condition that would indicate previous snow ingestion 4. Excessive debris and contamination as a result of the ingestion ‹› If any of the above conditions are observed, replace the air cleaner element. Remove any snow or ice that may have accumulated in the air intake duct. Note Winter covers for trucks that are equipped with the Duramax(TM) Diesel Engine are included with vehicle orders that ship to the following areas: All of Canada, and the following states: Alaska, Colorado, Idaho, Maine, Michigan, Minnesota, Montana, New Hampshire, New York, North Dakota, South Dakota, Vermont, Wisconsin, Wyoming. These vehicles should not need a new cover. 4. Install the grille opening section ONLY (if using the 2 piece cover) of the winter front cover following the usage guidelines provided in the Owners Manual for the appropriate type winter cover. ‹› If the customer does not have a cover, obtain and install the grille opening section ONLY , GM P/N 25822811 (GMC) or GM P/N 25822812 (Chevrolet). 5. The grille opening cover MUST BE installed to ensure a complete repair, BEFORE ENCOUNTERING SNOW. This repair allows warm air to be circulated into the air cleaner. Additional Information to Advise Customer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 08-06-04-054B > Jan > 11 > Diesel Engine - Low Power/MIL ON/DTC P0101 > Page 4509 Important If the vehicle is driven in a snow storm before installing the winter cover and the customer chooses to resolve the issue, they must follow this procedure using the following steps: 1. Remove ANY ice or snow that may have accumulated in the air intake duct, BEFORE REPLACING the air cleaner element. 2. INSTALL the winter cover BEFORE continuing to drive the truck. 3. Turn OFF the ignition, and all electrical accessories and components. 4. Remove the key from the vehicle, THEN open and close the door. 5. WAIT for 2 minutes to allow the engine control module (ECM) to power down. This can be verified by watching for the instrument panel cluster (IPC) gage needles to drop slightly. 1. Allowing the ECM to power down will let DTC P0101 revert to a History DTC and the vehicle should return to full power if the issue has been eliminated. 2. Advise the customer to take the vehicle to the dealer as soon as possible to verify the condition has been eliminated. Ambient (Outside) Air Temperature Sensor Relocation For vehicles equipped with Automatic Temperature Control HVAC (RPO CJ2), the ambient (outside) air temperature sensor needs to be relocated using the following procedure: 1. Remove the radiator grille. Refer to the Radiator Grille Replacement procedure in SI. 2. Remove the ambient air sensor from its current location by carefully lifting the sensor from the radiator support cross bar. 3. Remove the harness clip nearest to the sensor. 4. Reinstall the ambient air sensor to the new location using the existing hole (1) in the lower section of the radiator support. 5. Reinstall the harness clip to the existing hole (2) in the radiator support. 6. Reinstall the radiator grille. Parts Information Warranty Information Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 08-06-04-054B > Jan > 11 > Diesel Engine - Low Power/MIL ON/DTC P0101 > Page 4510 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 08-06-04-054A > Jan > 10 > Engine - Reduced Power/MIL ON/DTC P0101 Air Filter Element: All Technical Service Bulletins Engine - Reduced Power/MIL ON/DTC P0101 TECHNICAL Bulletin No.: 08-06-04-054A Date: January 07, 2010 Subject: Snow or Ice Ingestion into Air Cleaner Element, Malfunction Indicator Lamp (MIL) Illuminated, Engine Power is Reduced Message Displayed, DTC P0101 Set (Perform Repair as Outlined) Models: 2007-2010 Chevrolet Silverado 2500/3500 Series 2007-2010 GMC Sierra 2500/3500 Series Equipped with Duramax(TM) Diesel Engine (RPO LMM) Please Refer to GMVIS Supercede: This bulletin is being revised to remove the graphic, update the Parts and Correction information and add information to advise a customer. Please discard Corporate Bulletin 08-06-04-054 (Section 06 - Engine / Propulsion System). Condition Some customers may comment on the malfunction indicator lamp (MIL) being illuminated and an Engine Power is Reduced message being displayed. The technician may observe DTC P0101 set as current or in history. Cause This condition may be caused by snow being ingested into the air cleaner housing and accumulating in the air cleaner element, resulting in restricted airflow into the engine. Correction 1. Verify the condition by questioning the customer as to when the condition occurs (such as during or right after a snow storm). ‹› If the condition occurs as described above, proceed to Step 2. ‹› If the condition does not occur as described above, refer to Diagnostic Trouble Code (DTC) List Vehicle in SI. 2. Remove the air cleaner element. Refer to Air Cleaner Element Replacement in SI. 3. Inspect the air cleaner element for the following conditions: 1. Packed snow 2. Frozen ice 3. A soaking wet condition that would indicate previous snow ingestion 4. Excessive debris and contamination as a result of the ingestion ‹› If any of the above conditions are observed, replace the air cleaner element. Remove any snow or ice that may have accumulated in the air intake duct. Note Winter covers for trucks that are equipped with the Duramax(TM) Diesel Engine are included with vehicle orders that ship to the following areas: All of Canada, and the following states: Alaska, Colorado, Idaho, Maine, Michigan, Minnesota, Montana, New Hampshire, New York, North Dakota, South Dakota, Vermont, Wisconsin, Wyoming. These vehicles should not need a new cover. 4. Install the grille opening section ONLY (if using the 2 piece cover) of the winter front cover following the usage guidelines provided in the Owners Manual for the appropriate type winter cover. ‹› If the customer does not have a cover, obtain and install the grille opening section ONLY, GM P/N 25822811 (GMC) or GM P/N 25822812 (Chevrolet). 5. The grille opening cover MUST BE installed to ensure a complete repair, BEFORE ENCOUNTERING SNOW. This repair allows warm air to be circulated into the air cleaner. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 08-06-04-054A > Jan > 10 > Engine - Reduced Power/MIL ON/DTC P0101 > Page 4515 Additional Information to Advise Customer Important If the vehicle is driven in a snow storm before installing the winter cover and the customer chooses to resolve the issue, they must follow this procedure using the following steps: 1. Remove ANY ice or snow that may have accumulated in the air intake duct, BEFORE REPLACING the air cleaner element. 2. INSTALL the winter cover BEFORE continuing to drive the truck. 3. Turn OFF the ignition, and all electrical accessories and components. 4. Remove the key from the vehicle, THEN open and close the door. 5. WAIT for 2 minutes to allow the engine control module (ECM) to power down. This can be verified by watching for the instrument panel cluster (IPC) gage needles to drop slightly. 1. Allowing the ECM to power down will let DTC P0101 revert to a History DTC and the vehicle should return to full power if the issue has been eliminated. 2. Advise the customer to take the vehicle to the dealer as soon as possible to verify the condition has been eliminated. Parts Information Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 4516 Air Filter Element: Service and Repair Air Cleaner Element Replacement Removal Procedure 1. Loosen the screw holding the air cleaner housing door in place. 2. Remove the air cleaner housing door. 3. Remove the air filter element. Installation Procedure 1. Stand facing the front fender on the passenger side of the vehicle. Insert the element into the housing. Place the palm of your hand on the inboard end of the element, and press the element into position. 2. Press both downward and inboard until the outboard end of the element clicks into place inboard of the locating tab. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 4517 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the air cleaner housing door and tighten the screw. Tighten the screw to 4 Nm (35 lb in). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair Fuel Pressure Relief Valve Replacement Removal Procedure 1. Remove the glow plug module and bracket. Refer to Glow Plug Control Module Replacement (See: Glow Plug System/Glow Plug Control Module/Service and Repair). 2. Remove the fuel pressure relief valve from the left fuel rail. Installation Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the fuel pressure relief valve to the left fuel rail. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Page 4522 Tighten the valve to 100 Nm (74 lb ft). 2. Install the glow plug module and bracket. Refer to Glow Plug Control Module Replacement (See: Glow Plug System/Glow Plug Control Module/Service and Repair). 3. Prime the fuel system. Refer to Fuel System Priming (See: Fuel Delivery and Air Induction/Service and Repair/Fuel System Priming). 4. Start the engine. If the engine stalls, repeat the above step. 5. Once the engine starts, inspect for fuel leaks. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications The minimum compression in any one cylinder is 2069 kPa (300 psi). There should not be more than 345 kPa (50 psi) difference between a suspect cylinder and the average compression of all 8 cylinders. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 4526 Compression Check: Testing and Inspection Engine Compression Test Special Tools * J 26999 - Compression Gauge * EN-47603 - Compression Gauge Adapter For equivalent regional tools, refer to Special Tools (See: Engine, Cooling and Exhaust/Engine/Tools and Equipment/Special Tools). 1. Ensure that the vehicle's batteries are in good condition, and fully charged. 2. Operate the vehicle until the engine is at normal operating temperature. 3. Shut off engine. 4. Disconnect glow plug nut; remove all 8 glow plugs. All 8 glow plugs must be removed from the engine during each cylinder test to obtain valid test results. 5. Prior to taking a compression reading, verify the cranking speed is greater than 140 RPM. If the cranking speed is below 140 RPM, repair the slow cranking speed condition before continuing with the compression test. Refer to Engine Cranks Slowly (See: Starting and Charging/Testing and Inspection/Symptom Related Diagnostic Procedures/Engine Cranks Slowly). 6. Install the EN-47603 - adapter in the glow plug hole for the cylinder that is being checked. Caution: Do not add oil to any cylinder during a compression test as extensive engine damage may result. 7. Connect the J 26999 - gauge to the EN-47603 - adapter. Caution: Do not crank the engine using the ignition switch, as the fuel injectors and the glow plug circuits will be energized and engine damage may result. 8. Using a remote start switch, crank the engine for 6 compression strokes, puffs, for the cylinder being tested. 9. Observe the J 26999 - gauge and note the reading as the compression test is being performed. A normal cylinder reading will be indicated if compression builds up quickly and evenly to the specified level. An abnormal reading will be indicated if compression is low on the first compression stroke, starts increasing on the following compression strokes but does not reach the specified level. 10. Record the compression reading for the cylinder just tested. 11. Disconnect the J 26999 gauge from the EN-47603 - adapter and remove adapter from the glow plug hole. 12. Repeat steps 8 through 13 for all remaining cylinders. All 8 cylinders must be tested to obtain valid test results. Record the readings. 13. The minimum compression in any one cylinder is 2069 kPa (300 psi). There should not be more than 345 kPa (50 psi) difference between a suspect cylinder and the average compression of all 8 cylinders. Note: Cylinder to cylinder variation may be at the high end of the specification on engines with less than 20,000 km (12,427 miles). * Normal-Compression builds up quickly and evenly to the specified compression for each cylinder. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 4527 * Piston Rings Leaking-Compression is low on the first stroke. Compression builds up with the following strokes but does not reach normal. * Valves Leaking-Compression is low on the first stroke. Compression usually does not build up on the following strokes. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications Valve Clearance Adjustment Specifications Valve Lash ........................................................................................................................................... ...................................................... 0.3 mm (0.012 in) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Adjustments > On Vehicle Valve Clearance: Adjustments On Vehicle Valve Clearance Adjustment 1. Remove the fan clutch. Refer to Fan Clutch Replacement (Diesel) (See: Engine, Cooling and Exhaust/Cooling System/Radiator Cooling Fan/Fan Clutch/Service and Repair). 2. Remove the upper valve rocker arm covers. Refer to Valve Rocker Arm Upper Cover Replacement - Left Side (See: Engine, Cooling and Exhaust/Engine/Cylinder Head Assembly/Valve Cover/Service and Repair/Valve Rocker Arm Upper Cover Replacement - Left Side) and Valve Rocker Arm Upper Cover Replacement - Right Side (See: Engine, Cooling and Exhaust/Engine/Cylinder Head Assembly/Valve Cover/Service and Repair/Valve Rocker Arm Upper Cover Replacement - Right Side). 3. Rotate the crankshaft in order to bring the number 1 cylinder to top dead center (TDC) of the compression stroke. The number 1 cylinder is the front cylinder on the right bank. The mark on the crankshaft balancer should be aligned with the mark on the engine. 4. Loosen the valve adjusting screws. 5. Insert a feeler gauge between the tip of the rocker arm and the valve bridge. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Adjustments > On Vehicle > Page 4533 6. Adjust the valve lash to 0.3 mm (0.012 in). Refer to Valve Clearance Adjustment Specifications (See: ) to determine which valves can be adjusted when the engine is at TDC. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 7. Tighten the lock nut. Tighten nut to 22 Nm (16 lb ft). 8. Rotate the crankshaft one revolution in order to bring the number 1 cylinder to TDC of the exhaust stroke. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Adjustments > On Vehicle > Page 4534 9. Loosen the valve adjusting screws. 10. Insert a feeler gauge between the tip of the rocker arm and the valve bridge. 11. Adjust the valve clearance to 0.3 mm (0.012 in). Refer to Valve Clearance Adjustment Specifications (See: ) to determine which valves can be adjusted when the engine is at TDC. 12. Tighten the lock nut. Tighten nut to 22 Nm (16 lb ft). 13. Install the upper valve rocker arm covers. Refer to Valve Rocker Arm Upper Cover Replacement - Left Side (See: Engine, Cooling and Exhaust/Engine/Cylinder Head Assembly/Valve Cover/Service and Repair/Valve Rocker Arm Upper Cover Replacement - Left Side) and Valve Rocker Arm Upper Cover Replacement - Right Side (See: Engine, Cooling and Exhaust/Engine/Cylinder Head Assembly/Valve Cover/Service and Repair/Valve Rocker Arm Upper Cover Replacement - Right Side). 14. Install the fan clutch. Refer to Fan Clutch Replacement (Diesel) (See: Engine, Cooling and Exhaust/Cooling System/Radiator Cooling Fan/Fan Clutch/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Adjustments > On Vehicle > Page 4535 Valve Clearance: Adjustments Off Vehicle Valve Clearance Adjustment 1. Rotate the crankshaft to bring the number 1 cylinder at the top dead center of the compression stroke. The number 1 cylinder is the front cylinder on the right bank. The mark on the crankshaft balancer should be aligned with the mark on the engine. 2. Loosen the valve adjusting screws. 3. Insert a feeler gauge between the tip of the rocker arm and the valve bridge. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Adjustments > On Vehicle > Page 4536 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Adjust the valve lash to 0.3 mm (0.012 in). Refer to Valve Clearance Adjustment Specifications (See: ) to determine which valves that can be adjusted when the engine is at Top Dead Center. Tighten the valve lash lock nut to 22 Nm (16 lb ft). 5. Rotate the crankshaft one revolution to bring the number 1 cylinder at Top Dead Center of the exhaust stroke. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Adjustments > On Vehicle > Page 4537 6. Adjust the valve lash to 0.3 mm (0.012 in). Refer to Valve Clearance Adjustment Specifications (See: ) to determine which valves that can be adjusted when the engine is at Top Dead Center. Tighten the valve lash lock nut to 22 Nm (16 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations Accelerator Pedal Position Sensor: Locations Harness Routing Views Brake Clutch Harness Routing 1 - Driver Door Frame 2 - X205 3 - X102 (JL1) 4 - Accelerator Pedal Position (APP) Sensor Connector 5 - Junction Block - Left I/P (except MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 4542 Accelerator Pedal Position Sensor: Diagrams Component Connector End Views Accelerator Pedal Position (APP) Sensor Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 4543 Accelerator Pedal Position Sensor: Description and Operation Accelerator Pedal Position System Description The accelerator pedal position (APP) sensor is mounted inside the accelerator pedal control assembly. The sensor is made up of the two individual sensors within a single housing. Each sensor has a unique functionality to determine pedal position. The accelerator pedal position (APP) system along with the engine control module (ECM) is used to calculate and control the amount of acceleration and deceleration through fuel injector control. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 4544 Accelerator Pedal Position Sensor: Service and Repair Accelerator Pedal Position Sensor Replacement Removal Procedure Caution: Handle the electronic throttle control components carefully. Use cleanliness in order to prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the electronic throttle control components. Do not immerse the electronic throttle control components in cleaning solvents of any type. 1. Remove the connector position assurance (CPA) retainer. 2. Disconnect the accelerator pedal position (APP) sensor electrical connector (1). 3. Remove the accelerator pedal bolts. 4. Remove the accelerator pedal. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 4545 Installation Procedure 1. Position the accelerator pedal to the accelerator pedal bracket. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the accelerator pedal bolts and tighten to 9 Nm (80 lb in).. 3. Connect the APP sensor electrical connector (1). 4. Install the CPA retainer. 5. Connect a scan tool to the diagnostic port in order to test for proper throttle-opening and throttle-closing range. 6. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle, and a wide open throttle (WOT). 7. Verify that the vehicle meets the following conditions: * The vehicle is not in a reduced engine power mode. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 4546 * The ignition is ON. * The engine is OFF. 8. Inspect the carpet fit under the accelerator pedal. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations Air Flow Meter/Sensor: Locations Harness Routing Views Engine Harness Routing - Top (4.3L) 1 - Mega Fuse Ring Terminal 2 - X175 (M30) 3 - J128 4 - J105 5 - J106 6 - J130 (M30 with NQG/NQH) 7 - Engine Control Module (ECM) X1 8 - Engine Control Module (ECM) X2 9 - G103 10 - X112 11 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Connector Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 4550 Air Flow Meter/Sensor: Diagrams Component Connector End Views Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (Diesel) Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (Gas) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 4551 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 4552 Air Flow Meter/Sensor: Service and Repair Mass Airflow Sensor with Intake Air Temperature Sensor Replacement Removal Procedure 1. Disconnect the engine wiring harness electrical connector (1) from the mass air flow (MAF)/intake air temperature (IAT) sensor. 2. Remove the MAF/IAT sensor TORX(R) screws. 3. Remove the MAF/IAT sensor. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 4553 1. Install the MAF/IAT sensor. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the MAF/IAT sensor TORX(R) screws. Tighten the screws to 8 Nm (70 lb in). 3. Connect the engine wiring harness electrical connector (1) to the MAF/IAT sensor. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams Intake Air Temperature Sensor: Diagrams Component Connector End Views Intake Air Temperature (IAT) Sensor 2 (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Intake Air Temperature (IAT) Sensor 2 Replacement Intake Air Temperature Sensor: Service and Repair Intake Air Temperature (IAT) Sensor 2 Replacement Intake Air Temperature (IAT) Sensor 2 Replacement Removal Procedure 1. Remove the air intake pipe. Refer to Air Intake Pipe Replacement (See: Fuel Delivery and Air Induction/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair/Air Intake Pipe Replacement). 2. Disconnect the engine wiring harness electrical connector (1) from the intake air temperature (IAT) sensor pigtail. 3. Remove the IAT sensor (2) from the center intake manifold. Installation Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Intake Air Temperature (IAT) Sensor 2 Replacement > Page 4559 1. Install the IAT sensor (2) to the center intake manifold. Tighten the sensor to 25 Nm (18 lb ft). 2. Connect the engine wiring harness electrical connector (1) to the IAT sensor pigtail. 3. Install the air intake pipe. Refer to Air Intake Pipe Replacement (See: Fuel Delivery and Air Induction/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair/Air Intake Pipe Replacement). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Intake Air Temperature (IAT) Sensor 2 Replacement > Page 4560 Intake Air Temperature Sensor: Service and Repair Mass Airflow Sensor with Intake Air Temperature Sensor Replacement Mass Airflow Sensor with Intake Air Temperature Sensor Replacement Removal Procedure 1. Disconnect the engine wiring harness electrical connector (1) from the mass air flow (MAF)/intake air temperature (IAT) sensor. 2. Remove the MAF/IAT sensor TORX(R) screws. 3. Remove the MAF/IAT sensor. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Intake Air Temperature (IAT) Sensor 2 Replacement > Page 4561 1. Install the MAF/IAT sensor. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the MAF/IAT sensor TORX(R) screws. Tighten the screws to 8 Nm (70 lb in). 3. Connect the engine wiring harness electrical connector (1) to the MAF/IAT sensor. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Current Sensor > Component Information > Diagrams Battery Current Sensor: Diagrams Component Connector End Views Battery Current Sensor (10 Series without MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Current Sensor > Component Information > Diagrams > Page 4565 Battery Current Sensor: Service and Repair Battery Current Sensor Replacement Removal Procedure 1. Remove the negative battery cable. Refer to Battery Negative Cable Replacement (V6) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Replacement (V8) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Replacement (Diesel) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 2. Mark the location of the battery current sensor on the battery cable with tape for reference during installation. 3. Remove the tape securing the battery current sensor to the negative battery cable. 4. Mark the location of the negative battery cable clips (1) and remove the clips from the cable. 5. Squeeze the negative battery cable branches together. Important: Note the orientation of the battery current sensor prior to removal. 6. Slide the battery current sensor (2) off of the negative battery cable. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Current Sensor > Component Information > Diagrams > Page 4566 1. Squeeze the negative battery cable branches together. Important: Ensure the battery current sensor is installed in the correct direction and location on the negative battery cable. 2. Slide the NEW battery current sensor (2) up onto the negative battery cable to the location previously marked during removal. 3. Wrap electrical tape around the battery current sensor leg in order to secure the sensor to the negative battery cable. 4. Install the negative battery cable clips (1) to the cable to the locations previously marked during removal. 5. Install the negative battery cable. Refer to Battery Negative Cable Replacement (V6) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Replacement (V8) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Replacement (Diesel) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 07-08-42-006E > Nov > 10 > Instruments Bulb Outage Detection Restoration Body Control Module: Customer Interest Instruments - Bulb Outage Detection Restoration INFORMATION Bulletin No.: 07-08-42-006E Date: November 11, 2010 Subject: Information on BCM Calibrations Available to Restore Bulb Outage Detection on Vehicles Produced by a Second Stage Manufacturer, Turn Signals Flash Fast after Factory Box Removed (Upfitter) Models: 2007-2011 Chevrolet Silverado 2007-2011 GMC Sierra Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 07-08-42-006D (Section 08 - Body and Accessories). The information contained in this bulletin applies to vehicles that are to be completed by a second stage manufacturer (upfitter) and may need to have the Body Control Module (BCM) rear turn signal bulb outage detection capability changed. All production vehicles will be manufactured with one of the following BCM rear turn signal bulb outage detection software options: 1. A standard production vehicle will have BCM software that checks for two bulbs functioning in each rear turn signal bulb circuit. If one or more bulbs are inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 2. Certain 2500 and 3500 models can be ordered with a new option (RPO 9U5) where the BCM checks for one bulb functioning in each rear turn signal bulb circuit. If the bulb goes inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 3. A vehicle built with a pickup box delete or chassis cab option (RPO ZW9) will be produced with a BCM program that has no turn signal bulb outage detection capability (LED compatible). The IPC turn signal indicator will flash at the same rate no matter how many turn signal bulbs are inoperative. In some cases, the upfitter may wish to change the turn signal bulb outage detection capability so that the turn signals work correctly with their upfit or to meet certain requirements. This will require contacting the Techline Customer Support Center (TCSC) to open a case and obtain a Vehicle Configuration Index (VCI) number. Advise the TCSC consultant which turn signal bulb outage detection capability is needed: 1. Factory standard production TWO bulb outage detection. 2. Optional (RPO 9U5) ONE bulb outage detection. NOTE: ONLY AVAILABLE ON CERTAIN 2007-2011 MODEL 2500 AND 3500 VEHICLES. 3. NO bulb outage detection (LED compatible). The BCM can then be reprogrammed with the correct software. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 07-08-42-006E > Nov > 10 > Instruments - Bulb Outage Detection Restoration Body Control Module: All Technical Service Bulletins Instruments - Bulb Outage Detection Restoration INFORMATION Bulletin No.: 07-08-42-006E Date: November 11, 2010 Subject: Information on BCM Calibrations Available to Restore Bulb Outage Detection on Vehicles Produced by a Second Stage Manufacturer, Turn Signals Flash Fast after Factory Box Removed (Upfitter) Models: 2007-2011 Chevrolet Silverado 2007-2011 GMC Sierra Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 07-08-42-006D (Section 08 - Body and Accessories). The information contained in this bulletin applies to vehicles that are to be completed by a second stage manufacturer (upfitter) and may need to have the Body Control Module (BCM) rear turn signal bulb outage detection capability changed. All production vehicles will be manufactured with one of the following BCM rear turn signal bulb outage detection software options: 1. A standard production vehicle will have BCM software that checks for two bulbs functioning in each rear turn signal bulb circuit. If one or more bulbs are inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 2. Certain 2500 and 3500 models can be ordered with a new option (RPO 9U5) where the BCM checks for one bulb functioning in each rear turn signal bulb circuit. If the bulb goes inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 3. A vehicle built with a pickup box delete or chassis cab option (RPO ZW9) will be produced with a BCM program that has no turn signal bulb outage detection capability (LED compatible). The IPC turn signal indicator will flash at the same rate no matter how many turn signal bulbs are inoperative. In some cases, the upfitter may wish to change the turn signal bulb outage detection capability so that the turn signals work correctly with their upfit or to meet certain requirements. This will require contacting the Techline Customer Support Center (TCSC) to open a case and obtain a Vehicle Configuration Index (VCI) number. Advise the TCSC consultant which turn signal bulb outage detection capability is needed: 1. Factory standard production TWO bulb outage detection. 2. Optional (RPO 9U5) ONE bulb outage detection. NOTE: ONLY AVAILABLE ON CERTAIN 2007-2011 MODEL 2500 AND 3500 VEHICLES. 3. NO bulb outage detection (LED compatible). The BCM can then be reprogrammed with the correct software. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 09-08-47-001A > Jun > 10 > Body Controls - Unable To Reprogram Body Control Module Body Control Module: All Technical Service Bulletins Body Controls - Unable To Reprogram Body Control Module INFORMATION Bulletin No.: 09-08-47-001A Date: June 14, 2010 Subject: Unable to Reprogram Body Control Module (BCM), BCM Reprogramming Did Not Complete - Revised Reprogramming Instructions Models: 2006-2010 Buick Lucerne 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX 2008-2010 Cadillac CTS 2010 Cadillac CTS Wagon 2010 Chevrolet Camaro 2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Impala 2007-2010 Chevrolet Avalanche, Equinox, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet Traverse 2007-2010 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2008-2010 GMC Savana 2010 GMC Terrain 2007-2009 Pontiac Torrent 2008-2009 Pontiac G8 2008-2009 HUMMER H2 2007-2009 Saturn OUTLOOK 2008-2009 Saturn VUE Refer to GMVIS Supercede: This bulletin is being revised to update the models and the model years. Please discard Corporate Bulletin Number 09-08-47-001 (Section 08 - Body and Accessories). Some technicians may experience an unsuccessful body control module (BCM) reprogramming event, when choosing the Reprogram ECU selection on the Service Programming System (SPS). The technician may also notice that when attempting to reprogram the BCM again after this incident has occurred, the BCM may not complete the programming event. This condition may be caused by the following: - A reprogramming event that was interrupted due to a lack of communication between the vehicle and the TIS2WEB terminal. - The vehicle experienced low system voltage during the reprogramming event. Important Do not replace the BCM for this condition. SPS Programming Process Selection Perform this procedure first. 1. If reprogramming has failed during the initial reprogramming event, back out of the SPS application completely. 2. Re-select SPS from the TIS2WEB terminal application. 3. When selecting the Programming Process , choose Replace and Program ECU , even though a new BCM is NOT being installed. 4. Reprogram the BCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the SPS procedures in SI. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 09-08-47-001A > Jun > 10 > Body Controls - Unable To Reprogram Body Control Module > Page 4584 During programming, the battery voltage must be maintained within the proper range of 12-15 volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. BCM Still Fails to Reprogram If the BCM still fails to reprogram perform this procedure: 1. Turn OFF the ignition, and remove the key. 2. Remove the fuses that power up the following modules/components for a minimum of 2 minutes: - BCM - EBCM - ECM - IS LPS (located in the left IP fusebox) - TCM 3. Open and close the driver door. Allow enough time for the retained accessory power (RAP) to turn OFF. 4. Reinstall the fuses. 5. When selecting the Programming Process , choose Replace and Program ECU , even though a new BCM is NOT being installed. 6. Reprogram the BCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the SPS procedures in SI. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 09-08-47-001A > Jun > 10 > Body Controls - Unable To Reprogram Body Control Module Body Control Module: All Technical Service Bulletins Body Controls - Unable To Reprogram Body Control Module INFORMATION Bulletin No.: 09-08-47-001A Date: June 14, 2010 Subject: Unable to Reprogram Body Control Module (BCM), BCM Reprogramming Did Not Complete - Revised Reprogramming Instructions Models: 2006-2010 Buick Lucerne 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX 2008-2010 Cadillac CTS 2010 Cadillac CTS Wagon 2010 Chevrolet Camaro 2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Impala 2007-2010 Chevrolet Avalanche, Equinox, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet Traverse 2007-2010 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2008-2010 GMC Savana 2010 GMC Terrain 2007-2009 Pontiac Torrent 2008-2009 Pontiac G8 2008-2009 HUMMER H2 2007-2009 Saturn OUTLOOK 2008-2009 Saturn VUE Refer to GMVIS Supercede: This bulletin is being revised to update the models and the model years. Please discard Corporate Bulletin Number 09-08-47-001 (Section 08 - Body and Accessories). Some technicians may experience an unsuccessful body control module (BCM) reprogramming event, when choosing the Reprogram ECU selection on the Service Programming System (SPS). The technician may also notice that when attempting to reprogram the BCM again after this incident has occurred, the BCM may not complete the programming event. This condition may be caused by the following: - A reprogramming event that was interrupted due to a lack of communication between the vehicle and the TIS2WEB terminal. - The vehicle experienced low system voltage during the reprogramming event. Important Do not replace the BCM for this condition. SPS Programming Process Selection Perform this procedure first. 1. If reprogramming has failed during the initial reprogramming event, back out of the SPS application completely. 2. Re-select SPS from the TIS2WEB terminal application. 3. When selecting the Programming Process , choose Replace and Program ECU , even though a new BCM is NOT being installed. 4. Reprogram the BCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the SPS procedures in SI. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 09-08-47-001A > Jun > 10 > Body Controls - Unable To Reprogram Body Control Module > Page 4590 During programming, the battery voltage must be maintained within the proper range of 12-15 volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. BCM Still Fails to Reprogram If the BCM still fails to reprogram perform this procedure: 1. Turn OFF the ignition, and remove the key. 2. Remove the fuses that power up the following modules/components for a minimum of 2 minutes: - BCM - EBCM - ECM - IS LPS (located in the left IP fusebox) - TCM 3. Open and close the driver door. Allow enough time for the retained accessory power (RAP) to turn OFF. 4. Reinstall the fuses. 5. When selecting the Programming Process , choose Replace and Program ECU , even though a new BCM is NOT being installed. 6. Reprogram the BCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the SPS procedures in SI. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 4591 Body Control Module: Diagrams Component Connector End Views Body Control Module (BCM) X1 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 4592 Body Control Module (BCM) X2 Body Control Module (BCM) X3 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 4593 Body Control Module (BCM) X4 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 4594 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 4595 Body Control Module (BCM) X5 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 4596 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 4597 Body Control Module (BCM) X6 Body Control Module (BCM) X7 (except MEX or A52) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 4598 Auxiliary Body Control Module (XBCM) X1 (EXP) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 4599 Auxiliary Body Control Module (XBCM) X2 (EXP) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 4600 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Auxiliary Body Control Module Replacement Body Control Module: Service and Repair Auxiliary Body Control Module Replacement Auxiliary Body Control Module Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Auxiliary Body Control Module Replacement > Page 4603 Body Control Module: Service and Repair Body Control Module Replacement Body Control Module Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Auxiliary Body Control Module Replacement > Page 4604 Body Control Module: Service and Repair Body Control Module Bracket Replacement Body Control Module Bracket Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Auxiliary Body Control Module Replacement > Page 4605 Body Control Module: Service and Repair Serial Data Gateway Module Replacement Serial Data Gateway Module Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Harness Routing Views Camshaft Position Sensor Jumper Harness Routing (4.8L/5.3L/6.0L/6.2L) 1 - X112 2 - Camshaft Position Sensor Jumper Harness Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 4609 Camshaft Position Sensor: Diagrams Component Connector End Views Camshaft Position (CMP) Actuator Solenoid Valve (LZ1, LY6, L96 or L9H) Camshaft Position (CMP) Sensor (LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 4610 Camshaft Position (CMP) Sensor (Gas except LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 4611 Camshaft Position (CMP) Sensor (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 4612 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 4613 Camshaft Position Sensor: Service Precautions Camshaft Position Actuator Removal and Installation Warning Warning Do not push or pull on the reluctor wheel of the camshaft position (CMP) actuator during removal or installation. The reluctor wheel is retained to the front of the CMP actuator by 3 roll pins. Pushing or pulling on the wheel may dislodge the wheel from the front of the actuator. The actuator return spring is under tension and may rotate the dislodged reluctor wheel, causing personal injury. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 4614 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor Replacement Removal Procedure 1. Remove the cooling fan pulley. Refer to Fan Pulley Replacement (See: Engine, Cooling and Exhaust/Cooling System/Radiator Cooling Fan/Service and Repair). 2. Remove the camshaft position (CMP) sensor bolt. 3. Remove the CMP sensor. Installation Procedure 1. Lubricate the CMP sensor O-ring with clean engine oil. 2. Install the CMP sensor. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 4615 3. Install the CMP sensor bolt. Tighten the bolt to 10 Nm (89 lb in). 4. Install the cooling fan pulley. Refer to Fan Pulley Replacement (See: Engine, Cooling and Exhaust/Cooling System/Radiator Cooling Fan/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Technical Service Bulletins > Recalls for Exhaust Temperature Sensor: > 11054 > Apr > 11 > Recall - Replace Exhaust Gas Temperature Sensor Technical Service Bulletin # 11054 Date: 110412 Recall - Replace Exhaust Gas Temperature Sensor PRODUCT EMISSION Bulletin No.: 11054 Date: April 12, 2011 Subject: 11054 - Reduced Engine Performance and Emission Control - Replace Exhaust Gas Temperature Sensors Models: 2010 Chevrolet Express, Silverado HD 2010 GMC Savana, Sierra HD With 6.6L V8 Duramax Diesel Engine (LMM) 2007-2009 Chevrolet Express, Kodiak, Silverado HD 2007-2009 GMC Savana, Sierra HD, TopKick With 6.6L V8 Duramax Diesel Engine (LMM) Serviced with a Suspect EGT Sensor Condition General Motors has decided to conduct a Voluntary Emission Recall involving certain 2010 model year Chevrolet Express, Silverado HD; and GMC Savana, Sierra HD vehicles equipped with a 6.6L V8 Duramax diesel engine (LMM); and 2007-2009 model year Chevrolet Express, Kodiak, Silverado HD; and GMC Savana, Sierra HD, and TopKick vehicles equipped with a 6.6L V8 Duramax diesel engine (LMM) that may have been serviced with a suspect Exhaust Gas Temperature (EGT) sensor. On these vehicles, the circuit board welds on the EGT sensors in the exhaust system may not be to GM specification. If a weld fails, the Service Engine Soon light will illuminate in the instrument panel, the exhaust gas may not be filtered properly, and the engine power may be reduced. Correction Dealers are to replace both EGT sensors. Vehicles Involved Involved are certain 2010 model year Chevrolet Express, Silverado HD; and GMC Savana, Sierra HD vehicles equipped with a 6.6L V8 Duramax diesel engine (LMM); and 2007-2009 model year Chevrolet Express, Kodiak, Silverado HD; and GMC Savana, Sierra HD, and TopKick vehicles equipped with a 6.6L V8 Duramax diesel engine (LMM) that may have been serviced with a suspect EGT sensor. Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Required Field Actions section in the Global Warranty system. Not all vehicles may be involved. For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to US and Canadian dealers through the GM GlobalConnect Recall Reports, or sent directly to export dealers. Dealers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information Parts required to complete this recall are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Service Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Technical Service Bulletins > Recalls for Exhaust Temperature Sensor: > 11054 > Apr > 11 > Recall - Replace Exhaust Gas Temperature Sensor > Page 4624 1. Remove and replace position 1 and position 2 exhaust gas temperature sensors (1). Refer to Exhaust Temperature Sensor Replacement in SI. 2. CALIFORNIA, CONNECTICUT, MASSACHUSETTS, MAINE, OREGON, VERMONT, & WASHINGTON VEHICLES ONLY: Install a Recall Identification Label. Also, for California vehicles complete a "Proof of Correction" certificate upon recall completion. Recall Identification Label California/Connecticut/Massachusetts/Maine/Oregon/Vermont/Washington Vehicles Only) Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five-digit dealer code of the dealer performing the recall service. This information may be inserted with a ballpoint pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Recall Identification Label, be sure to pull the tab to allow adhesion of the clear protective covering. Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials by ordering on the web from DWD Store, www.gmdealerworld.com, and then click on the DWD Store link. Request Item Number S-1015 when ordering. Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a transaction using the table below. Customer Notification - For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter included with this bulletin). In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper maintenance. The vehicle may fail a state or local emission inspection test if the recall work is not completed. Customer Notification - For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the attached sample letter. In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Technical Service Bulletins > Recalls for Exhaust Temperature Sensor: > 11054 > Apr > 11 > Recall - Replace Exhaust Gas Temperature Sensor > Page 4625 maintenance. The vehicle may fail a state or local emission inspection test if the recall work is not completed. Dealer Recall Responsibility All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. ***THE FOLLOWING 2 PARAGRAPHS ARE NOT FOR CANADA OR EXPORT*** When a California emissions recall is completed by a GM dealer, the dealer must provide the vehicle owner a "Proof of Correction Certificate" which the owner may need to present to the California Department Of Motor Vehicles (DMV) when renewing their vehicle registration. Without this correction certificate, the owner may be unable to renew their vehicle registration. Additional Certificates can be obtained, at no charge, from Dealer Support Materials by ordering on the web from the DWD Store, www.gmdealerworld.com, and then click on the DWD Store link; request GM Item Number 1825 when ordering. Disclaimer Owner Letter Owner Letter Dear General Motors Customer: This notice is sent to inform you that General Motors is conducting a voluntary emission recall that includes your vehicle. Reason For This Recall: General Motors has decided to conduct a Voluntary Emission Recall involving certain 2010 model year Chevrolet Express, Silverado HD; and GMC Savana, Sierra HD vehicles equipped with a 6.6L V8 Duramax diesel engine; and 2007-2009 model year Chevrolet Express, Kodiak, Silverado HD; and GMC Savana, Sierra HD, and TopKick vehicles equipped with a 6.6L V8 Duramax diesel engine that may have been serviced with a suspect Exhaust Gas Temperature (EGT) sensor. The circuit board welds on the EGT sensors in the exhaust system may not be to GM specification. If a weld fails, the Service Engine Soon light will illuminate in the instrument panel, the exhaust gas may not be filtered properly, and the engine power may be reduced. What Will Be Done: Your GM dealer will replace both EGT sensors. This service will be performed for you at no charge. What You Should Do: Please contact your GM dealer as soon as possible to arrange a service date and to assure parts availability. Instructions for making this correction have been sent to your dealer. Please ask your dealer if you wish to know how much time will be needed to schedule, process, and repair your vehicle. If you have any questions or need any assistance, just contact your dealer or the appropriate Customer Assistance Center at the number listed below. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Technical Service Bulletins > Recalls for Exhaust Temperature Sensor: > 11054 > Apr > 11 > Recall - Replace Exhaust Gas Temperature Sensor > Page 4626 Emission Law Information: In order to ensure your full protection under the emission warranty made applicable to your vehicle by State and Federal Law, and your right to participate in future recalls, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could legally be determined to be lack of proper maintenance of your vehicle. Also, your vehicle may fail a state or local emission inspection if this recall is not accomplished. IMPORTANT MESSAGE FOR CALIFORNIA RESIDENTS The California Air Resources Board (CARB) requires vehicle emission recalls be completed prior to California registration renewal. Uncorrected emission recalls will result in the inability to renew your California vehicle registration. At the time of emission recall completion, your California dealer will issue a "Proof of Correction Certificate". Keep this certificate and, if required, present it to the Department of Motor Vehicles when renewing your California registration as proof of recall completion. We are sorry to cause you this inconvenience; however, we have taken this action in the interest of your continued satisfaction with our products. Jim Moloney General Director, Customer and Relationship Services 11054 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exhaust Temperature Sensor: > 11054 > Apr > 11 > Recall - Replace Exhaust Gas Temperature Sensor Technical Service Bulletin # 11054 Date: 110412 Recall - Replace Exhaust Gas Temperature Sensor PRODUCT EMISSION Bulletin No.: 11054 Date: April 12, 2011 Subject: 11054 - Reduced Engine Performance and Emission Control - Replace Exhaust Gas Temperature Sensors Models: 2010 Chevrolet Express, Silverado HD 2010 GMC Savana, Sierra HD With 6.6L V8 Duramax Diesel Engine (LMM) 2007-2009 Chevrolet Express, Kodiak, Silverado HD 2007-2009 GMC Savana, Sierra HD, TopKick With 6.6L V8 Duramax Diesel Engine (LMM) Serviced with a Suspect EGT Sensor Condition General Motors has decided to conduct a Voluntary Emission Recall involving certain 2010 model year Chevrolet Express, Silverado HD; and GMC Savana, Sierra HD vehicles equipped with a 6.6L V8 Duramax diesel engine (LMM); and 2007-2009 model year Chevrolet Express, Kodiak, Silverado HD; and GMC Savana, Sierra HD, and TopKick vehicles equipped with a 6.6L V8 Duramax diesel engine (LMM) that may have been serviced with a suspect Exhaust Gas Temperature (EGT) sensor. On these vehicles, the circuit board welds on the EGT sensors in the exhaust system may not be to GM specification. If a weld fails, the Service Engine Soon light will illuminate in the instrument panel, the exhaust gas may not be filtered properly, and the engine power may be reduced. Correction Dealers are to replace both EGT sensors. Vehicles Involved Involved are certain 2010 model year Chevrolet Express, Silverado HD; and GMC Savana, Sierra HD vehicles equipped with a 6.6L V8 Duramax diesel engine (LMM); and 2007-2009 model year Chevrolet Express, Kodiak, Silverado HD; and GMC Savana, Sierra HD, and TopKick vehicles equipped with a 6.6L V8 Duramax diesel engine (LMM) that may have been serviced with a suspect EGT sensor. Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Required Field Actions section in the Global Warranty system. Not all vehicles may be involved. For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to US and Canadian dealers through the GM GlobalConnect Recall Reports, or sent directly to export dealers. Dealers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information Parts required to complete this recall are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Service Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exhaust Temperature Sensor: > 11054 > Apr > 11 > Recall - Replace Exhaust Gas Temperature Sensor > Page 4632 1. Remove and replace position 1 and position 2 exhaust gas temperature sensors (1). Refer to Exhaust Temperature Sensor Replacement in SI. 2. CALIFORNIA, CONNECTICUT, MASSACHUSETTS, MAINE, OREGON, VERMONT, & WASHINGTON VEHICLES ONLY: Install a Recall Identification Label. Also, for California vehicles complete a "Proof of Correction" certificate upon recall completion. Recall Identification Label California/Connecticut/Massachusetts/Maine/Oregon/Vermont/Washington Vehicles Only) Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five-digit dealer code of the dealer performing the recall service. This information may be inserted with a ballpoint pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Recall Identification Label, be sure to pull the tab to allow adhesion of the clear protective covering. Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials by ordering on the web from DWD Store, www.gmdealerworld.com, and then click on the DWD Store link. Request Item Number S-1015 when ordering. Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a transaction using the table below. Customer Notification - For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter included with this bulletin). In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper maintenance. The vehicle may fail a state or local emission inspection test if the recall work is not completed. Customer Notification - For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the attached sample letter. In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exhaust Temperature Sensor: > 11054 > Apr > 11 > Recall - Replace Exhaust Gas Temperature Sensor > Page 4633 maintenance. The vehicle may fail a state or local emission inspection test if the recall work is not completed. Dealer Recall Responsibility All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. ***THE FOLLOWING 2 PARAGRAPHS ARE NOT FOR CANADA OR EXPORT*** When a California emissions recall is completed by a GM dealer, the dealer must provide the vehicle owner a "Proof of Correction Certificate" which the owner may need to present to the California Department Of Motor Vehicles (DMV) when renewing their vehicle registration. Without this correction certificate, the owner may be unable to renew their vehicle registration. Additional Certificates can be obtained, at no charge, from Dealer Support Materials by ordering on the web from the DWD Store, www.gmdealerworld.com, and then click on the DWD Store link; request GM Item Number 1825 when ordering. Disclaimer Owner Letter Owner Letter Dear General Motors Customer: This notice is sent to inform you that General Motors is conducting a voluntary emission recall that includes your vehicle. Reason For This Recall: General Motors has decided to conduct a Voluntary Emission Recall involving certain 2010 model year Chevrolet Express, Silverado HD; and GMC Savana, Sierra HD vehicles equipped with a 6.6L V8 Duramax diesel engine; and 2007-2009 model year Chevrolet Express, Kodiak, Silverado HD; and GMC Savana, Sierra HD, and TopKick vehicles equipped with a 6.6L V8 Duramax diesel engine that may have been serviced with a suspect Exhaust Gas Temperature (EGT) sensor. The circuit board welds on the EGT sensors in the exhaust system may not be to GM specification. If a weld fails, the Service Engine Soon light will illuminate in the instrument panel, the exhaust gas may not be filtered properly, and the engine power may be reduced. What Will Be Done: Your GM dealer will replace both EGT sensors. This service will be performed for you at no charge. What You Should Do: Please contact your GM dealer as soon as possible to arrange a service date and to assure parts availability. Instructions for making this correction have been sent to your dealer. Please ask your dealer if you wish to know how much time will be needed to schedule, process, and repair your vehicle. If you have any questions or need any assistance, just contact your dealer or the appropriate Customer Assistance Center at the number listed below. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exhaust Temperature Sensor: > 11054 > Apr > 11 > Recall - Replace Exhaust Gas Temperature Sensor > Page 4634 Emission Law Information: In order to ensure your full protection under the emission warranty made applicable to your vehicle by State and Federal Law, and your right to participate in future recalls, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could legally be determined to be lack of proper maintenance of your vehicle. Also, your vehicle may fail a state or local emission inspection if this recall is not accomplished. IMPORTANT MESSAGE FOR CALIFORNIA RESIDENTS The California Air Resources Board (CARB) requires vehicle emission recalls be completed prior to California registration renewal. Uncorrected emission recalls will result in the inability to renew your California vehicle registration. At the time of emission recall completion, your California dealer will issue a "Proof of Correction Certificate". Keep this certificate and, if required, present it to the Department of Motor Vehicles when renewing your California registration as proof of recall completion. We are sorry to cause you this inconvenience; however, we have taken this action in the interest of your continued satisfaction with our products. Jim Moloney General Director, Customer and Relationship Services 11054 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Exhaust Temperature Sensor Replacement - Position 1 Exhaust Temperature Sensor: Service and Repair Exhaust Temperature Sensor Replacement Position 1 Exhaust Temperature Sensor Replacement - Position 1 Removal Procedure Caution: The exhaust temperature sensor and exhaust pressure differential sensor line fittings may be difficult to remove when the engine exhaust system temperature is below 48°C (120°F). Excessive force may damage the threads in the exhaust manifold or exhaust pipe. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the exhaust temperature sensor electrical connector (1) from the chassis wiring harness electrical connector (2). 3. Remove the exhaust temperature sensor. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Exhaust Temperature Sensor Replacement - Position 1 > Page 4637 Note: A special anti-seize compound is used in the sensor or line fittings threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor or line fitting easier to remove. New, or service replacement sensors or line fittings already have the compound applied to the threads. If the sensor or line fittings are removed from an exhaust component and if for any reason the sensor or line fitting are reinstalled, the threads must have anti-seize compound applied before reinstallation. 1. If reinstalling the old temperature sensor or differential pressor sensor line fittings, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the exhaust temperature sensor. Tighten the sensor to 45 Nm (33 lb ft). 3. Connect the exhaust temperature sensor electrical connector (1) to the chassis wiring harness electrical connector (2). 4. Lower the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Exhaust Temperature Sensor Replacement - Position 1 > Page 4638 Exhaust Temperature Sensor: Service and Repair Exhaust Temperature Sensor Replacement Position 2 Exhaust Temperature Sensor Replacement - Position 2 Removal Procedure Caution: The exhaust temperature sensor and exhaust pressure differential sensor line fittings may be difficult to remove when the engine exhaust system temperature is below 48°C (120°F). Excessive force may damage the threads in the exhaust manifold or exhaust pipe. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the exhaust temperature sensor (3) electrical connector from the chassis wiring harness electrical connector (4). 3. Remove the exhaust temperature sensor. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Exhaust Temperature Sensor Replacement - Position 1 > Page 4639 Note: A special anti-seize compound is used in the sensor or line fittings threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor or line fitting easier to remove. New, or service replacement sensors or line fittings already have the compound applied to the threads. If the sensor or line fittings are removed from an exhaust component and if for any reason the sensor or line fitting are reinstalled, the threads must have anti-seize compound applied before reinstallation. 1. If reinstalling the old temperature sensor or differential pressor sensor line fittings, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the exhaust temperature sensor. Tighten the sensor to 45 Nm (33 lb ft). 3. Connect the exhaust temperature sensor (3) electrical connector to the chassis wiring harness electrical connector (4). 4. Lower the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Clutch Switch, ECM > Component Information > Diagrams Clutch Switch: Diagrams Component Connector End Views Clutch Pedal Position (CPP) Switch (TZ0) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps Coolant Temperature Sensor/Switch (For Computer): Customer Interest Engine - MIL ON P0116/P1400 Set In Very Cold Temps TECHNICAL Bulletin No.: 10-06-04-008A Date: January 24, 2011 Subject: Malfunction Indicator Lamp (MIL) Illuminated at Very Cold Ambient Temperatures When Using Engine Coolant Heater, DTC P0116 and/or P1400 Set (Relocate Engine Coolant Temperature (ECT) Sensor and Engine Coolant Heater Cord) Models: 2006-2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2006-2010 Cadillac Escalade 2006-2007 Chevrolet Monte Carlo 2006-2009 Chevrolet Impala SS, TrailBlazer 2006-2010 Chevrolet Avalanche, Express, Silverado Tahoe 2006-2009 GMC Envoy 2006-2010 GMC Savana, Sierra, Yukon 2006-2008 Pontiac Grand Prix 2006-2009 Saab 9-7X Equipped with V8 Engine RPO LC9, LH6, LH8, LH9, L76, LS2, LS4, LFA, LZ1, L92, L94, L9H or L20, L96, LMF, LMG, LY2, LY5, LY6 Please Refer to GMVIS Attention: To properly correct this condition, you must follow both of the procedures to relocate the ECT sensor and the engine coolant heater cord. Supercede: This bulletin is being revised to add cast iron block engine RPOs and to update the Warranty Information coverage period. Please discard Corporate Bulletin Number 10-06-04-008 (Section 06 - Engine/Propulsion System). Condition Some customers may comment that the malfunction indicator lamp (MIL) illuminates after starting the vehicle when they were using the engine coolant heater in very cold ambient temperatures. This usually occurs in a range of -23 to -40°C (-10 to -40°F) or colder. The technician may observe on a scan tool DTC P0116 and/or P1400 set as Current or in History. Cause This condition may be caused by the engine control module (ECM) determining that the ignition OFF time requirement has been met at start-up and interpreting the temperature difference between the engine coolant temperature (ECT) sensor and the intake air temperature (IAT) sensor as being outside of a calibrated range. Correction Important DO NOT replace the ECM for this condition. Relocating the ECT Sensor 1. Turn ON the ignition with the engine OFF. 2. Perform the diagnostic system check - vehicle. Refer to Diagnostic System Check - Vehicle in SI. ‹› If DTC P0116 and/or P1400 are set and the customer WAS using the engine coolant heater, proceed to Step 3. ‹› If DTC P0116 and/or P1400 are set and the customer WAS NOT using the engine coolant heater, refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. 3. Turn OFF the ignition. Warning To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 4651 under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator are still hot. 4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle. Refer to Cooling System Draining and Filling in SI. 7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor. 10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J 38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle. 13. Disconnect the wiring harness connector from the ECT sensor (2). 14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT sensor in the hole of the cylinder head where the plug was removed. Tighten Tighten to 20 Nm (15 lb ft). 18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was removed Tighten Tighten to 20 Nm (15 lb ft). Important Leave enough wire attached to the ECT sensor harness connector in order to create manageable splices that are at least 40 mm (1.5 in) away from the other splice. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 4652 20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit. Cut off the ECT sensor harness connector and wiring. 21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured TO or WITHIN an existing protective conduit. Note This step is to set up and verify the length of wiring that is required before cutting. 22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the appropriate length. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. 26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit using tie straps. Important You MUST run the engine at the specified RPM and until it reaches normal operating temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool down in order to top off the coolant level as needed. 28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI. 29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan tool to clear any DTCs. Relocating the Engine Coolant Heater Cord Important For reference, the procedure and graphics that are shown are from a Chevrolet Silverado, but are similar for the other vehicles listed above. 1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit from the engine compartment in order to determine the required extension cord length. 3. Obtain an extension cord with the following features: - 120 volt - 14/3 gauge - 15A capacity - Three prong - Polarized plug and receptacle - Chemical resistant - Grounded terminals - Designed for use in a cold outdoor environment - Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight - Maximum length of 2.5-3 m (8-10 ft) 4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N 12345579 (in Canada, use P/N 10953481) or an equivalent. 6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 4653 7. Wrap electrical tape around the connection as shown. 8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to the engine coolant crossover pipe as shown. 9. Continue to route the extension cord to the exit location desired by the customer as shown. 10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the engine coolant heater cord to the vehicle that were released to provide length. Part Information The extension cord may be obtained at any of the following outlets: - Lowes* - Home Depot* - Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number: CWRSJTOW3C14-10 USA: Cords should bear the UL symbol. Canada: Cords should bear the ULc symbol or CSA approval. *We believe these sources and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from these firms or for any such items that may be available from other sources. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 4654 Warranty Information (excluding Saab Models) For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps Coolant Temperature Sensor/Switch (For Computer): All Technical Service Bulletins Engine - MIL ON P0116/P1400 Set In Very Cold Temps TECHNICAL Bulletin No.: 10-06-04-008A Date: January 24, 2011 Subject: Malfunction Indicator Lamp (MIL) Illuminated at Very Cold Ambient Temperatures When Using Engine Coolant Heater, DTC P0116 and/or P1400 Set (Relocate Engine Coolant Temperature (ECT) Sensor and Engine Coolant Heater Cord) Models: 2006-2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2006-2010 Cadillac Escalade 2006-2007 Chevrolet Monte Carlo 2006-2009 Chevrolet Impala SS, TrailBlazer 2006-2010 Chevrolet Avalanche, Express, Silverado Tahoe 2006-2009 GMC Envoy 2006-2010 GMC Savana, Sierra, Yukon 2006-2008 Pontiac Grand Prix 2006-2009 Saab 9-7X Equipped with V8 Engine RPO LC9, LH6, LH8, LH9, L76, LS2, LS4, LFA, LZ1, L92, L94, L9H or L20, L96, LMF, LMG, LY2, LY5, LY6 Please Refer to GMVIS Attention: To properly correct this condition, you must follow both of the procedures to relocate the ECT sensor and the engine coolant heater cord. Supercede: This bulletin is being revised to add cast iron block engine RPOs and to update the Warranty Information coverage period. Please discard Corporate Bulletin Number 10-06-04-008 (Section 06 - Engine/Propulsion System). Condition Some customers may comment that the malfunction indicator lamp (MIL) illuminates after starting the vehicle when they were using the engine coolant heater in very cold ambient temperatures. This usually occurs in a range of -23 to -40°C (-10 to -40°F) or colder. The technician may observe on a scan tool DTC P0116 and/or P1400 set as Current or in History. Cause This condition may be caused by the engine control module (ECM) determining that the ignition OFF time requirement has been met at start-up and interpreting the temperature difference between the engine coolant temperature (ECT) sensor and the intake air temperature (IAT) sensor as being outside of a calibrated range. Correction Important DO NOT replace the ECM for this condition. Relocating the ECT Sensor 1. Turn ON the ignition with the engine OFF. 2. Perform the diagnostic system check - vehicle. Refer to Diagnostic System Check - Vehicle in SI. ‹› If DTC P0116 and/or P1400 are set and the customer WAS using the engine coolant heater, proceed to Step 3. ‹› If DTC P0116 and/or P1400 are set and the customer WAS NOT using the engine coolant heater, refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. 3. Turn OFF the ignition. Warning To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 4660 under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator are still hot. 4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle. Refer to Cooling System Draining and Filling in SI. 7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor. 10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J 38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle. 13. Disconnect the wiring harness connector from the ECT sensor (2). 14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT sensor in the hole of the cylinder head where the plug was removed. Tighten Tighten to 20 Nm (15 lb ft). 18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was removed Tighten Tighten to 20 Nm (15 lb ft). Important Leave enough wire attached to the ECT sensor harness connector in order to create manageable splices that are at least 40 mm (1.5 in) away from the other splice. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 4661 20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit. Cut off the ECT sensor harness connector and wiring. 21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured TO or WITHIN an existing protective conduit. Note This step is to set up and verify the length of wiring that is required before cutting. 22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the appropriate length. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. 26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit using tie straps. Important You MUST run the engine at the specified RPM and until it reaches normal operating temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool down in order to top off the coolant level as needed. 28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI. 29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan tool to clear any DTCs. Relocating the Engine Coolant Heater Cord Important For reference, the procedure and graphics that are shown are from a Chevrolet Silverado, but are similar for the other vehicles listed above. 1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit from the engine compartment in order to determine the required extension cord length. 3. Obtain an extension cord with the following features: - 120 volt - 14/3 gauge - 15A capacity - Three prong - Polarized plug and receptacle - Chemical resistant - Grounded terminals - Designed for use in a cold outdoor environment - Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight - Maximum length of 2.5-3 m (8-10 ft) 4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N 12345579 (in Canada, use P/N 10953481) or an equivalent. 6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 4662 7. Wrap electrical tape around the connection as shown. 8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to the engine coolant crossover pipe as shown. 9. Continue to route the extension cord to the exit location desired by the customer as shown. 10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the engine coolant heater cord to the vehicle that were released to provide length. Part Information The extension cord may be obtained at any of the following outlets: - Lowes* - Home Depot* - Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number: CWRSJTOW3C14-10 USA: Cords should bear the UL symbol. Canada: Cords should bear the ULc symbol or CSA approval. *We believe these sources and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from these firms or for any such items that may be available from other sources. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 4663 Warranty Information (excluding Saab Models) For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 4664 Coolant Temperature Sensor/Switch (For Computer): Diagrams Component Connector End Views Engine Coolant Temperature (ECT) Sensor (Diesel) Engine Coolant Temperature (ECT) Sensor (Gas) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 4665 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Engine Coolant Temperature Sensor Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams Crankshaft Position Sensor: Diagrams Component Connector End Views Crankshaft Position (CKP) Sensor (LU3) Crankshaft Position (CKP) Sensor (Gas except LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 4669 Crankshaft Position (CKP) Sensor (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 4670 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement Crankshaft Position Sensor Replacement Removal Procedure 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 2. Remove the right wheelhouse panel. Refer to Front Wheelhouse Liner Replacement - Right Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side)Front Wheelhouse Liner Replacement - Right Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side). 3. Disconnect the crankshaft position (CKP) sensor electrical connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 4673 4. Remove the CKP sensor bolt. 5. Remove the CKP sensor. 6. If necessary, remove the CKP sensor spacer bolts. 7. If necessary, remove the CKP sensor spacer. Installation Procedure 1. If necessary, lubricate a NEW CKP spacer O-ring with clean engine oil. 2. If necessary, install the NEW O-ring to the CKP sensor spacer. Note: The crankshaft position sensor spacers are machined with different timing positions. However, if the crankshaft position sensor spacer requires replacement, replace with a grade "C" spacer. 3. If necessary, install the CKP sensor spacer. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. If necessary, install the CKP sensor spacer bolts. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 4674 Tighten the bolts to 10 Nm (89 lb in). 5. Lubricate a NEW CKP sensor O-ring with clean engine oil. 6. Install the NEW O-ring to the CKP sensor. 7. Install the CKP sensor. 8. Install the CKP sensor bolt. Tighten the bolt to 10 Nm (89 lb in). 9. Connect the CKP sensor electrical connector. 10. Install the right wheelhouse panel. Refer to Front Wheelhouse Liner Replacement - Right Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side)Front Wheelhouse Liner Replacement - Right Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side). 11. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 4675 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Exciter Ring and Oil Pump Drive Gear Replacement Crankshaft Position Sensor Exciter Ring and Oil Pump Drive Gear Replacement Removal Procedure 1. Remove the engine front cover. Refer to Engine Front Cover Replacement (See: Engine, Cooling and Exhaust/Engine/Timing Components/Timing Cover/Service and Repair). 2. Remove the upper oil pan. Refer to Upper Oil Pan Replacement (See: Engine, Cooling and Exhaust/Engine/Engine Lubrication/Oil Pan/Service and Repair/Upper Oil Pan Replacement). Caution: Do not use an impact driver to remove or install the oil pump driven gear nut. Use of an impact driver may shear the oil pump drive gear pin in the crankshaft. 3. While holding the secondary oil pump shaft with a hex driver, remove the oil pump driven gear nut. 4. Remove the oil pump driven gear. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 4676 5. Remove the oil pump drive gear and crankshaft sensor reluctor. Do not damage the crankshaft reluctor teeth. Note: Do not remove the reluctor from the oil pump drive gear unless replacing the reluctor or the oil pump drive gear. The reluctor is timed to the gear and once removed the correct timing will be lost. 6. Remove the crankshaft reluctor to oil pump drive gear bolts. 7. Inspect the crankshaft reluctor for the damage, bent teeth, being bent or warped. 8. Inspect the oil pump drive gear for damaged or worn teeth. 9. Inspect the oil pump drive gear crankshaft pin for wear. 10. Inspect the groove of the crankshaft pin in the oil pump drive gear for wear. 11. Replace any parts that are damaged or worn. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 4677 Note: The crankshaft reluctor and the oil pump drive gear are timed at the factory. In order to re-establish proper timing, install knock pins in the oil pump drive gear if the crankshaft reluctor was removed from the oil pump drive gear. The knock pins are available through the parts department. 1. Install the knock pins in the oil pump drive gear to a height of 4.5-5.5 mm (0.177-0.217 in) 2. Install the crankshaft reluctor on the oil pump drive gear. Ensure the reluctor is aligned on the knock pins. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the crankshaft reluctor bolts and tighten to 8 Nm (71 lb in). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 4678 Note: Do not damage the teeth on the crankshaft reluctor. 4. Install the oil pump drive gear and reluctor to the crankshaft. 5. Install the oil pump driven gear. Caution: Do not use an impact driver to remove or install the oil pump driven gear nut. Use of an impact driver may shear the oil pump drive gear pin in the crankshaft. 6. While holding the secondary oil pump shaft with a hex driver, install the oil pump driven gear nut and tighten to 100 Nm (74 lb ft). 7. Install the upper oil pan. Refer to Upper Oil Pan Replacement (See: Engine, Cooling and Exhaust/Engine/Engine Lubrication/Oil Pan/Service and Repair/Upper Oil Pan Replacement). 8. Install the engine front cover. Refer to Engine Front Cover Replacement (See: Engine, Cooling and Exhaust/Engine/Timing Components/Timing Cover/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams Data Link Connector: Diagrams Component Connector End Views Data Link Connector (DLC) Data Link Resistor Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Page 4682 Data Link Resistor 2 (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Power-Up/Calibration ID Engine Control Module: Technical Service Bulletins Engine Controls - Aftermarket Power-Up/Calibration ID INFORMATION Bulletin No.: 08-06-04-006H Date: February 07, 2011 Subject: Information on Identifying Non-GM ECM Calibration Usages for Duramax(TM) Diesel Engines RPOs LBZ, LLY, LMM, LML, LGH and Power-up Hardware Detection for Duramax(TM) Diesel Engine RPO LMM - Photograph Tech 2(R) Calibration IDs and Calibration Verification Numbers (CVNs) and Transmission Data Screen Before Removing Engine/Transmission/Drivetrain Components Models: 2006-2011 Chevrolet Express, Kodiak, Silverado 2006-2011 GMC Savana, Sierra, TopKick Equipped With Duramax(TM) Diesel Engine RPOs LBZ, LLY, LMM, LML, LGH Please Refer to GMVIS Attention: In order to process an engine/transmission/drivetrain hard part WARRANTY CLAIM, you MUST photograph the required Tech 2(R) screen information BEFORE disassembly or removing engine/transmission/drivetrain components from the vehicle. Supercede: This bulletin is being revised to update the model years and RPOs. Please discard Corporate Bulletin Number 08-06-04-006G (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission, diesel oxidation catalyst (DOC) and exhaust particulate filter failures that are the result of non-GM (aftermarket Power-up Kits ) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine , transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage to the powertrain and driveline components whenever the presence of a non-GM calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of first sale, or subsequently updated by GM or its dealers with approved calibrations. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different than those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM issued engine control modifications do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines procedures to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine, transmission, transfer case or rear axle components, and before disassembly, repair or replacement of an engine, transmission, transfer case or rear axle assembly under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that the diesel oxidation catalyst (DOC) needs replacement. Note BEFORE authorizing any Duramax(TM) diesel engine or transmission replacement, the PQC will require digital photographs of the following Tech 2(R) screens: - For RPOs LLY and LBZ only: Calibration ID Numbers and Verification Numbers from the Vehicle Information screen - For RPO LMM only: Calibration ID Numbers and Verification Numbers from the Vehicle Information AND the Programming History screen. - For RPO LMM only: Transmission Data screen containing the Max Transmission Calc Engine Torque parameter. Symptoms Caused by Aftermarket Power-up Kit Some customers may have reprogrammed the engine control module (ECM) with a non-GM released calibration. The Power-Up Kit engine calibration changes fueling and timing parameters and likely contributes to the following vehicle conditions: - Poor performance - Driveability concerns - Increased emissions Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Power-Up/Calibration ID > Page 4687 - Black smoke (This symptom is not valid for the Duramax(TM) diesel engine RPO LMM equipped with the exhaust particulate filter. The filter will trap black smoke unless it is cracked, melted or has been removed from the exhaust system.) - Knocking noise - Engine damage (Refer to Corporate Bulletin Number 06-06-01-007C for additional information.) 2005-2007 RPO LLY and LBZ Instructions for Confirming Calibration Verification Numbers (CVNs) - Power-up Kit Detection Important In order to process an engine/transmission/drivetrain WARRANTY CLAIM , you MUST photograph the required Tech 2(R) screen information BEFORE disassembly or removing the engine/transmission/drivetrain components from the vehicle. 1. Go to TIS2WEB 2. Select: Calibration Information (SPS Info) 3. Enter the VIN 4. Select: Get Cal ID 5. Select: ECM Engine Control Module 6. Select: Next 7. Select: Complete History 8. Print 9. Take the printout to the vehicle along with the Tech 2(R) 10. Plug in the Tech 2(R) 11. Go to diagnostics and build the vehicle 12. Select: Powertrain 13. Select: Engine 14. *Select: Engine Control Module 15. *Select: Module ID Information or I/M Information System if Module ID Information selection is not available. 16. *If: I/M Information System was selected in step 15, it may be necessary to select: Vehicle Information in order to display the calibration information. *Steps may vary by engine controller. 17. Compare the Calibration ID and Calibration Verification Number (CVN) to the CVN shown on the TIS2WEB printout. Although the part numbers will be the same for each, it is the CVN that will determine if the calibration is GM issued. The CVNs should be the same. ‹› If the CVN information is displayed as "N/A" , it will be necessary to contact the TCSC to obtain the CVN information. ‹› If the part numbers match and ANY CVNs DO NOT match the printout, it is likely that a non-GM certified calibration has been installed. ‹› If ALL of the CVNs are EXACTLY the same the calibration is GM issued. Vehicle Information Screen 18. Take clear digital picture(s) of the Tech 2(R) Vehicle Information screen(s) showing the VIN, the Calibration IDs and the Verification Numbers. Retain the printout information and the Tech 2(R) screen photographs with the repair order. 1. E-mail copies of the digital pictures to [email protected]. In the subject line of the E-mail include the phrase "Duramax(TM) diesel", the complete VIN and Dealer BAC. In the body of the E-mail include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an email reply after the calibrations have been validated. The email reply will advise the dealer if the calibrations are OEM. 2. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 3. You may call the PQC two hours after submitting the required information for authorization to replace the assembly. This will provide them time to receive, review the information and set up a case on the request. Be prepared to provide all of the usual documentation that is normally Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Power-Up/Calibration ID > Page 4688 required when requesting an assembly authorization from the PQC. 2007-2011 RPO LMM Instructions for Confirming Calibration Verification Numbers (CVNs) Power-up Kit Detection Important In order to process an engine/transmission/drivetrain WARRANTY CLAIM , you MUST photograph the required Tech 2(R) screen information BEFORE disassembly or removing the engine/transmission/drivetrain components from the vehicle. For 2007-2011 applications, an engine control module (ECM) algorithm was implemented that records the engine calibration part number and calibration verification number (CVN) for the last 10 flash programming events. The ECM records the engine calibration part number because it contains the parameters for increasing torque and fueling rates. If a vehicle comes in for service for a driveability/powertrain concern as a result of a Power-Up Kit installation, the dealership technician can read the last 10 engine calibration part numbers and CVN history using a Tech 2(R). The dealership technician will input each ECM calibration part number into the TIS2WEB/SPS CVN database to confirm the CVN history information. Refer to the following Tech 2(R) path table to verify the ECM calibrations. 1. Build the vehicle with the Tech 2(R). 2. Select F0: Engine Control Module. 3. Select F5: Module Identification Information. 4. Select F1: Programming History. 5. Turn On the ignition, with the engine Off. 6. Press the ENTER Key to Continue. Important An original production engine operation part number programmed in the ECM from the supplier, which is the last part number shown, would not be in the TIS2WEB/SPS database. 7. Record the Calibration ID Numbers and Calibration Verification Numbers from the Tech 2(R) Programming History Screen. If the list of Calibration Part Numbers is less than 10, the first Calibration ID Number (bottom of the list) will not be in TIS2WEB/SPS CVN database. In this case, the first Calibration ID Number is programmed at the ECM production factory and is reprogrammed at the vehicle assembly plant. 8. From TIS2WEB/SPS, record the Calibration Part Number into the CVN Database. Get the CVN. ‹› If the CVN DOES NOT MATCH the CVN database, an unauthorized engine calibration part WAS PROGRAMMED into the ECM. ‹› If the CVN MATCHES the CVN database, the calibration/s are GM issued and an unauthorized engine calibration part WAS NOT used. Programming History Screen 9. Take a clear digital picture of the Tech 2(R) Programming History screen showing the VIN, Calibration IDs and the CVNs. Retain the printout information and the Tech 2(R) screen photograph with the repair order. Vehicle Information Screen 1. Take a clear digital picture of the Tech 2(R) Vehicle Information screen. Retain the printout information and the Tech 2(R) screen photograph with the repair order. 2. Take a clear digital picture of the Transmission Data screen that contains the Max Transmission Calc Engine Torque parameter. The path table is outlined in the following Instructions for Tech 2 Transmission Data Path section. Retain the Tech 2(R) Transmission Data screen photograph with the repair order. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Power-Up/Calibration ID > Page 4689 3. E-mail copies of the digital pictures to [email protected]. In the subject line of the E-mail include the phrase "Duramax(TM) diesel", the complete VIN and Dealer BAC. In the body of the E-mail include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an email reply after the calibrations have been validated. The email reply will advise the dealer if the calibrations are OEM. 4. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 5. You may call the PQC two hours after submitting the required information for authorization to replace the assembly. This will provide them time to receive, review the information and set up a case on the request. Be prepared to provide all of the usual documentation that is normally required when requesting an assembly authorization from the PQC. 2007-2011 RPO LMM Instructions for Tech 2 Transmission Data Path - Power-up Hardware Detection Transmission Data ONLY Available With GMC Sierra, TopKick, Chevrolet Kodiak, Silverado An example of this hardware is a propane injection system. A transmission control module (TCM) algorithm has been implemented that records a maximum calculated input torque. This information is available via the Tech 2(R). 1. Build the vehicle with the Tech 2(R). 2. Select F3: Transmission Control Module 3. Select F1: Data Display 4. Select F0: Transmission Data 5. Highlight: Max Transmission Calc Engine Torque Transmission Data Screen (Max. Trans Calc. Engine Torque Parameter) 6. Take a clear digital picture of the Tech 2(R) screen showing the Transmission Data and the Max Transmission Calc Engine Torque parameter. 7. Retain the Tech 2(R) Transmission Data screen photograph with the repair order. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Power-Up/Calibration ID > Page 4690 Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Power-Up/Calibration ID > Page 4691 Engine Control Module: Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Power-Up/Calibration ID > Page 4692 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Power-Up/Calibration ID > Page 4693 Engine Control Module: Technical Service Bulletins Diesel Engine - Damage Due To Power-Up Devices INFORMATION Bulletin No.: 06-06-01-007F Date: March 31, 2010 Subject: Information On Identifying Duramax(TM) Diesel LB7, LLY, LMM, LBZ Overpower Engine Breakdown or Non-Function Due to Aftermarket Power-Up Devices vs. Non Overpower Engine Non-Function of Pistons, Cylinders, Valvetrain Components and/or Turbocharger DTC P003A Set Models: 2001-2010 Chevrolet Silverado 2003-2009 Chevrolet Kodiak 2006-2010 Chevrolet Express 2001-2010 GMC Sierra 2003-2009 GMC TopKick 2006-2010 GMC Savana Equipped With Duramax(TM) Turbocharged Diesel Engine RPOs LB7, LLY, LMM, LBZ Please Refer to GMVIS Supercede: This bulletin is being revised to add text to the end of the Caution statement. Please discard Corporate Bulletin Number 06-06-01-007E (Section 06 - Engine/Propulsion System). Caution Customers should be informed if a hard part failure is observed in the engine, transmission, transfer case and/or other driveline components, it is likely that powertrain components were weakened to the point of premature failure, while subjected to the higher stresses from Aftermarket Power-Up Devices. Failures associated with the installation of Aftermarket Power-Up Devices, which have been verified, are not covered under the terms of the New Vehicle Warranty. In the majority of these cases, the Fixed Operations Manager (FOM) (in Canada, Warranty Manager) should be contacted and the remaining portion of the powertrain portion of the New Vehicle Warranty blocked. GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage. General Motors Position On Aftermarket Power-Up Devices Important General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. Refer to Service Bulletin Number 04-06-04-054A or newer - Warranty Admin. - Non-GM Parts and Accessories (Aftermarket). Important For further information on aftermarket power-up kits, refer to February 2006 Emerging Issues Course Number 10206.02D. In Canada, information on aftermarket power-up kits was covered in the April 2006 TAC TALK program. Aftermarket power-up devices are non-approved by General Motors. These devices are usually piggy-backed in the main engine harness or remain connected to the diagnostic connector to upload the calibration to the ECM. Recent warranty reviews of returned engines show engine breakdown or non-function due to power-up devices that are utilized for increased horsepower and torque. The following information will assist technicians in identifying overpower engine breakdown or non-function due to aftermarket power-up devices vs. non overpower engine breakdown or non-function. Non-GM parts can alter the design of the vehicle. GM dealers need to be aware of the quality of parts being installed on vehicles. If failure occurs as a result of installation of sub-par parts, warranty coverage may be denied. Refer to Service Bulletin Number 04-06-04-054A or newer Warranty Admin. - Non-GM Parts and Accessories (Aftermarket). Installed Power-Up Kit Aftermarket power-up kits have become a very popular add on for performance-minded customers. These devices can add horsepower and torque and can add additional stress to the engine. These aftermarket calibrations take the Duramax(TM) powertrain outside of its design torque and horsepower rating. They do this by altering air/fuel ratios and injector timing, resulting in excessive cylinder pressure and temperature. When these calibrated parameters are altered, it will upset the design balance and can lead to a reduction of engine life expectancy. Generally, in inspection of Duramax(TM) engine failure due to power-up failures, two or more cylinders will be affected. Installed Power-Up Kit - Once installed, the calibration may mask itself with the factory original calibration ID and may remain the same. Refer to Service Bulletin Number 08-06-04-006F or newer - Information on Identifying Non-GM Calibration Usage for LMM Duramax(TM) Diesel Engine. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Power-Up/Calibration ID > Page 4694 - A Tech 2(R) will not positively enable you to identify the use of a power-up device. - Some companies that offer power-up devices claim increases of 150 or more horsepower and 300 or more lb/ft pounds of torque. - A vehicle that is used to the power-up device potential 100% of the time will see earlier engine wear and breakdown. - A vehicle that takes advantage of additional power, but on a less frequent basis, may not see premature engine wear and breakdown until later in the engine's life. - A vehicle not pushed to its limits of the power-up device often may not encounter premature wear and breakdown until after the engine is out of warranty. Duramax(TM) Powertrain Horsepower / Torque Ratings The following horsepower and torque increase over the past years required new internal components to accommodate the increase. - LB7 - 300 hp with 520 ft/lb of torque for model years 2000-2004 - LLY - 310 hp with 605 ft/lb of torque for model years 2004-2008 - LBZ - 360 hp with 650 ft/lb of torque for model year 2006-2008 - LMM - 365 hp with 660 ft/lb of torque for model year 2007-2009 LBZ Improvements To reliably achieve an increase in 50 horsepower with 45 ft/lb torque, the Duramax (TM) diesel had to be revised in many areas. A few of the revisions on the 2006 LBZ were: - New pistons with a revised compression ratio. - Wrist pins that are larger in diameter. - Connecting rods with added material to increase the I section strength. - Engine block and machining changes - Cylinder heads Duramax(TM) Life Expectancy The Duramax(TM) 6.6L V8 Turbo Diesel Engine is sold with a warranty of 100,000 miles/160,000 kilometers. The Duramax(TM) has been tested to survive upwards of 200,000 miles/320,000 kilometers. The Duramax(TM) powertrain is designed for reliability, peak horsepower and torque within its design limits. When a customer installs a power-up device, it drastically reduces the mileage ratings. Important Cylinder Wall Spotting (commonly referred to leopard spots) is from the induction hardening process of the top 1/3 of the cylinder wall. This is normal for the Duramax (TM) Diesel. Identifying Fuel Related Aftermarket Power-Up Devices Aftermarket companies have developed a performance pressure relief fuel valve for Duramax(TM) diesel engines. Refer to above graphic illustration. The performance pressure relief fuel valve attaches to the fuel rail in place of the OEM valve and will not allow any fuel return to the tank, giving 100% of the fuel to be available for additional engine performance. This may cause additional fuel related driveability concerns and may set the following DTCs: - DTC P1093 Fuel Rail Pressure (FRP) Low During Power Enrichment - DTC P0087 Fuel Rail Pressure (FRP) Too Low Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Power-Up/Calibration ID > Page 4695 Aftermarket companies have developed a replacement performance/economy fuel injector nozzle. Refer to above illustration. The performance/economy fuel injector nozzles replace the OEM fuel injector nozzles. The aftermarket companies claim increased horsepower, improved fuel atomization, lower exhaust gas temperatures and increase fuel economy. This may cause additional fuel related driveability concerns and may cause internal engine damage to the pistons and fuel injector nozzles. Identifying Overpower Engine Premature Wear and Breakdown When premature wear and breakdown is encountered due to an aftermarket power-up device, it has some very specific characteristics to the internal engine components. The following list will assist in identifying these characteristics as you tear down the engine. - Pistons will be cracked in the lip area, or a hole in the pistons. - Pistons can also be melted on the lip of the combustion bowl, or the top of the pistons can be melted. - Crosshatch will be polished off the cylinder wall in the major thrust face of cylinder below ring belt travel. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Power-Up/Calibration ID > Page 4696 - Piston pin bore will show signs of scoring, the wrist pins will be discolored, and can have oil coking on them. The connecting rod bushing surface will have accelerated wear. The above illustration shows a connecting rod bushing. - Oil coking on the underside of the piston between the wrist pin bosses. - Signs of bearing fretting will also be noticed on the connecting rod and main bearing caps. Refer to the above illustration for fretting of main bearing cap 1 and back side of connection rod bearing 2. - Excessive heat in engine compartment caused by overpower device. Refer to above illustration (1). Non Overpower Engine Premature Wear and Breakdown The following pictures show results of overheat, overspeed, low/no oil pressure or injector breakdown and how they differ from aftermarket power-up device premature wear and breakdown. Engine Overheat Overheat can be caused by a loss of coolant or a general cooling system failure. Some of the indicators of overheat are: Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Power-Up/Calibration ID > Page 4697 - Melted pistons. - Head gasket breakdown or non-function. - Warped cylinder heads. - Crankshaft and connecting rod discolored. Engine Overspeed Causes If an engine has been run faster than design capability (redline), and has caused damage as a result, it may be a result of one of the following conditions: - Leaking or failed turbocharger (TC) oil seals. - Oil evident in the intake runners and compressor side of the TC. - Starting fluid use or alternative fuel added to the engine such as ether. Engine Overspeed Results The following are indicators that an overspeed event took place: - Valve train damage. - Pushrods that are bent (4). - Broken valve bridge buttons after cylinder head removal (2). - Rocker arm tip damage (1). - Dry or rusted cylinders from the use of ether, propane or nitrous oxide. - Piston to valve contact. - Cam gear pin shear. Lack of Oil Pressure Lack of lubrication causes rapid bearing wear or bearing to seize. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Power-Up/Calibration ID > Page 4698 Bearing failure. Spun main bearings. Engine Premature Wear and Breakdown Due to Improper Function of Fuel Injector A fuel injector may fracture a piston or melt a piston but the damage will be limited to that cylinder only and all other pistons and cylinder walls are OK. In some cases hydraulic lock will occur on the suspected cylinder with an over-fueling fuel injector. Hydraulic lock on the suspected cylinder will cause a bent connecting rod. This can be verified with piston protrusion measurements. 2007-2010 RPO LMM Only Turbocharger DTC P003A Set General Motors has identified a turbocharger (TC) failure mode involving Power-Up Kits that causes soot leakage and DTC P003A to be set. The Power-Up Kits create an overtemperature condition from the increased exhaust gas temperatures that results in a permanent and excessive turbine housing distortion at the TC case halves. 1. A technician may observe one or more of the following conditions: - DTC P003A being set as Current or in History. - An unusual odor emanating from the TC due to an overtemperature condition. - Soot leaking and accumulating at the V-band clamp that secures the TC case halves together. - Limited or unresponsive travel when Commanding the TC Vane Pos. Ctrl. Solenoid ON and OFF with a scan tool. 2. If DTC P003A is found as Current or in History, OR there is evidence of soot leakage (1) in the area of the V-band clamp (1), then technicians MUST verify if the engine control module (ECM) has a Power-Up Kit aftermarket calibration installed or an aftermarket hardware device has been installed. Refer to Service Bulletin Number 08-06-04-006F or newer for the calibration verification information and procedures. How to Handle a Suspect Engine Failure Due to a Power-Up Device Dealers should not automatically decline warranty assistance on engine failures due to the fact that a power-up device or modification is evident or suspected. The technician must identify that the failure is due to a power-up device by teardown analysis and diagnosis of the engine components. The following steps should be taken if an engine failure occurs and it is suspected that the modification or addition of a power-up device maybe the cause of the engine failure. If unclear of this process or direction feel free to contact your Fixed Operations Manager (in Canada, Warranty Manager) for further support. 1. The technician should use proper engine diagnostics to lead him/her to the failed engine components. The Aftermarket Power-Up Kit Check List should be followed and if it is determined that at least three of the Aftermarket Power-Up Kit Check List items match the engine component failures then it can be decided that the failure is not a warrantable claim. 2. Engine failures that meet at least three criteria of the Aftermarket Power-Up Kit Check List are considered failures that are not manufacturer's defects in workmanship or materials. 3. The dealership should contact the PQC, open a case to review the findings and make the final decision on warranty coverage. The Fixed Operations Manager (in Canada, Warranty Manager) should be notified of the PQC decision. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Power-Up/Calibration ID > Page 4699 4. Denied claims should be documented as follows: 1. The Aftermarket Power-Up Kit Check List completed with the technicians detailed written findings of the diagnosis on the repair order and retained in the repair order file. 2. Photographs of the failed parts should be retained in the repair order file. 5. The customer should be advised that the failure of their engine was not due to a manufacturer's defect in workmanship or materials and therefore the warranty claim is denied on this failure. Aftermarket Power-Up Kit Check List Important Print and use this aftermarket power-up kit check list when performing an engine disassembly investigation of overpower engine breakdown or non-function. Retain a copy of this checklist and photographs of the failed parts in the repair order file. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4700 Engine Control Module: Locations Harness Routing Views Engine Harness Routing - Left Front Side (4.8L/5.3L/6.0L/6.2L except LFA/HP2) 1 - Air Intake Duct 2 - X111 3 - Fuse Block - Underhood X2 4 - X109 5 - X110 (NQF/NQG/NQH) 6 Engine Control Module (ECM) X2 7 - Engine Control Module (ECM) X1 8 - G102 9 - J105 Engine Chassis Harness Routing - Top Front (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4701 1 - Battery - Right 2 - Fuse Holder 3 - X127 4 - X108 5 - X107 6 - X123 (PTO) 7 - Fuse Block Underhood 8 - X109 9 - Battery - Left 10 - Engine Control Module (ECM) 11 - Transmission Control Module (TCM) Engine Harness Routing - Top (4.3L) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4702 1 - Mega Fuse Ring Terminal 2 - X175 (M30) 3 - J128 4 - J105 5 - J106 6 - J130 (M30 with NQG/NQH) 7 - Engine Control Module (ECM) X1 8 - Engine Control Module (ECM) X2 9 - G103 10 - X112 11 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Connector Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4703 Engine Control Module: Diagrams Component Connector End Views Engine Control Module (ECM) X1 (LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4704 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4705 Engine Control Module (ECM) X1 (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4706 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4707 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4708 Engine Control Module (ECM) X1 (LY2, LMG, LC9, LY5, LH6, L76 or L9H) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4709 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4710 Engine Control Module (ECM) X1 (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4711 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4712 Engine Control Module (ECM) X1 (LY6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4713 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4714 Engine Control Module (ECM) X2 (LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4715 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4716 Engine Control Module (ECM) X2 (LY2, LY6 or L9H with Y91) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4717 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4718 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4719 Engine Control Module (ECM) X2 (LMG, LC9, LY5, LH6, L76 or L9H without Y91) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4720 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4721 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4722 Engine Control Module (ECM) X2 (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4723 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4724 Engine Control Module (ECM) X2 (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4725 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4726 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4727 Engine Control Module (ECM) X3 (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4728 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4729 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Engine Control Module Description Engine Control Module: Description and Operation Engine Control Module Description Engine Control Module Description The powertrain has electronic controls to reduce exhaust emissions while maintaining excellent driveability and fuel economy. The engine control module (ECM) is the control center of this system. The ECM monitors numerous engine and vehicle functions. The ECM constantly monitors information from various sensors and other inputs, and controls the systems that affect vehicle performance and emissions. The ECM also performs diagnostic tests on various parts of the system. The ECM can recognize operational problems and alert the driver via the malfunction indicator lamp (MIL). When the ECM detects a malfunction, the ECM stores a diagnostic trouble code (DTC). The problem area is identified by the particular DTC that is set. The control module supplies a buffered voltage to various sensors and switches. Review the components and wiring diagrams in order to determine which systems are controlled by the ECM. Malfunction Indicator Lamp (MIL) Operation The malfunction indicator lamp (MIL) is located in the instrument panel cluster. The MIL will display as either SERVICE ENGINE SOON or one of the following symbols when commanded ON: The MIL indicates that an emissions related fault has occurred and vehicle service is required. The following is a list of the modes of operation for the MIL: * The MIL illuminates when the ignition is turned ON, with the engine OFF. This is a bulb test to ensure the MIL is able to illuminate. * The MIL turns OFF after the engine is started if a diagnostic fault is not present. * The MIL remains illuminated after the engine is started if the control module detects a fault. A diagnostic trouble code (DTC) is stored any time the control module illuminates the MIL due to an emissions related fault. The MIL turns OFF after three consecutive ignition cycles in which a Test Passed has been reported for the diagnostic test that originally caused the MIL to illuminate. * The MIL flashes if the control module detects a misfire condition which could damage the catalytic converter. * When the MIL is illuminated and the engine stalls, the MIL will remain illuminated as long as the ignition is ON. * When the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition is cycled OFF and then ON. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Engine Control Module Description > Page 4732 Engine Control Module: Description and Operation Engine Idle Control System Description Engine Idle Control System Description High Idle Switch The high idle switch will slowly increase engine RPM to the calibrated high idle speed when depressed. The high idle speed can be programmed by using a scan tool. Refer to High Idle Switch Programming (See: Fuel Delivery and Air Induction/Idle Speed/Service and Repair). If the High Idle Switch is not operating as desired, refer to High Idle Switch Diagnosis (See: Testing and Inspection/Component Tests and General Diagnostics/High Idle Switch Diagnosis). Manual High Idle The diesel engine has a high idle system to improve the warm-up time of the engine in cold weather conditions. This system allows the engine control module (ECM) to increase the idle speed above the normal calibrated value. The ECM increases the idle speed using the following adjustments: * The fuel injection timing is changed * The fuel injection quantity is changed * The turbocharger vane position is commanded closed-The vane position will be farther closed than any other normal operating condition. The instrument panel will indicate the high idle system is active one of two ways: * The driver information center (DIC) will indicate an active high idle system on light duty trucks. * An indicator lamp will flash on medium duty trucks. * The manual high idle feature comes enabled from the factory. The Elevated Idle function in the scan tool will disable or enable this feature. If the engine does not increase to the calibrated high idle speed after the procedure is performed, use the scan tool to verify the Elevated Idle speed feature is enabled. Manual High Idle Speed Enable and Disable To enable or disable the manual high idle system perform the following procedure: 1. Turn the ignition ON, with the engine OFF. 2. Depress the accelerator pedal to the floor and hold down. 3. While the accelerator pedal is depressed, depress the brake pedal 3 times in less than 8 seconds. 4. Release the accelerator pedal. 5. Start the engine. When the procedure is followed the engine idle speed will slowly increased to the calibrated high idle speed. This is 1,200 RPM for light duty, and 1,500 RPM for medium duty trucks. The idle speed will return to normal if any of the following conditions occur: * There is brake, clutch, or throttle input from the driver. * The automatic transmission is shifted out of Park or Neutral. * The air temperature is more than 7°C (45°F). * The engine coolant temperature (ECT) is more than 68°C (154°F). * The vehicle speed exceeds 0 km/h (0 mph). The high idle system will reactivate automatically when the following conditions occur: * The engine has been idling for more than 30 seconds. * The transmission is placed in Park or Neutral. * The vehicle speed is 0 km/h (0 mph). * The ambient air temperature is less than 3°C (37°F). * The ECT is less than 68°C (154°F). * The brake, clutch and throttle pedals are not depressed. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 4733 Engine Control Module: Service and Repair Engine Control Module Replacement Caution: * Turn the ignition OFF when installing or removing the control module connectors and disconnecting or reconnecting the power to the control module (battery cable, powertrain control module (PCM)/engine control module (ECM)/transaxle control module (TCM) pigtail, control module fuse, jumper cables, etc.) in order to prevent internal control module damage. * Control module damage may result when the metal case contacts battery voltage. DO NOT contact the control module metal case with battery voltage when servicing a control module, using battery booster cables, or when charging the vehicle battery. * In order to prevent any possible electrostatic discharge damage to the control module, do no touch the connector pins or the soldered components on the circuit board. * Remove any debris from around the control module connector surfaces before servicing the control module. Inspect the control module connector gaskets when diagnosing or replacing the control module. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant intrusion into the control module. * The replacement control module must be programmed. Note: Before removing the engine control module (ECM), use the scan tool to capture the ECM data. This captured data will then need to be restored into the NEW ECM. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning). Removal Procedure 1. Using a scan tool, capture the ECM data. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 3. Disconnect the ECM electrical connectors (2). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 4734 4. Release the ECM upper retaining tabs. 5. Remove the ECM from the bracket. Installation Procedure 1. Place the bottom edge of the ECM into the bracket lower retainers. 2. Push the ECM towards the bracket until the upper edge of the ECM snaps into place. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 4735 3. Connect the ECM electrical connectors (2). 4. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 5. If a NEW ECM was installed, program the ECM. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Diagrams Fuel Level Sensor: Diagrams Component Connector End Views Fuel Level Sensor - Primary (Diesel) Fuel Level Sensor - Secondary (Diesel with 31 Series without NQZ) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Diagrams > Page 4739 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor (Cab/Chassis - Rear Tank) Fuel Level Sensor: Service and Repair Fuel Level Sensor (Cab/Chassis - Rear Tank) Fuel Level Sensor Replacement (Cab/Chassis - Rear Tank) Removal Procedure 1. Remove the sending unit. Refer to Fuel Sender Assembly Replacement (See: Fuel Delivery and Air Induction/Fuel Tank/Fuel Gauge Sender/Service and Repair). 2. Disconnect the fuel level sensor electrical connector (1). 3. Remove the sensor retaining clip (3). 4. Squeeze the locking tangs (2) and remove the fuel level sensor. Installation Procedure 1. Install the fuel level sensor. 2. Install the sensor retaining clip (3). 3. Connect the sensor electrical connector (1). 4. Install the sending unit. Refer to Fuel Sender Assembly Replacement (See: Fuel Delivery and Air Induction/Fuel Tank/Fuel Gauge Sender/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor (Cab/Chassis - Rear Tank) > Page 4742 Fuel Level Sensor: Service and Repair Fuel Level Sensor Replacement (35 Reg/Ext/Crew Cab With 34 gal Tank) Fuel Level Sensor Replacement (35 Reg/Ext/Crew Cab With 34 gal Tank) Removal Procedure 1. Remove the fuel tank module. Refer to Fuel Tank Fuel Pump Module Replacement (25 Ext/Crew Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15/25 Reg/Ext/Crw Cab With 34 Gal Tnk) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Ext/Crew Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Reg Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (35 Reg/Ext/Crew Cab With 34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair). 2. Disconnect the fuel level sensor wiring pigtail electrical connector (1) from the module cover. 3. Remove the fuel level sensor wiring pigtail from under the module clip (2). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor (Cab/Chassis - Rear Tank) > Page 4743 4. Gently push in the fuel level sensor retainers (1), disengaging them from the module reservoir. 5. Slide the fuel level sensor up, in order to remove the sensor from the module slot. Installation Procedure 1. Position the fuel level sensor over the slot in the reservoir and slide the sensor down into the slot. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor (Cab/Chassis - Rear Tank) > Page 4744 2. Ensure that the fuel level sensor retainers (1) engage the module reservoir. 3. Install the fuel level sensor wiring pigtail under the module clip (2) behind the fuel pump wires. 4. Connect the fuel level sensor wiring pigtail electrical connector (1) to the module cover. 5. Install the fuel tank module. Refer to Fuel Tank Fuel Pump Module Replacement (25 Ext/Crew Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15/25 Reg/Ext/Crw Cab With 34 Gal Tnk) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Ext/Crew Cab With 26 Gal Tank) ( See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Reg Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (35 Reg/Ext/Crew Cab With 34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor (Cab/Chassis - Rear Tank) > Page 4745 Fuel Level Sensor: Service and Repair Fuel Sender Assembly Replacement Fuel Sender Assembly Replacement Special Tools J 45722 Fuel Sender Lock Ring Wrench Removal Procedure 1. Remove the fuel tank. Refer to Fuel Tank Replacement (Pickup) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (Cab/Chassis - Front) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (Cab/Chassis - Rear) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement). 2. Disconnect the fuel lines from the sending unit. Refer to Metal Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Metal Collar Quick Connect Fitting Service) or Plastic Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). Caution: Avoid damaging the lock ring. Use only J-45722 to prevent damage to the lock ring. Caution: Do Not handle the fuel sender assembly by the fuel pipes. The amount of leverage generated by handling the fuel pipes could damage the joints. Note: Do NOT use impact tools. Significant force will be required to release the lock ring. The use of a hammer and screwdriver is not recommended. Secure the fuel tank in order to prevent fuel tank rotation. 3. Use the J 45722 and a long breaker-bar in order to unlock the fuel sender lock ring. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor (Cab/Chassis - Rear Tank) > Page 4746 4. Remove the sending unit and seal. Discard the seal. 5. Clean the sending unit sealing surfaces. Note: Some lock rings were manufactured with "DO NOT REUSE" stamped into them. These lock rings may be reused if they are not damaged or warped. Note: Inspect the lock ring for damage due to improper removal or installation procedures. If damage is found, install a NEW lock ring. Note: Check the lock ring for flatness. 6. Place the lock ring on a flat surface. Measure the clearance between the lock ring and the flat surface using a feeler gauge at 7 points. 7. If warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement. 8. If warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor (Cab/Chassis - Rear Tank) > Page 4747 1. Install the sending unit and a NEW seal. Note: Always replace the fuel sender seal when installing the fuel sender assembly. Replace the lock ring if necessary. DO NOT apply any type of lubrication in the seal groove. Ensure the lock ring is installed with the correct side facing upward. A correctly installed lock ring will only turn in a clockwise direction. 2. Use the J 45722 in order to install the fuel sender lock ring. Turn the fuel sender lock ring in a clockwise direction. 3. Connect the fuel lines to the sending unit. Refer to Metal Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Metal Collar Quick Connect Fitting Service) or Plastic Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). 4. Install the fuel tank. Refer to Fuel Tank Replacement (Pickup) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (Cab/Chassis - Front) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (Cab/Chassis - Rear) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Diagrams Fuel Tank Pressure Sensor: Diagrams Component Connector End Views Fuel Tank Pressure (FTP) Sensor (Gas) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Diagrams > Page 4751 Fuel Tank Pressure Sensor: Service and Repair Fuel Tank Pressure Sensor Replacement (35 Reg/Ext/Crew Cab With 34 Gal Tank) Removal Procedure 1. Remove the fuel tank. Refer to Fuel Tank Replacement (35 Reg/Ext/Crew Cab With 34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15 Ext/Crew Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15/25 Reg/Ext/Crw Cab With 34 Gal Tnk) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15 Rec Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (25 Ext/Crew Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement). 2. Remove the fuel tank pressure sensor by pulling straight up using a slight rocking motion. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Diagrams > Page 4752 1. Install the fuel tank pressure sensor. 2. Install the fuel tank pressure sensor cover. 3. Install the fuel tank. Refer to Fuel Tank Replacement (35 Reg/Ext/Crew Cab With 34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15 Ext/Crew Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15/25 Reg/Ext/Crw Cab With 34 Gal Tnk) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15 Rec Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (25 Ext/Crew Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > High Idle Switch > Component Information > Testing and Inspection High Idle Switch: Testing and Inspection High Idle Switch Diagnosis Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions )provide an overview of each diagnostic category. Diagnostic Fault Information Reference Information Schematic Reference Engine Controls Schematics (See: Diagrams/Electrical Diagrams) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning)for scan tool information Circuit/System Verification Ignition ON, observe the scan tool High Idle switch parameter while exercising the switch. The reading should change between ON/OFF. Circuit/System Testing 1. Ignition OFF, disconnect the harness connector at the high idle switch. 2. Test for less than 5 ohms between the ground circuit terminal A and ground. ‹› If greater than 5 ohms, test the ground circuit for an open/high resistance. 3. Ignition ON, verify the scan tool High Idle switch parameter is OFF. ‹› If not OFF, test the signal circuit for a short to ground. If the circuit tests normal, replace the ECM. 4. Install a 3A fused jumper wire between the signal circuit terminal C and ground. Verify the scan tool High Idle switch parameter is ON. ‹› If not ON, test the signal circuit for a short to voltage or an open/high resistance. If the circuit tests normal, replace the ECM. 5. If all circuits test normal, test or replace the high idle switch. Component Testing Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > High Idle Switch > Component Information > Testing and Inspection > Page 4756 1. Ignition OFF, disconnect the harness connector at the high idle switch. 2. Test for infinite resistance between the signal terminal C and the ground circuit terminal A with the switch in the open position. ‹› If less than infinite resistance, replace the high idle switch. 3. Test for less than 1 ohm between the signal terminal C and the ground terminal A with the switch in the closed position. ‹› If greater than 1 ohm, replace the high idle switch. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Specifications Information Bus: Specifications Fastener Tightening Specifications Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions Information Bus: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Schematic Symbols Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4762 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4763 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4764 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4765 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4766 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4767 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4768 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4769 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4770 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4771 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4772 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4773 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4774 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4775 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4776 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4777 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4778 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4779 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4780 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4781 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4782 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4783 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4784 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4785 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4786 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4787 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4788 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4789 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4790 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4791 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4792 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4793 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4794 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4795 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4796 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Information and Instructions > Page 4800 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4801 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4802 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4803 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4804 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4805 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4806 Information Bus: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed with Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4807 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4808 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Connector Test Adapters) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4809 Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Test Lamp) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Fused Jumper Wires) * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage Drop) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Frequency) * Testing Ground and Low Reference Circuits (See: Testing and Inspection/Component Tests and General Diagnostics/Testing Ground and Low Reference Circuits) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fuses) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Circuit Breakers) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fusible Links) Troubleshooting with a Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Testing for a Short to Voltage Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4810 Testing for a Short to Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure tests for a short to voltage in a circuit. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the Digital Multimeter (DMM) to the V (DC) position. 4. Connect the positive lead of the DMM to one end of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. Turn ON the ignition and operate all accessories. 7. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Special Tools J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure). Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents). Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4811 The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the frequency of a signal. Note: Connecting the Digital Multimeter (DMM) to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Set to Hz on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4812 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the Digital Multimeter (DMM). 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the difference in voltage potential between 2 points. 1. Set the Digital Multimeter (DMM) to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4813 Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Backprobe Note: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4814 (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for Continuity Testing for Continuity Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures verify good continuity in a circuit. With a Digital Multimeter (DMM) 1. Set the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Select the MIN MAX function on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4815 Testing for Electrical Intermittents Testing for Electrical Intermittents Special Tools J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. Note: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions). 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4816 visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing for Terminal Fretting Some intermittent conditions can be caused by wire terminal fretting corrosion. Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can pile up enough at the electrical contact spots that the electrical resistance across the connection increases. Movement between the contacting surfaces as small as 10 to 100 microns can cause fretting. To put this in perspective, a sheet of paper is about 100 microns thick, so fretting motion is small and hard to see. Vibration and thermal expansion/contraction are the main sources that create fretting motion. Since vehicles vibrate and can experience large temperature swings, they are a good source for fretting motion. Tin, copper, nickel, and iron surfaces are all susceptible to fretting corrosion. Fretting corrosion can be difficult to see but it looks like small, dark smudges on the terminals contact surface. To correct a fretting condition disconnect the suspect connector and add Nyogel lubricant 760G (dielectric grease) to both sides of the connector terminals. Then reconnect the connector and wipe away any excess lubricant. This will correct the additional terminal contact resistance due to the terminal fretting corrosion. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4817 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics). * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Ground Distribution Schematics). Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Checking Aftermarket Accessories). * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4818 Note: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures test for a short to ground in a circuit. With a Digital Multimeter (DMM) 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohms position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Danger: High voltage circuits should only be tested using a digital multimeter (DMM) and test leads with at least a CAT III rating, such as the J 39200-A Digital Multimeter. Failure to follow the procedures exactly as written may result in serious injury or death. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Digital Multimeter (DMM) Basic Requirements Service information is validated using digital multimeters that meet or exceed the following requirements. Using a multimeter that does not meet these basic requirements may give inaccurate readings which could lead to an incorrect diagnosis. Display and Settings 1. Four digits displayed 2. Voltage, amperage, resistance, frequency, diode test settings, and min-max function 3. Display positive and negative values Voltage 1. Have at least 10 M ohm input impedance Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4819 2. Test a DC voltage range of 0.1-1000 V. 3. Test an AC voltage range of 0.1-1000 V. Amperage 1. Test a DC amperage range of 0.1µA-10 A. 2. Test an AC amperage range of 0.1µA-10 A. Resistance Test a resistance range of 0.1 ohm-40 Mohm and displays infinite for a value greater than 40 M ohm (O.L. (Over-load)) Frequency Test for a frequency range of 0.5 HZ-199 K HZ Diode Test 1. Apply at least 1 mA when performing the diode bias test 2. Display the break over voltage drop (0-3 V) of a forward biased diode 3. Display infinite (O.L. (Over-load)) when a diode is reverse biased Min-Max Readings 1. Can update at a 1 ms sample rate 2. Saves and displays minimum and maximum values Note: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Probe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors). * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the EL-38125-580 GM Approved Terminal Release Tool Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the EL-38125-580 GM Approved Terminal Release Tool Kit , ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the EL-38125-580 GM Approved Terminal Release Tool Kit label on the inside of the EL-38125-580 GM Approved Terminal Release Tool Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4820 Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/EPC Connectors AFL/EPC Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4821 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 3. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4822 View showing depressing of the lever lock release tab. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4823 6. Release the rear lower half of the wiredress cover. 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4824 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4825 Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Bosch Connectors (ECM) Bosch Connectors (ECM) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4826 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. 2. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4827 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-bladed tool to release the locking tabs and remove the dress cover. 4. The terminal positive assurance (TPA) is located in the front of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4828 5. Use a small flat-blade tool to remove TPA from the connector. 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4829 Note: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4830 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4831 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Terminal Replacement Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4832 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4833 5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Position Assurance Locks) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Terminal Position Assurance Locks) * AFL/EPC Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/AFL/EPC Connectors) * Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (BSK))Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (0.64))Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (2.8 JPT))Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (ECM)) * Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Weather Pack))Delphi Connectors (Push To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Push to Seat))Delphi Connectors Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4834 (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Pull to Seat))Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro-Pack 100W))Delphi Connectors (Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro .64))Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (12-Way)) * FCI Connectors (Lever Lock) (See: General Electrical Diagnostic Procedures/Connector Repairs/FCI Connectors (Lever Lock)) * JST Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/JST Connectors) * Kostal Connectors (Glow Plug Control Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Glow Plug Control Module))Kostal Connectors (Transmission) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Transmission)) * Molex Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Molex Connectors) * Sumitomo Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Sumitomo Connectors) * Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (CM 42-Way))Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Sensor))Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (0.25 Cap))Tyco/AMP Connectors (43-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (43-Way))Tyco/AMP Connectors (Door Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Door Module))Tyco/AMP Connectors (102-Way Inline) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (102-Way Inline))Tyco/AMP Connectors (Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Seat))Tyco/AMP Connectors (SIR) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (SIR)) * Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (2-Way))Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (16-Way)) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4835 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4836 * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4837 * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4838 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4839 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4840 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Push to Seat) Delphi Connectors (Push To Seat) Special Tools J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4841 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs). 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Terminated Lead Repair 1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice sleeves depending on the gauge size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Delphi Connectors (Pull to Seat) Delphi Connectors (Pull To Seat) Special Tools Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4842 J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Note: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4843 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. View of a typical Micro 64 connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4844 Depress the lock and pull the lever over and past the lock. View of the connector when released from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4845 View of another type of Micro 64 connector. Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4846 View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4847 Note: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4848 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4849 Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Note: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4850 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4851 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4852 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4853 1. Cut the wire as close to the terminal as possible. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4854 Terminal Replacement Procedure After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Special Tools J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Note: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals). 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12-Way) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4855 Delphi Connectors (12-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4856 4. Release the lower wire dress cover locking tab. 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4857 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4858 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors (Lever Lock) FCI Connectors (Lever Lock) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4859 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. The release tab is located on the top of the wiredress cover. 3. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4860 6. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4861 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4862 1. While depressing the lock, remove the connector from the component. 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4863 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. 4. View of the TPA when removed from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4864 5. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Glow Plug Control Module) Kostal Connectors (Glow Plug Control Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4865 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4866 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4867 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. Note: The front TPA cannot be removed from the connector. Only move it to the preset position. 6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm). 7. Use a small flat-blade tool to completely remove the rear TPA from the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4868 8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Transmission) Kostal Connectors (Transmission) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4869 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4870 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Terminal Replacement Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4871 After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4872 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4873 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4874 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4875 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4876 3. To assemble the connector, reverse the connector disassembly procedure. Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4877 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4878 7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4879 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4880 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4881 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4882 Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4883 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4884 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4885 6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (102-Way Inline) Tyco/AMP Connectors (102-Way Inline) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4886 View of a typical connector in the assembled position. 1. Pull the locking lever to the 90 degree position from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4887 2. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal. 3. Slide the male connector body out away from the guide plates. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4888 Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 4. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. 5. Using terminal release tool J 38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4889 6. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 7. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4890 8. The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool J-38125-11A or equivalent to release the locking tab and slide the connector off the female body. 9. Move the locking lever 180 degrees from the connected position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4891 10. With the locking lever in the 180 degree position the guide plates can be removed from the connector body. Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 11. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4892 12. Using terminal release tool J 38125-216, lift the terminal plate past the terminals and out of the connector body cavity. 13. Terminal plate will bind slightly on each corner. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4893 14. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 15. Using terminal release tool J 38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4894 16. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 17. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4895 18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever. 19. Slide the male connector body back inward toward the guide plates. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4896 20. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly. 21. Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Seat) Tyco/AMP Connectors (Seat) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4897 Removal Procedure 1. Grasp the locking slide lever and pull outward from the end of the connector. 2. As the slide lever is pulled out the mating connector is lifted from the seated position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4898 Note: TPA is keyed and can only be inserted in one direction. 3. Using terminal release tool J 38125-11A or equivalent, push the TPA tabs into the connector body. 4. Pull the TPA from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4899 5. Using terminal release tool J 38125-11A or equivalent, release the connector wire dress cover locking tab. 6. With the lock tab released, lift the connector wire dress cover from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4900 7. Using terminal release tool J 38125-212, press the prongs into the holes each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 8. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4901 9. Using terminal release tool J 38125-556, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (SIR) Tyco/AMP Connectors (SIR) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4902 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4903 3. Using terminal tool J-38125-11A or equivalent, release the wire dress cover locking tabs. 4. Pivot connector wire dress cover while removing from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4904 5. Using terminal tool J-38125-11A or equivalent, remove the TPA by lifting straight off the connector body. 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals Repairing Connector Terminals Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4905 Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gauge size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4906 2. Disconnect the connector from the component. 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4907 4. Relieve the tension on the nose piece retainers by inserting J 38125-12A into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. 5. Once the nose piece retainers are relaxed, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4908 6. On the opposite side of the nose piece, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4909 8. Insert the J 38125-553 tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4910 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. If the TPA is removed, be sure to reinstall it before reconnecting the connector. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4911 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Special Tools Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4912 J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Note: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4913 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4914 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4915 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4916 1. While depressing the lock, pull the two connector halves apart. Note: The TPA is fragile and may break if not done carefully. 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. 3. View of the male half of the connector with female terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4917 4. View of the female half of the connector with male terminals. 5. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. View of the female half of the connector with male terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4918 7. View of the male half of the connector with female terminals. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4919 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are a one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine if the element in the fuse is broken (2). If not broken (1), also check for continuity using a Digital Multimeter (DMM) or a continuity tester. If the element is broken or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a Digital Multimeter (DMM) at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gauge size. Repairing a Fusible Link Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4920 Flat Wire Repairs The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Special Tools J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool * J 38125-5 Ultra Torch Special Tool The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Note: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Description and Operation). GMLAN Connector Terminal Repair Note: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) for the appropriate connector repair procedure. GMLAN Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4921 Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4922 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Special Tools J-38125 Terminal Repair Kit Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4923 repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs High Temperature Wiring Repairs Special Tools J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gauge size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4924 splice. Note: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4925 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4926 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the wire insulation has been chafed, or broken, enough to show the conductive portion of the wire, and the wire is not damaged, determine the length of insulation that needs to be repaired. If the repair is less than 280 mm (11 in), cut the wire within the damaged area. Then slide the appropriate heat shrink tubing (listed below) over the wire, and repair the wire by splicing the wires together. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Once the wire is spliced together slide heat shrink tubing over the damaged area and apply heat to seal the repaired wire. If the wire is damaged, or the damaged area is larger than 280 mm (11 in), then replace the damaged wire by splicing in a new section of wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4927 SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Special Tools J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4928 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4929 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4930 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Special Tools J-38125 Terminal Repair Kit Note: Use only DuraSeal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use DuraSeal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use DuraSeal splice sleeves where there are special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4931 * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4932 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4933 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the instructions for Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Staggering the splices by 65 mm (2.5 in) is recommended. Note: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product AL-36FR to replace the damaged mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Flat Wire Repairs) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/GMLAN Wiring Repairs) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Heated Oxygen Sensor Wiring Repairs) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves) * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Twisted or Shielded Cable) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Inline Harness Diodes) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/SIR/SRS Wiring Repairs) US English/Metric Conversion US English/Metric Conversion Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4934 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4935 Testing Ground and Low Reference Circuits Testing Ground and Low Reference Circuits Because a test lamp can light with up to 200 ohm in a ground or low reference circuit they are not recommended to be used for this type of test. A low impedance test lamp can light and indicate the circuit is good when there is as much as 20-30 ohm present, while a high impedance test lamp can light with up to 200 ohm present in the circuit. This is why the Digital Multi-Meter (DMM) is used when validating a ground or low reference circuit continuity. When using the DMM there are many vehicle conditions that can affect the ground and low reference continuity testing. If these conditions are not met, a ground or low reference circuit test can fail on a good circuit. This may cause longer diagnosis time and incorrect component replacement. Any current flow through a ground or low reference circuit, while being tested, will skew the DMM continuity reading, or display a reading higher than when there is no current flowing. Performing a ground or low reference circuit continuity test, in reference to the vehicles battery negative terminal, will have the highest risk of failing a good ground or low reference circuit test than any other ground reference point. The best ground test points would be a control module housing (if the control modules housing is metal and grounded), door jamb striker (if attached to metal), under dash metal frame work, engine block, or body ground studs (other than where the negative battery cable is attached). A typical DMM ground or low reference circuit continuity reading can be as high as 100 ohm with the ignition ON, and drop to 15-25 ohm after the ignition is turned OFF. The reading will drop below 10 ohm after 30-40 seconds, then below 5 ohm after 60 seconds. Once the vehicle completely goes to sleep (generally 3-10 minutes) the reading will drop below 0.3 ohm. The following list of conditions may need to be met to ensure a valid continuity reading on a ground or low reference circuit: * Ignition OFF * Key out of the ignition switch (when not equipped with keyless entry and remote start) * Retained Accessory Power (RAP) OFF (open and close the driver door after ignition OFF) * Battery charger set at a 2 A or less charge rate * Scan tool not communicating with any vehicle control module (in some cases it may need to be disconnected from the DLC) * All entry doors closed * Headlamps OFF (auto headlamps disabled) * Any delay lighting OFF * HVAC after blow OFF * Any accessory that can work when the ignition is OFF * Wait up to 60 seconds (after all other listed conditions are met) Activating the DOOR LOCK function with a key fob can greatly reduce the time to achieve a valid ground or low reference continuity test result. Terminal Removal Terminal Removal Special Tools * EL-38125-580 - Terminal Release Tool Kit * EL-35616 - Connector Test Adapter Kit For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repair procedures. 1. Find the appropriate connector end view within the connector end view section. The connector end view has the following information: Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4936 * Diagnostic probe tool * Terminal release tool * Terminal/terminated lead part numbers Note: Not using the proper test kit probe may cause damage to the terminal(s) that are probed. 2. Determine if a terminal is damaged. * Locate the diagnostic probe tool from the connector end view. The connector end view describes the color and part number to help the technician find and use the correct tool. * Connect the probe tool to the Digital Multimeter. * Insert the probe tool into the cavity and follow the procedures from the Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter). 3. Disconnect the connector body to perform the repair. 4. Use the following procedure to remove the terminal from the connector body. Note: Several procedures for specific connector bodies are called out in the Wiring Repairs section. * The terminal position assurance (TPA) and connector position assurance (CPA) should be removed before releasing the terminal for the connector body. * Look at the connector end view to locate the cavity of the damaged terminal and find the proper terminal release tool from the terminal release tool kit. Note: Using the incorrect terminal release tool can damage the connector body. * Insert the terminal release tool into the cavity. Note: Some terminals have a lever that must be disengaged before the terminal can be released. 5. Gently pull the wire out of the back of the connector. 6. Repair the terminal by following the Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) procedure. 7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminated Lead Repair Terminated Lead Repair Special Tools * J-38125-8 - Splice Sleeve Crimp Tool Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4937 * J-38125-5 - Ultra Torch For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) procedures. Terminated leads are terminals that are crimped onto wires. The terminated lead can be used throughout the vehicle since it is designed for temperatures up to 150°C. The length of the wire is 450 mm. The DuraSeal splice sleeve has the following 2 critical features: * A special heat shrink tubing that environmentally seals the splice. The shrink tubing contains a sealing adhesive inside the shrink tubing. * A cross hatched (knurled) core crimp that provides the necessary contact integrity for sensitive low energy circuits. 1. Use the connector end view to identify the correct terminated lead. 2. The terminated lead package should include a DuraSeal splice sleeve. If not, use the chart to identify the correct part. 3. Open the harness by removing any tape: Use a sewing seam ripper, or a comparable tool, to cut open the harness, to avoid wire insulation damage. 4. Depending on how many terminals need repairs, cut the terminal and wire back at least 40 mm. Try to keep the harness wire length the same. If more than one terminated lead is required, stagger the lengths by 40 mm. This helps reduce the bundle size of the wire harness. 5. Use the EL-38125-10 - tool in order to position the DuraSeal splice sleeve in the proper color nest of the splice sleeve crimp tool. The crimp tool has four nests, one for each color. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4938 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the J-38125-5 - ultra torch , apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4939 Information Bus: Connector Views Component Connector End Views Serial Data Gateway (SDG) Module X1 (HP2) Serial Data Gateway (SDG) Module X2 (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4940 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4941 Information Bus: Electrical Diagrams Data Communication Schematics Low Speed Bus - 1 of 3 Low Speed Bus - 2 of 3 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4942 Low Speed Bus - 3 of 3 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4943 High Speed Bus - 1 of 6 (except MEX/HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4944 High Speed Bus - 2 of 6 (except MEX/HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4945 High Speed Bus - 3 of 6 (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4946 High Speed Bus - 4 of 6 (MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4947 High Speed Bus - 5 of 6 (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4948 High Speed Bus - 6 of 6 (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4949 Serial Data Communication Enable Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4950 Accessory Wakeup Serial Data and Local Interconnect Network Bus Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4951 Powertrain Expansion Bus (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4952 Serial Data Gateway (SDG) Module (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4953 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Page 4954 Information Bus: Description and Operation Data Link Communications Description and Operation Circuit Description The communication among control modules is performed through the high speed GMLAN serial data circuits and the low speed GMLAN serial data circuit. The modules that need real time communication are attached to the High Speed GMLAN network. The body control module (BCM) is the gateway between the high and low speed networks. Refer to Body Control System Description and Operation (See: Body and Frame/Body Control Systems/Description and Operation) for more information about the gateway. Signal supervision is the process of determining whether an expected signal is being received or not. Some messages are sent on a periodic basis and are interpreted as a heartbeat of a device. If such a signal is lost, the signal supervision part of the software will set a no communication DTC (U. code) against the missing device. This code is mapped on the Tech 2 screen as a code against the physical device. A lost communication DTC typically is set in modules other than the module with a communication failure. GMLAN High Speed Circuit Description The data link connector (DLC) allows a scan tool to communicate with the high speed GMLAN serial data circuit. The serial data is transmitted on 2 twisted wires that allow speed up to 500 Kb/s. The twisted pair is terminated with two 120-ohm resistors, one is internal to the engine control module (ECM) and the other is after the electronic brake control module (EBCM), or if equipped, the suspension control module. The high speed GMLAN is a differential bus. The high speed GMLAN serial data bus (+) and high speed GMLAN serial data (-) are driven to opposite extremes from a rest or idle level. The idle level, which is approximately 2.5 volts, is considered recessive transmitted data and is interpreted as a logic 1. Driving the lines to their extremes, adds 1 volt to the high speed GMLAN serial data bus (+) and subtracts 1 volt from the high speed GMLAN serial data bus (-) wire. If a communication signal is lost, the application will set a no communication code against the respective control module. This code is mapped on the Tech 2 screen as a code against the physical device. Note: a loss of serial data DTC does not represent a failure of the module that the code is set in. The high speed GMLAN serial data allows communication between the body control module (BCM), ECM, transmission control module (TCM), vehicle communication interface module (VCIM), 4WD control module, EBCM, and the suspension control module depending on RPO. GMLAN Low Speed Circuit Description The data link connector (DLC) allows a scan tool to communicate with the low speed GMLAN serial data circuit. The serial data is transmitted over a single wire to the appropriate control modules. Under normal vehicle operating conditions, the speed of the buss is 33.33 Kb/s. This protocol produces a simple pulse train sent out over the GMLAN low speed serial data bus. When a module pulls the buss high, 5 volts, this creates a logic state of 0 on the buss. When the buss is pulled low, 0 volts, it is translated as a logic state of 1. To wake the control modules connected to the GMLAN low speed serial data buss, a wake up signal is sent out over the buss. Modules connected to the GMLAN low speed buss can be part of a virtual network as described in GMLAN High Speed Circuit Description above. The modules on the GMLAN low speed serial data buss are connected to the buss using several splice or "star" connectors separating groups of modules. The following lists state the splices and modules connected to the low speed serial data circuits: I/P Splice * Data link connector (DLC), connected only to the instrument panel (I/P) splice * Amplifier (Amp) * Rear seat audio (RSA) * Vehicle communication interface module (VCIM) * Digital radio receiver (DRR) * Inside rearview mirror module (ISRVM), connected through the mid I/P fuse block * Instrument panel cluster (IPC) * Body control module (BCM) * Theft deterrent module (TDM) * Heater ventilation and air conditioning (HVAC) * Radio * Driver door switch (DDS), connected through the left I/P fuse block * Passenger door switch (PDS), connected through the right I/P fuse block Body Splice * Articulating running board module (ARBM) * Ultrasonic park assist (UPA) * Memory seat module (MSM) * Liftgate module (LGM) * Passenger presence system (PPS) * Inflatable restraint vehicle rollover sensor (ROS) * Inflatable restraint sensing and diagnostic module (SDM) Data Link Connector (DLC) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Page 4955 The data link connector (DLC) is a standardized 16-cavity connector. The DLC low speed serial data circuit is connected directly to the instrument panel (I/P) splice then to all other splices or modules. Connector design and location is dictated by an industry wide standard, and is required to provide the following: * Pin 1 GMLAN low speed communications terminal * Pin 4 scan tool power ground terminal * Pin 5 common signal ground terminal * Pin 6 high speed GMLAN serial data bus (+) terminal * Pin 14 high speed GMLAN serial data bus (-) terminal * Pin 16 scan tool power, battery positive voltage terminal Serial Data Reference The scan tool communicates over the various busses on the vehicle. When a scan tool is installed on a vehicle, the scan tool will try to communicate with every module that could be optioned into the vehicle. If an option is not installed on the vehicle, the scan tool will display No COMM for that options specific control module. In order to avert misdiagnoses of No Communication with a specific module, refer to Data Link References (See: Testing and Inspection/Initial Inspection and Diagnostic Overview) for a list of modules, the busses they communicate with, and the RPO codes for a specific module. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Information Bus: Initial Inspection and Diagnostic Overview Data Link References This table identifies which serial data link that a particular module uses for in-vehicle data transmission. Some modules may use more than one data link to communicate. Some modules may have multiple communication circuits passing through them without actively communicating on that data link. This table is used to assist in correcting a communication malfunction. For the description and operation of these serial data communication circuits refer to Data Link Communications Description and Operation (See: Description and Operation). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4958 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4959 Information Bus: Symptom Related Diagnostic Procedures Symptoms - Data Communications Symptoms - Data Communications Note: The following steps must be completed before using the symptom tables. 1. Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) before using the symptom tables in order to verify that all of the following are true: * There are no DTCs set. * The control modules can communicate via the serial data links. 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Data Link Communications Description and Operation (See: Description and Operation). Visual/Physical Inspection * Inspect for aftermarket devices which could affect the operation of the systems. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Checking Aftermarket Accessories). * Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom. Intermittent Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections ( See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections). Symptom List Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom: * Scan Tool Does Not Power Up (See: Scan Tool Does Not Power Up) * Scan Tool Does Not Communicate with High Speed GMLAN Device (See: Scan Tool Does Not Communicate with High Speed GMLAN Device) * Scan Tool Does Not Communicate with Low Speed GMLAN Device (See: Scan Tool Does Not Communicate with Low Speed GMLAN Device ) * Scan Tool Does Not Communicate with Powertrain High Speed GMLAN Device (See: Scan Tool Does Not Communicate with Powertrain High Speed GMLAN Device) Scan Tool Does Not Communicate with High Speed GMLAN Device Scan Tool Does Not Communicate with High Speed GMLAN Device Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Diagnostic Fault Information Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4960 Circuit/System Description The serial data is transmitted on two twisted wires that allow speeds up to 500 Kb/s. The twisted pair is terminated with two 120 ohms resistors, one is internal to the engine control module (ECM) and the other can be a separate resistor in a connector assembly or in another control module. The resistors are used as the load for the High Speed GMLAN buss during normal vehicle operation. The high speed GMLAN is a differential bus. The high speed GMLAN serial data bus (+) and high speed GMLAN serial data (-) are driven to opposite extremes from a rest or idle level of approximately 2.5 V. Driving the lines to their extremes, adds one volt to the high speed GMLAN serial data bus (+) circuit and subtracts one volt from the high speed GMLAN serial data bus (-) circuit. If serial data is lost, control modules will set a no communication code against the non-communicating control module. Note that a loss of serial data DTC does not represent a failure of the module that set it. Diagnostic Aids * Sometimes, while diagnosing a specific customer concern or after a repair, you may notice a history U-code present. However, there is no associated "current" or "active" status. Loss-of-communication U-codes such as these can set for a variety of reasons. Many times, they are transparent to the vehicle operator and technician, and/or have no associated symptoms. Eventually, they will erase themselves automatically after a number of fault-free ignition cycles. This condition would most likely be attributed to one of these scenarios: - A control module on the data communication circuit was disconnected while the communication circuit is awake. - Power to one or more modules was interrupted during diagnosis - A low battery condition was present, so some control modules stop communicating when battery voltage drops below a certain threshold. - Battery power was restored to the vehicle and control modules on the communication circuit did not all re-initialize at the same time. - If a loss-of-communication U-code appears in history for no apparent reason, it is most likely associated with one of the scenarios above. These are all temporary conditions and should never be interpreted as an intermittent fault, causing you to replace a part. * Do not replace a control module reporting a U-code. The U-code identifies which control module needs to be diagnosed for a communication issue. * Communication may be available between the BCM and the scan tool with the high speed GMLAN serial data system inoperative. This condition is due to the BCM using both the high and low speed GMLAN systems. * An open in the DLC ground circuit terminal 5 will allow the scan tool to operate but not communicate with the vehicle. When the scan tool attempts to communicate with the vehicle a message "no CANdi module detected" will be displayed. * The engine will not start when there is a total malfunction of the high speed GMLAN serial data bus. * Technicians may find various Local Area Network (LAN) communication Diagnostic Trouble Codes (DTC) and no low speed GMLAN communications with the scan tool. * The engine will not start when there is a total malfunction of the high speed GMLAN serial data bus. These conditions may be caused by the installation of an aftermarket navigation radio module (see bulletins). Some customers may comment of one or more of the following concerns: - Vehicle will not crank. - Vehicle cranks but will not start. - Vehicle stability enhancement system warning lights and messages. - PRNDL gear indicator position errors. - Tire Pressure Monitor (TPM) system warning lights. Reference Information Schematic Reference * Data Communication Schematics (See: Diagrams/Electrical Diagrams) * Control Module References (See: Testing and Inspection/Programming and Relearning) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views) Description and Operation Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4961 Data Link Communications Description and Operation (See: Description and Operation) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning) for scan tool information Circuit/System Testing Note: Each control module may need to be disconnected to isolate a circuit fault. Use the schematic to identify the following: * Control modules the vehicle is equipped with * High speed GMLAN serial data circuit terminating resistors * Control module locations on the high speed GMLAN serial data circuits * Each control module's high speed GMLAN serial data circuit terminals 1. Attempt to communicate with all control modules on the high speed GMLAN serial data circuit, refer to Data Link References (See: Initial Inspection and Diagnostic Overview). Communications should not be available with two or more control modules on the high speed GMLAN serial data circuit. ‹› If only one control module is not communicating, diagnose that control module only; refer to DTC U0100-U02FF (with HP2) (See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/U Code Charts/U0100)DTC U0100-U02FF (without HP2) (See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/U Code Charts/U0100). 2. Disconnect the scan tool from the DLC. The following tests will be done at the DLC connector. 3. All access doors closed, ignition OFF for 60 seconds, test for less than 10 ohm between the ground circuit terminal 5 and ground. ‹› If greater than the specified range, test the ground circuit for an open/high resistance. 4. Ignition ON, test for less than 4.5 V between the serial data circuits listed below and ground: * Terminal 6 * Terminal 14 ‹› If greater than the specified range, test the serial data circuit for a short to voltage; refer to Testing the Serial Data Circuits for a Short to Voltage. 5. Ignition OFF for 60 seconds, test for greater than 100 ohm between the serial data circuits listed below and ground: * Terminal 6 * Terminal 14 ‹› If not the specified value, test the serial data circuit for a short to ground; refer to Testing the Serial Data Circuits for a Short to ground. 6. Test for 50-70 ohm between the serial data circuits terminal 6 and terminal 14. ‹› If less than 35 ohm, test for a short between the serial data circuits; refer to Testing the Serial Data Circuits for a Short between the Circuits. ‹› If 35-50 ohm there may be a third terminating resistor between the serial data circuits. This can happen if the incorrect control module is installed. Some control modules are available with and without the terminating resistors installed to reduce the need of terminating resistors in the wiring harness. ‹› If greater than 70 ohm but less than infinite, test the serial data circuit for an open/high resistance; refer to Testing the Serial Data Circuits for an Open/High Resistance. ‹› If infinite, test the serial data circuits between the DLC and the first connection to the serial data circuit for an open/high resistance. Testing the Serial Data Circuits for a Short to Voltage 1. Ignition OFF, disconnect the harness connectors with the high speed GMLAN serial data circuits at an easily accessible control module. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4962 2. Ignition ON, test for greater than 4.5 V between each serial data circuit at the control module connector that was just disconnected and ground. Verify that one or more serial data circuits are greater than 4.5 V. ‹› If all serial data circuits are less than the specified range, replace the control module that was disconnected. 3. Ignition OFF, disconnect the harness connectors with the high speed GMLAN serial data circuits at another control module, in the direction of the circuit shorted to voltage. 4. Ignition ON, test for greater than 4.5 V between the serial data circuits at the control module connector that was just disconnected and ground. Verify that one or more serial data circuits are greater than 4.5 V. ‹› If all serial data circuits are less than the specified range, replace the control module that was just disconnected. 5. Repeat step 3 until one of the follow conditions are isolated: * A short to voltage on the serial data circuit between 2 control modules * A short to voltage on the serial data circuit between a control module and a terminating resistor. Testing the Serial Data Circuits for a Short to Ground 1. Ignition OFF, disconnect the harness connectors with the high speed GMLAN serial data circuits at an easily accessible control module. 2. Ignition OFF for 60 seconds, test for less than 1k ohm between each serial data circuit at the control module connector that was just disconnected and ground. Verify that one or more serial data circuits are less than 1k ohm. ‹› If all serial data circuits are greater than the specified range, replace the control module that was disconnected. 3. Disconnect the harness connectors with the high speed GMLAN serial data circuits at another control module, in the direction of the circuit shorted to ground. 4. Ignition OFF for 60 seconds, test for less than 1k ohm between the serial data circuits at the control module connector that was just disconnected and ground. Verify that one or more serial data circuits are less than 1k ohm. ‹› If greater than the specified range for all serial data circuits, replace the control module that was just disconnected. 5. Repeat step 3 until one of the follow conditions are isolated: * A short to ground on the serial data circuit between 2 control modules * A short to ground on the serial data circuit between a control module and a terminating resistor Testing the Serial Data Circuits for a Short between the Circuits 1. Ignition OFF, disconnect the harness connectors with the high speed GMLAN serial data circuits at an easily accessible control module that is not communicating. 2. Ignition OFF for 60 seconds, test for less than 35 ohm between each pair of serial data circuits at the control module connector that was just disconnected. Verify that one pair of serial data circuits are less than 35 ohm. ‹› If each pair of serial data circuits is greater than the specified range, replace the control module that was disconnected. 3. Connect the harness connectors at the control module that was disconnected. 4. Disconnect the harness connectors with the high speed GMLAN serial data circuits at another control module, in the direction of the circuits shorted together. 5. Ignition OFF for 60 seconds, test for less than 35 ohm between each pair of serial data circuits at the control module connector that was just disconnected. Verify that one pair of serial data circuits are less than 35 ohm. ‹› If each pair of serial data circuits is within the specified range, replace the control module that was just disconnected. 6. Repeat step 3 until one of the following conditions are isolated: * Serial data circuits shorted together between 2 control modules * Serial data circuits shorted together between a control module and a terminating resistor * A shorted terminating resistor Testing the Serial Data Circuits for an Open/High Resistance 1. Ignition OFF, disconnect the harness connectors with the high speed GMLAN serial data circuits at an easily accessible control module that is not communicating. 2. Ignition OFF for 60 seconds, test for greater than 100k ohm between each pair of serial data circuits at the control module connector that was just disconnected. Verify that one pair of serial data circuits are greater than 100k ohm. ‹› If each pair of serial data circuits is less than the specified range, replace the control module that was disconnected. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4963 3. Connect the harness connectors at the control module that was disconnected. 4. Disconnect the harness connectors with the high speed GMLAN serial data circuits at another control module, in the direction of the open circuit. 5. Ignition OFF for 60 seconds, test for greater than 100k ohm between each pair of serial data circuits at the control module connector that was just disconnected. Verify that one pair of serial data circuits are greater than 100k ohm. ‹› If each pair of serial data circuits is less than the specified range, replace the control module that was just disconnected. 6. Repeat step 3 until one of the following conditions are isolated: * An open/high resistance on the serial data circuit between 2 control modules * An open/high resistance on the serial data circuit between a control module and a terminating resistor * An open/high resistance terminating resistor Repair Instructions Perform the Diagnostic Repair Verification (See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the repair. * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/GMLAN Wiring Repairs) * Control Module References (See: Testing and Inspection/Programming and Relearning) for control module replacement, setup, and programming Scan Tool Does Not Communicate with Low Speed GMLAN Device Scan Tool Does Not Communicate with Low Speed GMLAN Device Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Diagnostic Fault Information Circuit/System Description Modules connected to the low speed GMLAN serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules when the ignition switch is in any position other than OFF. The low speed GMLAN serial data circuit uses JX 221, JX 339, and, if equipped, JX 223 as common connection points between some modules and the data link connector (DLC). Diagnostic Aids * Sometimes, while diagnosing a specific customer concern or after a repair, you may notice a history U-code present. However, there is no associated "current" or "active" status. Loss-of-communication U-codes such as these can set for a variety of reasons. Many times, they are transparent to the vehicle operator and technician, and/or have no associated symptoms. Eventually, they will erase themselves automatically after a number of fault-free ignition cycles. This condition would most likely be attributed to one of these scenarios: - A control module on the data communication circuit was disconnected while the communication circuit is awake. - Power to one or more modules was interrupted during diagnosis - A low battery condition was present, so some control modules stop communicating when battery voltage drops below a certain threshold. - Battery power was restored to the vehicle and control modules on the communication circuit did not all re-initialize at the same time. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4964 - If a loss-of-communication U-code appears in history for no apparent reason, it is most likely associated with one of the scenarios above. These are all temporary conditions and should never be interpreted as an intermittent fault, causing you to replace a part. * Do not replace a control module reporting a U-code. The U-code identifies which control module needs to be diagnosed for a communication issue. * Communication may be available between the BCM and the scan tool with the high speed GMLAN serial data system inoperative. This condition is due to the BCM using both the high and low speed GMLAN systems. * An open in the DLC ground circuit terminal 5 will allow the scan tool to operate but not communicate with the vehicle. When the scan tool attempts to communicate with the vehicle a message "no CANdi module detected" will be displayed. * The engine will not start when there is a total malfunction of the high speed GMLAN serial data bus. * Technicians may find various Local Area Network (LAN) communication Diagnostic Trouble Codes (DTC) and no low speed GMLAN communications with the scan tool. * The engine will not start when there is a total malfunction of the high speed GMLAN serial data bus. These conditions may be caused by the installation of an aftermarket navigation radio module (see bulletins). Some customers may comment of one or more of the following concerns: - Vehicle will not crank. - Vehicle cranks but will not start. - Vehicle stability enhancement system warning lights and messages. - PRNDL gear indicator position errors. - Tire Pressure Monitor (TPM) system warning lights. Reference Information Schematic Reference Data Communication Schematics (See: Diagrams/Electrical Diagrams) Connector End View Reference * Component Connector End Views (See: Diagrams/Connector Views) * Splice Pack Connector End Views (See: Diagrams/Connector Views/Splices By Number) Description and Operation Data Link Communications Description and Operation (See: Description and Operation) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) Circuit/System Testing Note: Use the schematic to identify the following: * Control modules the vehicle is equipped with * Control module locations on the low speed GMLAN serial data circuit * Each control module's low speed GMLAN serial data circuit terminals 1. Attempt to communicate with all control modules on the low speed GMLAN serial data circuit, refer to Data Link References (See: Initial Inspection and Diagnostic Overview). Communications should not be available with two or more control modules on the low speed GMLAN serial data circuit. ‹› If only one control module is not communicating, diagnose that control module only, refer to DTC U0100-U02FF (with HP2) (See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/U Code Charts/U0100)DTC U0100-U02FF (without HP2) (See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/U Code Charts/U0100). ‹› If one or more control modules are communicating but not all, refer to Testing the Serial Data Circuit for an Open/High Resistance. 2. Disconnect the scan tool from the DLC. The following tests will be done at the DLC connector. 3. All access doors closed, ignition OFF for 60 seconds, test for less than 10 ohm between the ground circuit terminal 5 and ground. ‹› If greater than the specified range, test the ground circuit for an open/high resistance. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4965 4. Ignition ON, test for less than 4.5 V between the serial data circuit terminal 1 and ground. ‹› If greater than the specified range, test the serial data circuit for a short to voltage, refer to Testing the Serial Data Circuit for a Short to Voltage. 5. Ignition OFF for 60 seconds, test for greater than 100 ohm between the serial data circuit terminal 1 and ground. ‹› If not the specified value, test the serial data circuit for a short to ground, refer to Testing the Serial Data Circuits for a Short to ground. 6. Disconnect the harness connector at the JX 221 splice pack. 7. Test for less than 2 ohm between the serial data circuit terminal 1 and the JX 221 splice pack terminal D. ‹› If greater than the specified range, test the serial data circuit for an open/high resistance. If the circuits test normal, replace the splice pack. Testing the Serial Data Circuits for a Short to Voltage 1. Ignition OFF, disconnect the harness connectors at the JX 221, JX 339, and JX 223 splice packs, as equipped. 2. Ignition ON, test for less than 4.5 V between the DLC serial data circuit terminal 1 and ground. ‹› If greater than the specified range, repair the short to voltage. 3. Test for less than 4.5 V between each serial data circuit and ground. ‹› If greater than the specified range, perform the appropriate test listed below: * Serial data circuits with one control module, test the serial data circuit for a short to voltage. If the circuit tests normal replace the control module. * Serial data circuits with 2 or more control modules, test each section of the serial data circuit for a short to voltage. If the circuits test normal, replace the control module that causes the short to voltage when connected. Testing the Serial Data Circuits for a Short to Ground 1. Ignition OFF, disconnect the harness connectors at the JX 221, JX 339, and JX 223 splice packs, as equipped. 2. Test for infinite resistance between the DLC serial data circuit terminal 1 and ground. ‹› If not the specified value, repair the short to ground. 3. Ignition OFF for 60 seconds, test for greater than 100 ohm between each serial data circuit and ground. ‹› If less than the specified range, perform the appropriate test listed below: * Serial data circuits with one control module, test the serial data circuit for a short to ground. If the circuit tests normal replace the control module. * Serial data circuits with 2 or more control modules, test each section of the serial data circuit for a short to ground. If the circuits test normal, replace the control module that causes the short to ground when connected. Testing the Serial Data Circuit for an Open/High Resistance 1. If equipped with a JX 339 splice pack, ignition ON, verify the scan tool communicates with one or more control modules connected to the JX 339 splice pack. ‹› If all control modules on the JX 339 spice pack do not communicate, test the serial data circuit between the JX 221 and JX 339 splice packs for an open/high resistance. If the circuit tests normal, test each splice pack for an open/high resistance. 2. Ignition OFF, disconnect one of the harness connectors listed below: * JX 221 if the control modules not communicating are connected to the JX 221 splice pack * JX 223 if the control modules not communicating are connected to the JX 223 splice pack, if equipped * JX 339 if the control modules not communicating are connected to the JX 339 splice pack 3. Install a 3A fused jumper wire between the disconnected splice pack connector terminal listed below and a low speed GMLAN serial data circuit that is not communicating: * JX 221 terminal D * JX 223 terminal A * JX 339 terminal A 4. Ignition ON, verify the scan tool communicates with the control modules connected to the low speed GMLAN serial data circuit. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4966 ‹› If any control module does not communicate, test each section of the serial data circuit for an open/high resistance. If the circuits test normal, replace the control module that does not communicate when connected. Repair Instructions Perform the Diagnostic Repair Verification (See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the repair. * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/GMLAN Wiring Repairs) * Control Module References (See: Testing and Inspection/Programming and Relearning) for module replacement, setup, and programming Scan Tool Does Not Power Up Scan Tool Does Not Power Up Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Diagnostic Fault Information Circuit/System Description The data link connector (DLC) is a standardized 16 cavity connector. Connector design and location is dictated by an industry wide standard, and is required to provide the following: * Scan tool B+ voltage at terminal 16 * Scan tool ground at terminal 4 * Common ground at terminal 5 Diagnostic Aids * The scan tool will power up with the ignition OFF. Some modules however, will not communicate unless the ignition is ON and the power mode master (PMM) module sends the appropriate power mode message. * If the B+ circuit, ground circuits, and connections of the DLC are functioning properly, the malfunction must be due to the scan tool/CANdi module. Reference Information Schematic Reference Data Communication Schematics (See: Diagrams/Electrical Diagrams) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views) Description and Operation Data Link Communications Description and Operation (See: Description and Operation) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4967 Repairs/Connector Repairs) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning) for scan tool information. Circuit/System Testing 1. Test for less than 2.0 ohms between the ground circuits terminal 4 of the DLC and ground, and terminal 5 of the DLC and ground. ‹› If greater than the specified range, test the ground circuit for an open/high resistance. 2. Ignition ON, verify a test lamp illuminates between the B+ circuit terminal 16 at the DLC and ground. ‹› If the test lamp does not illuminate, test the voltage supply circuit for a short to ground or an open/high resistance. 3. If all circuits test normal, refer to the scan tool/CANdi module user guide. Repair Instructions Perform the Diagnostic Repair Verification (See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the repair. Scan Tool Does Not Communicate with Powertrain High Speed GMLAN Device Scan Tool Does Not Communicate with Powertrain High Speed GMLAN Device Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions )provides an overview of each diagnostic category. Diagnostic Fault Information Circuit/System Description The serial data is transmitted on two twisted wires that allow speeds up to 500 Kb/s. The twisted pair is terminated with two 120 ohms resistors, one is internal to the engine control module (ECM) and the other can be a separate resistor in a connector assembly or in another control module. The resistors are used as the load for the Powertrain High Speed GMLAN buss during normal vehicle operation. The Powertrain High Speed GMLAN is a differential bus. The Powertrain High Speed GMLAN serial data bus (+) and Powertrain High Speed GMLAN serial data (-) are driven to opposite extremes from a rest or idle level of approximately 2.5 V. Driving the lines to their extremes, adds one volt to the Powertrain High Speed GMLAN serial data bus (+) circuit and subtracts one volt from the Powertrain High Speed GMLAN serial data bus (-) circuit. If serial data is lost, control modules will set a no communication code against the non-communicating control module. Note that a loss of serial data DTC does not represent a failure of the module that set it. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4968 Diagnostic Aids * Sometimes, while diagnosing a specific customer concern or after a repair, you may notice a history U-code present. However, there is no associated "current" or "active" status. Loss-ofcommunication U-codes such as these can set for a variety of reasons. Many times, they're transparent to the vehicle operator and technician, and/or have no associated symptoms. Eventually, they will erase themselves automatically after a number of fault-free ignition cycles. This condition would most likely be attributed to one of these scenarios: - A control module on the data communication circuit was disconnected while the communication circuit is awake. - Power to one or more modules was interrupted during diagnosis - A low battery condition was present, so some control modules stop communicating when battery voltage drops below a certain threshold. - Battery power was restored to the vehicle and control modules on the communication circuit did not all re-initialize at the same time. - If a loss-of-communication U-code appears in history for no apparent reason, it is most likely associated with one of the scenarios above. These are all temporary conditions and should never be interpreted as an intermittent fault, causing you to replace a part. * Do not replace a control module reporting a U code. The U code identifies which control module needs to be diagnosed for a communication issue. * Communication may be available between the BCM and the scan tool with the Powertrain High Speed GMLAN serial data system inoperative. This condition is due to the BCM using both the high and low speed GMLAN systems. * An open in the DLC ground circuit terminal 5 will allow the scan tool to operate but not communicate with the vehicle. When the scan tool attempts to communicate with the vehicle a message "no CANdi module detected" will be displayed. * The engine will not start when there is a total malfunction of the Powertrain High Speed GMLAN serial data bus. * Technicians may find various Local Area Network (LAN) communication Diagnostic Trouble Codes (DTC) and no low speed GMLAN communications with the scan tool. * The engine will not start when there is a total malfunction of the high speed GMLAN serial data bus. These conditions may be caused by the installation of an aftermarket navigation radio module (see bulletins). Some customers may comment of one or more of the following concerns: - Vehicle will not crank. - Vehicle cranks but will not start. - Vehicle stability enhancement system warning lights and messages. - PRNDL gear indicator position errors. - Tire Pressure Monitor (TPM) system warning lights. Reference Information Schematic Reference * Data Communication Schematics (See: Diagrams/Electrical Diagrams) * Control Module References (See: Testing and Inspection/Programming and Relearning) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views) Description and Operation Data Link Communications Description and Operation (See: Description and Operation) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning) for scan tool information Circuit/System Testing Note: Each control module may need to be disconnected to isolate a circuit fault. Use the schematic to identify the following: * Control modules the vehicle is equipped with Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4969 * Powertrain High Speed GMLAN serial data circuit terminating resistors * Control module locations on the Powertrain High Speed GMLAN serial data circuits * Each control module's Powertrain High Speed GMLAN serial data circuit terminals 1. Attempt to communicate with all control modules on the Powertrain High Speed GMLAN serial data circuit, refer to Data Link References (See: Initial Inspection and Diagnostic Overview). Communications should not be available with two or more control modules on the Powertrain High Speed GMLAN serial data circuit. ‹› If only one control module is not communicating, diagnose that control module only; refer to DTC U0100-U02FF (with HP2) (See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/U Code Charts/U0100)DTC U0100-U02FF (without HP2) (See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/U Code Charts/U0100). 2. Disconnect the scan tool from the DLC. The following tests will be done at the DLC connector. 3. All access doors closed, ignition OFF for 60 seconds, test for less than 10 ohm between the ground circuit terminal 5 and ground. ‹› If greater than the specified range, test the ground circuit for an open/high resistance. 4. Ignition ON, test for less than 4.5 V between the serial data circuits listed below and ground: * Terminal 3 * Terminal 11 ‹› If greater than the specified range, test the serial data circuit for a short to voltage; refer to Testing the Serial Data Circuits for a Short to Voltage. 5. Ignition OFF for 60 seconds, test for greater than 100 ohm between the serial data circuits listed below and ground: * Terminal 3 * Terminal 11 ‹› If not the specified value, test the serial data circuit for a short to ground; refer to Testing the Serial Data Circuits for a Short to ground. 6. Test for 50-70 ohm between the serial data circuits terminal 3 and terminal 11. ‹› If less than 35 ohm, test for a short between the serial data circuits; refer to Testing the Serial Data Circuits for a Short between the Circuits. ‹› If 35-50 ohm there may be a third terminating resistor between the serial data circuits. This can happen if the incorrect control module is installed. Some control modules are available with and without the terminating resistors installed to reduce the need of terminating resistors in the wiring harness. ‹› If greater than 70 ohm but less than infinite, test the serial data circuit for an open/high resistance; refer to Testing the Serial Data Circuits for an Open/High Resistance. ‹› If infinite, test the serial data circuits between the DLC and the first connection to the serial data circuit for an open/high resistance. Testing the Serial Data Circuits for a Short to Voltage 1. Ignition OFF, disconnect the harness connectors with the Powertrain High Speed GMLAN serial data circuits at an easily accessible control module. 2. Ignition ON, test for greater than 4.5 V between each serial data circuit at the control module connector that was just disconnected and ground. Verify that one or more serial data circuits are greater than 4.5 V. ‹› If all serial data circuits are less than the specified range, replace the control module that was disconnected. 3. Ignition OFF, disconnect the harness connectors with the Powertrain High Speed GMLAN serial data circuits at another control module, in the direction of the circuit shorted to voltage. 4. Ignition ON, test for greater than 4.5 V between the serial data circuits at the control module connector that was just disconnected and ground. Verify that one or more serial data circuits are greater than 4.5 V. ‹› If all serial data circuits are less than the specified range, replace the control module that was just disconnected. 5. Repeat step 3 until one of the follow conditions are isolated: * A short to voltage on the serial data circuit between 2 control modules * A short to voltage on the serial data circuit between a control module and a terminating resistor. Testing the Serial Data Circuits for a Short to Ground 1. Ignition OFF, disconnect the harness connectors with the Powertrain High Speed GMLAN serial data circuits at an easily accessible control module. 2. Ignition OFF for 60 seconds, test for less than 1k ohm between each serial data circuit at the control module connector that was just disconnected Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4970 and ground. Verify that one or more serial data circuits are less than 1k ohm. ‹› If all serial data circuits are greater than the specified range, replace the control module that was disconnected. 3. Disconnect the harness connectors with the Powertrain High Speed GMLAN serial data circuits at another control module, in the direction of the circuit shorted to ground. 4. Ignition OFF for 60 seconds, test for less than 1k ohm between the serial data circuits at the control module connector that was just disconnected and ground. Verify that one or more serial data circuits are less than 1k ohm. ‹› If greater than the specified range for all serial data circuits, replace the control module that was just disconnected. 5. Repeat step 3 until one of the follow conditions are isolated: * A short to ground on the serial data circuit between 2 control modules * A short to ground on the serial data circuit between a control module and a terminating resistor. Testing the Serial Data Circuits for a Short between the Circuits 1. Ignition OFF, disconnect the harness connectors with the Powertrain High Speed GMLAN serial data circuits at an easily accessible control module that is not communicating. 2. Ignition OFF for 60 seconds, test for less than 35 ohm between each pair of serial data circuits at the control module connector that was just disconnected. Verify that one pair of serial data circuits are less than 35 ohm. ‹› If each pair of serial data circuits is greater than the specified range, replace the control module that was disconnected. 3. Connect the harness connectors at the control module that was disconnected. 4. Disconnect the harness connectors with the Powertrain High Speed GMLAN serial data circuits at another control module, in the direction of the circuits shorted together. 5. Ignition OFF for 60 seconds, test for less than 35 ohm between each pair of serial data circuits at the control module connector that was just disconnected. Verify that one pair of serial data circuits are less than 35 ohm. ‹› If each pair of serial data circuits is within the specified range, replace the control module that was just disconnected. 6. Repeat step 3 until one of the following conditions are isolated: * Serial data circuits shorted together between 2 control modules * Serial data circuits shorted together between a control module and a terminating resistor * A shorted terminating resistor Testing the Serial Data Circuits for an Open/High Resistance 1. Ignition OFF, disconnect the harness connectors with the Powertrain High Speed GMLAN serial data circuits at an easily accessible control module that is not communicating. 2. Ignition OFF for 60 seconds, test for greater than 100k ohm between each pair of serial data circuits at the control module connector that was just disconnected. Verify that one pair of serial data circuits are greater than 100k ohm. ‹› If each pair of serial data circuits is less than the specified range, replace the control module that was disconnected. 3. Connect the harness connectors at the control module that was disconnected. 4. Disconnect the harness connectors with the Powertrain High Speed GMLAN serial data circuits at another control module, in the direction of the open circuit. 5. Ignition OFF for 60 seconds, test for greater than 100k ohm between each pair of serial data circuits at the control module connector that was just disconnected. Verify that one pair of serial data circuits are greater than 100k ohm. ‹› If each pair of serial data circuits is less than the specified range, replace the control module that was just disconnected. 6. Repeat step 3 until one of the following conditions are isolated: * An open/high resistance on the serial data circuit between 2 control modules * An open/high resistance on the serial data circuit between a control module and a terminating resistor * An open/high resistance terminating resistor Repair Instructions Perform the Diagnostic Repair Verification (See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the repair. * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4971 Procedures/Wiring Repairs/GMLAN Wiring Repairs) * Control Module References (See: Testing and Inspection/Programming and Relearning)for control module replacement, setup, and programming Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams Knock Sensor: Diagrams Component Connector End Views Knock Sensor (KS) 1 (Gas) Knock Sensor (KS) 2 (Gas) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 4975 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 4979 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 4980 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 4981 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 4982 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 4983 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 4984 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 4985 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Testing and Inspection Malfunction Indicator Lamp: Testing and Inspection Malfunction Indicator Lamp (MIL) Diagnosis Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Circuit/System Description The malfunction indicator lamp (MIL) is located on the instrument panel cluster (IPC). The MIL informs the driver that an emission system fault has occurred and that the engine control system requires service. The engine control module (ECM) monitors the MIL control circuit for conditions that are incorrect for the commanded states of the MIL. For example, a failure condition exists if the ECM detects low voltage when the MIL is commanded OFF, or high voltage when the MIL is commanded ON. Diagnostic Aids An intermittent or poor connection at the MIL control circuit at the inline harness connector may cause this DTC to set. Inspect the connector terminals for any condition that may result in excessive resistance. Refer to Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections). Reference Information Schematic Reference * Engine Controls Schematics (See: Diagrams/Electrical Diagrams) * Instrument Cluster Schematics (See: Diagrams/Electrical Diagrams/Instrument Panel, Gauges and Warning Indicators/System Diagram/Instrument Cluster Schematics) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) DTC Type Reference Powertrain Diagnostic Trouble Code (DTC) Type Definitions (See: Testing and Inspection/Diagnostic Trouble Code Descriptions/Powertrain Diagnostic Trouble Code (DTC) Type Definitions) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning) for scan tool information Circuit/System Verification Ignition ON, command the MIL ON and OFF with a scan tool. The MIL should turn ON and OFF with each command. Circuit/System Testing 1. Ignition ON, verify that the IPC warning indicators are illuminated. ‹› If the IPC warning indicators are not illuminated, test the IPC ignition circuit for a short to ground or an open/high resistance. If the circuit Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Testing and Inspection > Page 4989 tests normal and the ignition circuit fuse is open, replace the IPC. 2. Ignition OFF, disconnect the ECM X2 harness connector. Ignition ON, the MIL should not illuminate. ‹› If the MIL is illuminated, test the MIL control circuit terminal X2-30 for a short to ground. If the circuit tests normal, replace the IPC. 3. Ignition ON, connect a 3A fused jumper wire between the MIL control circuit terminal X2-30 and ground. The MIL should illuminate. ‹› If the MIL does not illuminate, test the MIL control circuit for a short to voltage, or an open/high resistance. If the circuit tests normal, replace the IPC/bulb. 4. If all circuits/connectors test normal, replace the ECM. Repair Instructions Perform the Diagnostic Repair Verification (See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. * Instrument Cluster Replacement (Without RPO SLT) (See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair/Instrument Cluster Replacement (Without RPO SLT))Instrument Cluster Replacement (With RPO SLT) (See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair/Instrument Cluster Replacement (With RPO SLT)) * Control Module References (See: Testing and Inspection/Programming and Relearning) for ECM and ICM replacement, setup, and programming Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams Manifold Pressure/Vacuum Sensor: Diagrams Component Connector End Views Manifold Absolute Pressure (MAP) Sensor (LU3) Manifold Absolute Pressure (MAP) Sensor (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Page 4993 Manifold Absolute Pressure (MAP) Sensor (Gas except LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Page 4994 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Page 4995 Manifold Pressure/Vacuum Sensor: Service and Repair Manifold Absolute Pressure Sensor Replacement Removal Procedure 1. Disconnect the engine wiring harness electrical connector (2) from the manifold absolute pressure (MAP) sensor. 2. Remove the MAP sensor bolt. 3. Remove the MAP sensor bracket and sensor. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Page 4996 1. Install the MAP sensor and bracket. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the MAP sensor bolt. Tighten the bolt to 10 Nm (89 lb in). 3. Connect the engine wiring harness electrical connector (2) to the MAP sensor. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams Oil Pressure Sensor: Diagrams Component Connector End Views Engine Oil Pressure (EOP) Sensor (Diesel) Engine Oil Pressure (EOP) Sensor (Gas except LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Page 5000 Engine Oil Pressure (EOP) Sensor (LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Page 5001 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Page 5002 Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement Special Tools DT-48827 Skip Shift Socket Removal Procedure 1. Remove the left wheelhouse inner panel. Refer to Front Wheelhouse Liner Replacement - Left Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Left Side)Front Wheelhouse Liner Replacement - Left Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Left Side). Note: Clean the area around the sensor. Do not allow debris to enter the engine. 2. Disconnect the oil pressure sensor electrical connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Page 5003 3. Using DT-48827 , remove the oil pressure sensor (1). Installation Procedure 1. Apply sealant to the threads of the oil pressure sensor. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Engine, Cooling and Exhaust/Engine/Specifications/Adhesives, Fluids, Lubricants, and Sealers) for the correct part number. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Using DT-48827 , install the oil pressure sensor (1). Tighten the sensor to 49 Nm (36 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Page 5004 3. Connect the oil pressure sensor electrical connector. 4. Install the left wheelhouse inner panel. Refer to Front Wheelhouse Liner Replacement - Left Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Left Side)Front Wheelhouse Liner Replacement - Left Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Left Side). 5. Check and add engine oil if necessary. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations Oxygen Sensor: Locations Harness Routing Views Heated Oxygen Sensor (HO2S) Jumper Harness Routing (LY6) 1 - X125 2 - Heated Oxygen Sensor (HO2S) Bank 2 Sensor 2 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 5008 Oxygen Sensor: Diagrams Component Connector End Views Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 (LU3) Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 (Gas except LU3 and except ZW9) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 5009 Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 (LY6 or L96 with ZW9) Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 2 (LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 5010 Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 2 (Gas except LU3) Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 (LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 5011 Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 (Gas except LU3 and except ZW9) Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 (LY6 or L96 with ZW9) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 5012 Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 2 (LU3) Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 2 (Gas except LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 5013 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service Precautions > Excessive Force and Oxygen Sensor Caution Oxygen Sensor: Service Precautions Excessive Force and Oxygen Sensor Caution Excessive Force and Oxygen Sensor Caution Caution: The oxygen sensor may be difficult to remove when the engine temperature is below 48°C (120°F). Excessive force may damage threads in the exhaust manifold or the exhaust pipe. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service Precautions > Excessive Force and Oxygen Sensor Caution > Page 5016 Oxygen Sensor: Service Precautions Heated Oxygen and Oxygen Sensor Caution Heated Oxygen and Oxygen Sensor Caution Caution: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen sensor (O2S). Removing the pigtail or the connector will affect sensor operation. Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical connector and the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of any type. Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring, connector, or terminal is damaged. This external clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air reference and degraded sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. * Do not damage the sensor pigtail and harness wires in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp bends or kinks could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire, where applicable. Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will cause poor engine performance. * Ensure that the peripheral seal remains intact on the vehicle harness connector in order to prevent damage due to water intrusion. The engine harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service Precautions > Excessive Force and Oxygen Sensor Caution > Page 5017 Oxygen Sensor: Service Precautions Heated Oxygen Sensor Resistance Learn Reset Caution Heated Oxygen Sensor Resistance Learn Reset Caution Caution: When replacing the HO2S perform the following: * A code clear with a scan tool, regardless of whether or not a DTC is set * HO2S heater resistance learn reset with a scan tool, where available Perform the above in order to reset the HO2S resistance learned value and avoid possible HO2S failure. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service Precautions > Excessive Force and Oxygen Sensor Caution > Page 5018 Oxygen Sensor: Service Precautions Silicon Contamination of Heated Oxygen Sensors Caution Silicon Contamination of Heated Oxygen Sensors Caution Caution: Contamination of the oxygen sensor can result from the use of an inappropriate RTV sealant (not oxygen sensor safe) or excessive engine coolant or oil consumption. Remove the HO2S and visually inspect the portion of the sensor exposed to the exhaust stream in order to check for contamination. If contaminated, the portion of the sensor exposed to the exhaust stream will have a white powdery coating. Silicon contamination causes a high but false HO2S signal voltage (rich exhaust indication). The control module will then reduce the amount of fuel delivered to the engine, causing a severe driveability problem. Eliminate the source of contamination before replacing the oxygen sensor. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Diagrams Pressure Feedback Exhaust Sensor: Diagrams Component Connector End Views Exhaust Pressure Differential Sensor (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 07-08-42-006E > Nov > 10 > Instruments - Bulb Outage Detection Restoration Body Control Module: Customer Interest Instruments - Bulb Outage Detection Restoration INFORMATION Bulletin No.: 07-08-42-006E Date: November 11, 2010 Subject: Information on BCM Calibrations Available to Restore Bulb Outage Detection on Vehicles Produced by a Second Stage Manufacturer, Turn Signals Flash Fast after Factory Box Removed (Upfitter) Models: 2007-2011 Chevrolet Silverado 2007-2011 GMC Sierra Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 07-08-42-006D (Section 08 - Body and Accessories). The information contained in this bulletin applies to vehicles that are to be completed by a second stage manufacturer (upfitter) and may need to have the Body Control Module (BCM) rear turn signal bulb outage detection capability changed. All production vehicles will be manufactured with one of the following BCM rear turn signal bulb outage detection software options: 1. A standard production vehicle will have BCM software that checks for two bulbs functioning in each rear turn signal bulb circuit. If one or more bulbs are inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 2. Certain 2500 and 3500 models can be ordered with a new option (RPO 9U5) where the BCM checks for one bulb functioning in each rear turn signal bulb circuit. If the bulb goes inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 3. A vehicle built with a pickup box delete or chassis cab option (RPO ZW9) will be produced with a BCM program that has no turn signal bulb outage detection capability (LED compatible). The IPC turn signal indicator will flash at the same rate no matter how many turn signal bulbs are inoperative. In some cases, the upfitter may wish to change the turn signal bulb outage detection capability so that the turn signals work correctly with their upfit or to meet certain requirements. This will require contacting the Techline Customer Support Center (TCSC) to open a case and obtain a Vehicle Configuration Index (VCI) number. Advise the TCSC consultant which turn signal bulb outage detection capability is needed: 1. Factory standard production TWO bulb outage detection. 2. Optional (RPO 9U5) ONE bulb outage detection. NOTE: ONLY AVAILABLE ON CERTAIN 2007-2011 MODEL 2500 AND 3500 VEHICLES. 3. NO bulb outage detection (LED compatible). The BCM can then be reprogrammed with the correct software. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 07-08-42-006E > Nov > 10 > Instruments - Bulb Outage Detection Restoration Body Control Module: All Technical Service Bulletins Instruments - Bulb Outage Detection Restoration INFORMATION Bulletin No.: 07-08-42-006E Date: November 11, 2010 Subject: Information on BCM Calibrations Available to Restore Bulb Outage Detection on Vehicles Produced by a Second Stage Manufacturer, Turn Signals Flash Fast after Factory Box Removed (Upfitter) Models: 2007-2011 Chevrolet Silverado 2007-2011 GMC Sierra Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 07-08-42-006D (Section 08 - Body and Accessories). The information contained in this bulletin applies to vehicles that are to be completed by a second stage manufacturer (upfitter) and may need to have the Body Control Module (BCM) rear turn signal bulb outage detection capability changed. All production vehicles will be manufactured with one of the following BCM rear turn signal bulb outage detection software options: 1. A standard production vehicle will have BCM software that checks for two bulbs functioning in each rear turn signal bulb circuit. If one or more bulbs are inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 2. Certain 2500 and 3500 models can be ordered with a new option (RPO 9U5) where the BCM checks for one bulb functioning in each rear turn signal bulb circuit. If the bulb goes inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 3. A vehicle built with a pickup box delete or chassis cab option (RPO ZW9) will be produced with a BCM program that has no turn signal bulb outage detection capability (LED compatible). The IPC turn signal indicator will flash at the same rate no matter how many turn signal bulbs are inoperative. In some cases, the upfitter may wish to change the turn signal bulb outage detection capability so that the turn signals work correctly with their upfit or to meet certain requirements. This will require contacting the Techline Customer Support Center (TCSC) to open a case and obtain a Vehicle Configuration Index (VCI) number. Advise the TCSC consultant which turn signal bulb outage detection capability is needed: 1. Factory standard production TWO bulb outage detection. 2. Optional (RPO 9U5) ONE bulb outage detection. NOTE: ONLY AVAILABLE ON CERTAIN 2007-2011 MODEL 2500 AND 3500 VEHICLES. 3. NO bulb outage detection (LED compatible). The BCM can then be reprogrammed with the correct software. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-08-47-001A > Jun > 10 > Body Controls - Unable To Reprogram Body Control Module Body Control Module: All Technical Service Bulletins Body Controls - Unable To Reprogram Body Control Module INFORMATION Bulletin No.: 09-08-47-001A Date: June 14, 2010 Subject: Unable to Reprogram Body Control Module (BCM), BCM Reprogramming Did Not Complete - Revised Reprogramming Instructions Models: 2006-2010 Buick Lucerne 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX 2008-2010 Cadillac CTS 2010 Cadillac CTS Wagon 2010 Chevrolet Camaro 2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Impala 2007-2010 Chevrolet Avalanche, Equinox, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet Traverse 2007-2010 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2008-2010 GMC Savana 2010 GMC Terrain 2007-2009 Pontiac Torrent 2008-2009 Pontiac G8 2008-2009 HUMMER H2 2007-2009 Saturn OUTLOOK 2008-2009 Saturn VUE Refer to GMVIS Supercede: This bulletin is being revised to update the models and the model years. Please discard Corporate Bulletin Number 09-08-47-001 (Section 08 - Body and Accessories). Some technicians may experience an unsuccessful body control module (BCM) reprogramming event, when choosing the Reprogram ECU selection on the Service Programming System (SPS). The technician may also notice that when attempting to reprogram the BCM again after this incident has occurred, the BCM may not complete the programming event. This condition may be caused by the following: - A reprogramming event that was interrupted due to a lack of communication between the vehicle and the TIS2WEB terminal. - The vehicle experienced low system voltage during the reprogramming event. Important Do not replace the BCM for this condition. SPS Programming Process Selection Perform this procedure first. 1. If reprogramming has failed during the initial reprogramming event, back out of the SPS application completely. 2. Re-select SPS from the TIS2WEB terminal application. 3. When selecting the Programming Process , choose Replace and Program ECU , even though a new BCM is NOT being installed. 4. Reprogram the BCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the SPS procedures in SI. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-08-47-001A > Jun > 10 > Body Controls - Unable To Reprogram Body Control Module > Page 5040 During programming, the battery voltage must be maintained within the proper range of 12-15 volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. BCM Still Fails to Reprogram If the BCM still fails to reprogram perform this procedure: 1. Turn OFF the ignition, and remove the key. 2. Remove the fuses that power up the following modules/components for a minimum of 2 minutes: - BCM - EBCM - ECM - IS LPS (located in the left IP fusebox) - TCM 3. Open and close the driver door. Allow enough time for the retained accessory power (RAP) to turn OFF. 4. Reinstall the fuses. 5. When selecting the Programming Process , choose Replace and Program ECU , even though a new BCM is NOT being installed. 6. Reprogram the BCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the SPS procedures in SI. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 07-08-46-002D > Jul > 09 > Audio System - Noise When Using OnStar(R) Electronic Noise Suppressor: All Technical Service Bulletins Audio System - Noise When Using OnStar(R) TECHNICAL Bulletin No.: 07-08-46-002D Date: July 29, 2009 Subject: Audio Whine Noise from Radio Speakers When Using OnStar(R) (Install Noise Suppression Filter) Models: 2007-2010 GM Passenger Cars and Trucks (Including Saturn) 2007-2010 HUMMER H2, H3 2007-2009 Saab 9-7X Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update the Warranty Information. Please discard Corporate Bulletin Number 07-08-46-002C (Section 08 - Body and Accessories). Condition Some customers may comment on an audio whine coming from the radio speakers when using the OnStar(R) system. The amplitude and frequency of the whine will change with an increase or decrease in engine speed. Cause This condition may be caused by electrical noise on the OnStar(R) Vehicle Communication Interface Module (VCIM) battery feed wire being passed to the microphone output pins at the radio. Correction Technicians are to install a noise suppression filter, P/N 1224205, into the OnStar(R) battery voltage circuit, a few centimeters (inches) from the VCIM. The filter package has three attached wires - a single yellow wire at one end with a yellow wire and a black wire at the other. Install the single yellow wire side into the battery voltage circuit towards the VCIM. Install the remaining single yellow wire into the battery voltage circuit toward the fuse and the black wire to ground. Important The noise suppression filter is polarity sensitive. The filter is designed to be most effective when the end with the capacitor ground is connected towards the source of the electrical noise. Install the filter in this polarity first. If the noise level is still not satisfactory, try disconnecting the capacitor ground. In some cases, if the first installation does not correct the noise, try reversing the filter polarity (removing the filter, turning it end for end and then reinstalling it) and grounding the capacitor lead. Parts Information Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table above. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 07-08-46-002D > Jul > 09 > Audio System - Noise When Using OnStar(R) > Page 5046 Warranty Information (Saab U.S. Models) Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 07-08-46-002D > Jul > 09 > Audio System - Noise When Using OnStar(R) > Page 5052 Warranty Information (Saab U.S. Models) Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 5053 Body Control Module: Diagrams Component Connector End Views Body Control Module (BCM) X1 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 5054 Body Control Module (BCM) X2 Body Control Module (BCM) X3 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 5055 Body Control Module (BCM) X4 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 5056 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 5057 Body Control Module (BCM) X5 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 5058 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 5059 Body Control Module (BCM) X6 Body Control Module (BCM) X7 (except MEX or A52) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 5060 Auxiliary Body Control Module (XBCM) X1 (EXP) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 5061 Auxiliary Body Control Module (XBCM) X2 (EXP) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 5062 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Auxiliary Body Control Module Replacement Body Control Module: Service and Repair Auxiliary Body Control Module Replacement Auxiliary Body Control Module Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Auxiliary Body Control Module Replacement > Page 5065 Body Control Module: Service and Repair Body Control Module Replacement Body Control Module Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Auxiliary Body Control Module Replacement > Page 5066 Body Control Module: Service and Repair Body Control Module Bracket Replacement Body Control Module Bracket Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Auxiliary Body Control Module Replacement > Page 5067 Body Control Module: Service and Repair Serial Data Gateway Module Replacement Serial Data Gateway Module Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Power-Up/Calibration ID Engine Control Module: Technical Service Bulletins Engine Controls - Aftermarket Power-Up/Calibration ID INFORMATION Bulletin No.: 08-06-04-006H Date: February 07, 2011 Subject: Information on Identifying Non-GM ECM Calibration Usages for Duramax(TM) Diesel Engines RPOs LBZ, LLY, LMM, LML, LGH and Power-up Hardware Detection for Duramax(TM) Diesel Engine RPO LMM - Photograph Tech 2(R) Calibration IDs and Calibration Verification Numbers (CVNs) and Transmission Data Screen Before Removing Engine/Transmission/Drivetrain Components Models: 2006-2011 Chevrolet Express, Kodiak, Silverado 2006-2011 GMC Savana, Sierra, TopKick Equipped With Duramax(TM) Diesel Engine RPOs LBZ, LLY, LMM, LML, LGH Please Refer to GMVIS Attention: In order to process an engine/transmission/drivetrain hard part WARRANTY CLAIM, you MUST photograph the required Tech 2(R) screen information BEFORE disassembly or removing engine/transmission/drivetrain components from the vehicle. Supercede: This bulletin is being revised to update the model years and RPOs. Please discard Corporate Bulletin Number 08-06-04-006G (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission, diesel oxidation catalyst (DOC) and exhaust particulate filter failures that are the result of non-GM (aftermarket Power-up Kits ) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine , transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage to the powertrain and driveline components whenever the presence of a non-GM calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of first sale, or subsequently updated by GM or its dealers with approved calibrations. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different than those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM issued engine control modifications do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines procedures to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine, transmission, transfer case or rear axle components, and before disassembly, repair or replacement of an engine, transmission, transfer case or rear axle assembly under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that the diesel oxidation catalyst (DOC) needs replacement. Note BEFORE authorizing any Duramax(TM) diesel engine or transmission replacement, the PQC will require digital photographs of the following Tech 2(R) screens: - For RPOs LLY and LBZ only: Calibration ID Numbers and Verification Numbers from the Vehicle Information screen - For RPO LMM only: Calibration ID Numbers and Verification Numbers from the Vehicle Information AND the Programming History screen. - For RPO LMM only: Transmission Data screen containing the Max Transmission Calc Engine Torque parameter. Symptoms Caused by Aftermarket Power-up Kit Some customers may have reprogrammed the engine control module (ECM) with a non-GM released calibration. The Power-Up Kit engine calibration changes fueling and timing parameters and likely contributes to the following vehicle conditions: - Poor performance - Driveability concerns - Increased emissions Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Power-Up/Calibration ID > Page 5072 - Black smoke (This symptom is not valid for the Duramax(TM) diesel engine RPO LMM equipped with the exhaust particulate filter. The filter will trap black smoke unless it is cracked, melted or has been removed from the exhaust system.) - Knocking noise - Engine damage (Refer to Corporate Bulletin Number 06-06-01-007C for additional information.) 2005-2007 RPO LLY and LBZ Instructions for Confirming Calibration Verification Numbers (CVNs) - Power-up Kit Detection Important In order to process an engine/transmission/drivetrain WARRANTY CLAIM , you MUST photograph the required Tech 2(R) screen information BEFORE disassembly or removing the engine/transmission/drivetrain components from the vehicle. 1. Go to TIS2WEB 2. Select: Calibration Information (SPS Info) 3. Enter the VIN 4. Select: Get Cal ID 5. Select: ECM Engine Control Module 6. Select: Next 7. Select: Complete History 8. Print 9. Take the printout to the vehicle along with the Tech 2(R) 10. Plug in the Tech 2(R) 11. Go to diagnostics and build the vehicle 12. Select: Powertrain 13. Select: Engine 14. *Select: Engine Control Module 15. *Select: Module ID Information or I/M Information System if Module ID Information selection is not available. 16. *If: I/M Information System was selected in step 15, it may be necessary to select: Vehicle Information in order to display the calibration information. *Steps may vary by engine controller. 17. Compare the Calibration ID and Calibration Verification Number (CVN) to the CVN shown on the TIS2WEB printout. Although the part numbers will be the same for each, it is the CVN that will determine if the calibration is GM issued. The CVNs should be the same. ‹› If the CVN information is displayed as "N/A" , it will be necessary to contact the TCSC to obtain the CVN information. ‹› If the part numbers match and ANY CVNs DO NOT match the printout, it is likely that a non-GM certified calibration has been installed. ‹› If ALL of the CVNs are EXACTLY the same the calibration is GM issued. Vehicle Information Screen 18. Take clear digital picture(s) of the Tech 2(R) Vehicle Information screen(s) showing the VIN, the Calibration IDs and the Verification Numbers. Retain the printout information and the Tech 2(R) screen photographs with the repair order. 1. E-mail copies of the digital pictures to [email protected]. In the subject line of the E-mail include the phrase "Duramax(TM) diesel", the complete VIN and Dealer BAC. In the body of the E-mail include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an email reply after the calibrations have been validated. The email reply will advise the dealer if the calibrations are OEM. 2. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 3. You may call the PQC two hours after submitting the required information for authorization to replace the assembly. This will provide them time to receive, review the information and set up a case on the request. Be prepared to provide all of the usual documentation that is normally Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Power-Up/Calibration ID > Page 5073 required when requesting an assembly authorization from the PQC. 2007-2011 RPO LMM Instructions for Confirming Calibration Verification Numbers (CVNs) Power-up Kit Detection Important In order to process an engine/transmission/drivetrain WARRANTY CLAIM , you MUST photograph the required Tech 2(R) screen information BEFORE disassembly or removing the engine/transmission/drivetrain components from the vehicle. For 2007-2011 applications, an engine control module (ECM) algorithm was implemented that records the engine calibration part number and calibration verification number (CVN) for the last 10 flash programming events. The ECM records the engine calibration part number because it contains the parameters for increasing torque and fueling rates. If a vehicle comes in for service for a driveability/powertrain concern as a result of a Power-Up Kit installation, the dealership technician can read the last 10 engine calibration part numbers and CVN history using a Tech 2(R). The dealership technician will input each ECM calibration part number into the TIS2WEB/SPS CVN database to confirm the CVN history information. Refer to the following Tech 2(R) path table to verify the ECM calibrations. 1. Build the vehicle with the Tech 2(R). 2. Select F0: Engine Control Module. 3. Select F5: Module Identification Information. 4. Select F1: Programming History. 5. Turn On the ignition, with the engine Off. 6. Press the ENTER Key to Continue. Important An original production engine operation part number programmed in the ECM from the supplier, which is the last part number shown, would not be in the TIS2WEB/SPS database. 7. Record the Calibration ID Numbers and Calibration Verification Numbers from the Tech 2(R) Programming History Screen. If the list of Calibration Part Numbers is less than 10, the first Calibration ID Number (bottom of the list) will not be in TIS2WEB/SPS CVN database. In this case, the first Calibration ID Number is programmed at the ECM production factory and is reprogrammed at the vehicle assembly plant. 8. From TIS2WEB/SPS, record the Calibration Part Number into the CVN Database. Get the CVN. ‹› If the CVN DOES NOT MATCH the CVN database, an unauthorized engine calibration part WAS PROGRAMMED into the ECM. ‹› If the CVN MATCHES the CVN database, the calibration/s are GM issued and an unauthorized engine calibration part WAS NOT used. Programming History Screen 9. Take a clear digital picture of the Tech 2(R) Programming History screen showing the VIN, Calibration IDs and the CVNs. Retain the printout information and the Tech 2(R) screen photograph with the repair order. Vehicle Information Screen 1. Take a clear digital picture of the Tech 2(R) Vehicle Information screen. Retain the printout information and the Tech 2(R) screen photograph with the repair order. 2. Take a clear digital picture of the Transmission Data screen that contains the Max Transmission Calc Engine Torque parameter. The path table is outlined in the following Instructions for Tech 2 Transmission Data Path section. Retain the Tech 2(R) Transmission Data screen photograph with the repair order. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Power-Up/Calibration ID > Page 5074 3. E-mail copies of the digital pictures to [email protected]. In the subject line of the E-mail include the phrase "Duramax(TM) diesel", the complete VIN and Dealer BAC. In the body of the E-mail include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an email reply after the calibrations have been validated. The email reply will advise the dealer if the calibrations are OEM. 4. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 5. You may call the PQC two hours after submitting the required information for authorization to replace the assembly. This will provide them time to receive, review the information and set up a case on the request. Be prepared to provide all of the usual documentation that is normally required when requesting an assembly authorization from the PQC. 2007-2011 RPO LMM Instructions for Tech 2 Transmission Data Path - Power-up Hardware Detection Transmission Data ONLY Available With GMC Sierra, TopKick, Chevrolet Kodiak, Silverado An example of this hardware is a propane injection system. A transmission control module (TCM) algorithm has been implemented that records a maximum calculated input torque. This information is available via the Tech 2(R). 1. Build the vehicle with the Tech 2(R). 2. Select F3: Transmission Control Module 3. Select F1: Data Display 4. Select F0: Transmission Data 5. Highlight: Max Transmission Calc Engine Torque Transmission Data Screen (Max. Trans Calc. Engine Torque Parameter) 6. Take a clear digital picture of the Tech 2(R) screen showing the Transmission Data and the Max Transmission Calc Engine Torque parameter. 7. Retain the Tech 2(R) Transmission Data screen photograph with the repair order. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Power-Up/Calibration ID > Page 5075 Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Power-Up/Calibration ID > Page 5076 Engine Control Module: Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Power-Up/Calibration ID > Page 5077 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Power-Up/Calibration ID > Page 5078 Engine Control Module: Technical Service Bulletins Diesel Engine - Damage Due To Power-Up Devices INFORMATION Bulletin No.: 06-06-01-007F Date: March 31, 2010 Subject: Information On Identifying Duramax(TM) Diesel LB7, LLY, LMM, LBZ Overpower Engine Breakdown or Non-Function Due to Aftermarket Power-Up Devices vs. Non Overpower Engine Non-Function of Pistons, Cylinders, Valvetrain Components and/or Turbocharger DTC P003A Set Models: 2001-2010 Chevrolet Silverado 2003-2009 Chevrolet Kodiak 2006-2010 Chevrolet Express 2001-2010 GMC Sierra 2003-2009 GMC TopKick 2006-2010 GMC Savana Equipped With Duramax(TM) Turbocharged Diesel Engine RPOs LB7, LLY, LMM, LBZ Please Refer to GMVIS Supercede: This bulletin is being revised to add text to the end of the Caution statement. Please discard Corporate Bulletin Number 06-06-01-007E (Section 06 - Engine/Propulsion System). Caution Customers should be informed if a hard part failure is observed in the engine, transmission, transfer case and/or other driveline components, it is likely that powertrain components were weakened to the point of premature failure, while subjected to the higher stresses from Aftermarket Power-Up Devices. Failures associated with the installation of Aftermarket Power-Up Devices, which have been verified, are not covered under the terms of the New Vehicle Warranty. In the majority of these cases, the Fixed Operations Manager (FOM) (in Canada, Warranty Manager) should be contacted and the remaining portion of the powertrain portion of the New Vehicle Warranty blocked. GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage. General Motors Position On Aftermarket Power-Up Devices Important General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. Refer to Service Bulletin Number 04-06-04-054A or newer - Warranty Admin. - Non-GM Parts and Accessories (Aftermarket). Important For further information on aftermarket power-up kits, refer to February 2006 Emerging Issues Course Number 10206.02D. In Canada, information on aftermarket power-up kits was covered in the April 2006 TAC TALK program. Aftermarket power-up devices are non-approved by General Motors. These devices are usually piggy-backed in the main engine harness or remain connected to the diagnostic connector to upload the calibration to the ECM. Recent warranty reviews of returned engines show engine breakdown or non-function due to power-up devices that are utilized for increased horsepower and torque. The following information will assist technicians in identifying overpower engine breakdown or non-function due to aftermarket power-up devices vs. non overpower engine breakdown or non-function. Non-GM parts can alter the design of the vehicle. GM dealers need to be aware of the quality of parts being installed on vehicles. If failure occurs as a result of installation of sub-par parts, warranty coverage may be denied. Refer to Service Bulletin Number 04-06-04-054A or newer Warranty Admin. - Non-GM Parts and Accessories (Aftermarket). Installed Power-Up Kit Aftermarket power-up kits have become a very popular add on for performance-minded customers. These devices can add horsepower and torque and can add additional stress to the engine. These aftermarket calibrations take the Duramax(TM) powertrain outside of its design torque and horsepower rating. They do this by altering air/fuel ratios and injector timing, resulting in excessive cylinder pressure and temperature. When these calibrated parameters are altered, it will upset the design balance and can lead to a reduction of engine life expectancy. Generally, in inspection of Duramax(TM) engine failure due to power-up failures, two or more cylinders will be affected. Installed Power-Up Kit - Once installed, the calibration may mask itself with the factory original calibration ID and may remain the same. Refer to Service Bulletin Number 08-06-04-006F or newer - Information on Identifying Non-GM Calibration Usage for LMM Duramax(TM) Diesel Engine. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Power-Up/Calibration ID > Page 5079 - A Tech 2(R) will not positively enable you to identify the use of a power-up device. - Some companies that offer power-up devices claim increases of 150 or more horsepower and 300 or more lb/ft pounds of torque. - A vehicle that is used to the power-up device potential 100% of the time will see earlier engine wear and breakdown. - A vehicle that takes advantage of additional power, but on a less frequent basis, may not see premature engine wear and breakdown until later in the engine's life. - A vehicle not pushed to its limits of the power-up device often may not encounter premature wear and breakdown until after the engine is out of warranty. Duramax(TM) Powertrain Horsepower / Torque Ratings The following horsepower and torque increase over the past years required new internal components to accommodate the increase. - LB7 - 300 hp with 520 ft/lb of torque for model years 2000-2004 - LLY - 310 hp with 605 ft/lb of torque for model years 2004-2008 - LBZ - 360 hp with 650 ft/lb of torque for model year 2006-2008 - LMM - 365 hp with 660 ft/lb of torque for model year 2007-2009 LBZ Improvements To reliably achieve an increase in 50 horsepower with 45 ft/lb torque, the Duramax (TM) diesel had to be revised in many areas. A few of the revisions on the 2006 LBZ were: - New pistons with a revised compression ratio. - Wrist pins that are larger in diameter. - Connecting rods with added material to increase the I section strength. - Engine block and machining changes - Cylinder heads Duramax(TM) Life Expectancy The Duramax(TM) 6.6L V8 Turbo Diesel Engine is sold with a warranty of 100,000 miles/160,000 kilometers. The Duramax(TM) has been tested to survive upwards of 200,000 miles/320,000 kilometers. The Duramax(TM) powertrain is designed for reliability, peak horsepower and torque within its design limits. When a customer installs a power-up device, it drastically reduces the mileage ratings. Important Cylinder Wall Spotting (commonly referred to leopard spots) is from the induction hardening process of the top 1/3 of the cylinder wall. This is normal for the Duramax (TM) Diesel. Identifying Fuel Related Aftermarket Power-Up Devices Aftermarket companies have developed a performance pressure relief fuel valve for Duramax(TM) diesel engines. Refer to above graphic illustration. The performance pressure relief fuel valve attaches to the fuel rail in place of the OEM valve and will not allow any fuel return to the tank, giving 100% of the fuel to be available for additional engine performance. This may cause additional fuel related driveability concerns and may set the following DTCs: - DTC P1093 Fuel Rail Pressure (FRP) Low During Power Enrichment - DTC P0087 Fuel Rail Pressure (FRP) Too Low Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Power-Up/Calibration ID > Page 5080 Aftermarket companies have developed a replacement performance/economy fuel injector nozzle. Refer to above illustration. The performance/economy fuel injector nozzles replace the OEM fuel injector nozzles. The aftermarket companies claim increased horsepower, improved fuel atomization, lower exhaust gas temperatures and increase fuel economy. This may cause additional fuel related driveability concerns and may cause internal engine damage to the pistons and fuel injector nozzles. Identifying Overpower Engine Premature Wear and Breakdown When premature wear and breakdown is encountered due to an aftermarket power-up device, it has some very specific characteristics to the internal engine components. The following list will assist in identifying these characteristics as you tear down the engine. - Pistons will be cracked in the lip area, or a hole in the pistons. - Pistons can also be melted on the lip of the combustion bowl, or the top of the pistons can be melted. - Crosshatch will be polished off the cylinder wall in the major thrust face of cylinder below ring belt travel. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Power-Up/Calibration ID > Page 5081 - Piston pin bore will show signs of scoring, the wrist pins will be discolored, and can have oil coking on them. The connecting rod bushing surface will have accelerated wear. The above illustration shows a connecting rod bushing. - Oil coking on the underside of the piston between the wrist pin bosses. - Signs of bearing fretting will also be noticed on the connecting rod and main bearing caps. Refer to the above illustration for fretting of main bearing cap 1 and back side of connection rod bearing 2. - Excessive heat in engine compartment caused by overpower device. Refer to above illustration (1). Non Overpower Engine Premature Wear and Breakdown The following pictures show results of overheat, overspeed, low/no oil pressure or injector breakdown and how they differ from aftermarket power-up device premature wear and breakdown. Engine Overheat Overheat can be caused by a loss of coolant or a general cooling system failure. Some of the indicators of overheat are: Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Power-Up/Calibration ID > Page 5082 - Melted pistons. - Head gasket breakdown or non-function. - Warped cylinder heads. - Crankshaft and connecting rod discolored. Engine Overspeed Causes If an engine has been run faster than design capability (redline), and has caused damage as a result, it may be a result of one of the following conditions: - Leaking or failed turbocharger (TC) oil seals. - Oil evident in the intake runners and compressor side of the TC. - Starting fluid use or alternative fuel added to the engine such as ether. Engine Overspeed Results The following are indicators that an overspeed event took place: - Valve train damage. - Pushrods that are bent (4). - Broken valve bridge buttons after cylinder head removal (2). - Rocker arm tip damage (1). - Dry or rusted cylinders from the use of ether, propane or nitrous oxide. - Piston to valve contact. - Cam gear pin shear. Lack of Oil Pressure Lack of lubrication causes rapid bearing wear or bearing to seize. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Power-Up/Calibration ID > Page 5083 Bearing failure. Spun main bearings. Engine Premature Wear and Breakdown Due to Improper Function of Fuel Injector A fuel injector may fracture a piston or melt a piston but the damage will be limited to that cylinder only and all other pistons and cylinder walls are OK. In some cases hydraulic lock will occur on the suspected cylinder with an over-fueling fuel injector. Hydraulic lock on the suspected cylinder will cause a bent connecting rod. This can be verified with piston protrusion measurements. 2007-2010 RPO LMM Only Turbocharger DTC P003A Set General Motors has identified a turbocharger (TC) failure mode involving Power-Up Kits that causes soot leakage and DTC P003A to be set. The Power-Up Kits create an overtemperature condition from the increased exhaust gas temperatures that results in a permanent and excessive turbine housing distortion at the TC case halves. 1. A technician may observe one or more of the following conditions: - DTC P003A being set as Current or in History. - An unusual odor emanating from the TC due to an overtemperature condition. - Soot leaking and accumulating at the V-band clamp that secures the TC case halves together. - Limited or unresponsive travel when Commanding the TC Vane Pos. Ctrl. Solenoid ON and OFF with a scan tool. 2. If DTC P003A is found as Current or in History, OR there is evidence of soot leakage (1) in the area of the V-band clamp (1), then technicians MUST verify if the engine control module (ECM) has a Power-Up Kit aftermarket calibration installed or an aftermarket hardware device has been installed. Refer to Service Bulletin Number 08-06-04-006F or newer for the calibration verification information and procedures. How to Handle a Suspect Engine Failure Due to a Power-Up Device Dealers should not automatically decline warranty assistance on engine failures due to the fact that a power-up device or modification is evident or suspected. The technician must identify that the failure is due to a power-up device by teardown analysis and diagnosis of the engine components. The following steps should be taken if an engine failure occurs and it is suspected that the modification or addition of a power-up device maybe the cause of the engine failure. If unclear of this process or direction feel free to contact your Fixed Operations Manager (in Canada, Warranty Manager) for further support. 1. The technician should use proper engine diagnostics to lead him/her to the failed engine components. The Aftermarket Power-Up Kit Check List should be followed and if it is determined that at least three of the Aftermarket Power-Up Kit Check List items match the engine component failures then it can be decided that the failure is not a warrantable claim. 2. Engine failures that meet at least three criteria of the Aftermarket Power-Up Kit Check List are considered failures that are not manufacturer's defects in workmanship or materials. 3. The dealership should contact the PQC, open a case to review the findings and make the final decision on warranty coverage. The Fixed Operations Manager (in Canada, Warranty Manager) should be notified of the PQC decision. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Power-Up/Calibration ID > Page 5084 4. Denied claims should be documented as follows: 1. The Aftermarket Power-Up Kit Check List completed with the technicians detailed written findings of the diagnosis on the repair order and retained in the repair order file. 2. Photographs of the failed parts should be retained in the repair order file. 5. The customer should be advised that the failure of their engine was not due to a manufacturer's defect in workmanship or materials and therefore the warranty claim is denied on this failure. Aftermarket Power-Up Kit Check List Important Print and use this aftermarket power-up kit check list when performing an engine disassembly investigation of overpower engine breakdown or non-function. Retain a copy of this checklist and photographs of the failed parts in the repair order file. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 5085 Engine Control Module: Locations Harness Routing Views Engine Harness Routing - Left Front Side (4.8L/5.3L/6.0L/6.2L except LFA/HP2) 1 - Air Intake Duct 2 - X111 3 - Fuse Block - Underhood X2 4 - X109 5 - X110 (NQF/NQG/NQH) 6 Engine Control Module (ECM) X2 7 - Engine Control Module (ECM) X1 8 - G102 9 - J105 Engine Chassis Harness Routing - Top Front (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 5086 1 - Battery - Right 2 - Fuse Holder 3 - X127 4 - X108 5 - X107 6 - X123 (PTO) 7 - Fuse Block Underhood 8 - X109 9 - Battery - Left 10 - Engine Control Module (ECM) 11 - Transmission Control Module (TCM) Engine Harness Routing - Top (4.3L) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 5087 1 - Mega Fuse Ring Terminal 2 - X175 (M30) 3 - J128 4 - J105 5 - J106 6 - J130 (M30 with NQG/NQH) 7 - Engine Control Module (ECM) X1 8 - Engine Control Module (ECM) X2 9 - G103 10 - X112 11 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Connector Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 5088 Engine Control Module: Diagrams Component Connector End Views Engine Control Module (ECM) X1 (LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 5089 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 5090 Engine Control Module (ECM) X1 (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 5091 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 5092 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 5093 Engine Control Module (ECM) X1 (LY2, LMG, LC9, LY5, LH6, L76 or L9H) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 5094 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 5095 Engine Control Module (ECM) X1 (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 5096 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 5097 Engine Control Module (ECM) X1 (LY6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 5098 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 5099 Engine Control Module (ECM) X2 (LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 5100 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 5101 Engine Control Module (ECM) X2 (LY2, LY6 or L9H with Y91) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 5102 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 5103 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 5104 Engine Control Module (ECM) X2 (LMG, LC9, LY5, LH6, L76 or L9H without Y91) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 5105 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 5106 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 5107 Engine Control Module (ECM) X2 (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 5108 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 5109 Engine Control Module (ECM) X2 (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 5110 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 5111 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 5112 Engine Control Module (ECM) X3 (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 5113 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 5114 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Engine Control Module Description Engine Control Module: Description and Operation Engine Control Module Description Engine Control Module Description The powertrain has electronic controls to reduce exhaust emissions while maintaining excellent driveability and fuel economy. The engine control module (ECM) is the control center of this system. The ECM monitors numerous engine and vehicle functions. The ECM constantly monitors information from various sensors and other inputs, and controls the systems that affect vehicle performance and emissions. The ECM also performs diagnostic tests on various parts of the system. The ECM can recognize operational problems and alert the driver via the malfunction indicator lamp (MIL). When the ECM detects a malfunction, the ECM stores a diagnostic trouble code (DTC). The problem area is identified by the particular DTC that is set. The control module supplies a buffered voltage to various sensors and switches. Review the components and wiring diagrams in order to determine which systems are controlled by the ECM. Malfunction Indicator Lamp (MIL) Operation The malfunction indicator lamp (MIL) is located in the instrument panel cluster. The MIL will display as either SERVICE ENGINE SOON or one of the following symbols when commanded ON: The MIL indicates that an emissions related fault has occurred and vehicle service is required. The following is a list of the modes of operation for the MIL: * The MIL illuminates when the ignition is turned ON, with the engine OFF. This is a bulb test to ensure the MIL is able to illuminate. * The MIL turns OFF after the engine is started if a diagnostic fault is not present. * The MIL remains illuminated after the engine is started if the control module detects a fault. A diagnostic trouble code (DTC) is stored any time the control module illuminates the MIL due to an emissions related fault. The MIL turns OFF after three consecutive ignition cycles in which a Test Passed has been reported for the diagnostic test that originally caused the MIL to illuminate. * The MIL flashes if the control module detects a misfire condition which could damage the catalytic converter. * When the MIL is illuminated and the engine stalls, the MIL will remain illuminated as long as the ignition is ON. * When the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition is cycled OFF and then ON. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Engine Control Module Description > Page 5117 Engine Control Module: Description and Operation Engine Idle Control System Description Engine Idle Control System Description High Idle Switch The high idle switch will slowly increase engine RPM to the calibrated high idle speed when depressed. The high idle speed can be programmed by using a scan tool. Refer to High Idle Switch Programming (See: Fuel Delivery and Air Induction/Idle Speed/Service and Repair). If the High Idle Switch is not operating as desired, refer to High Idle Switch Diagnosis (See: Testing and Inspection/Component Tests and General Diagnostics/High Idle Switch Diagnosis). Manual High Idle The diesel engine has a high idle system to improve the warm-up time of the engine in cold weather conditions. This system allows the engine control module (ECM) to increase the idle speed above the normal calibrated value. The ECM increases the idle speed using the following adjustments: * The fuel injection timing is changed * The fuel injection quantity is changed * The turbocharger vane position is commanded closed-The vane position will be farther closed than any other normal operating condition. The instrument panel will indicate the high idle system is active one of two ways: * The driver information center (DIC) will indicate an active high idle system on light duty trucks. * An indicator lamp will flash on medium duty trucks. * The manual high idle feature comes enabled from the factory. The Elevated Idle function in the scan tool will disable or enable this feature. If the engine does not increase to the calibrated high idle speed after the procedure is performed, use the scan tool to verify the Elevated Idle speed feature is enabled. Manual High Idle Speed Enable and Disable To enable or disable the manual high idle system perform the following procedure: 1. Turn the ignition ON, with the engine OFF. 2. Depress the accelerator pedal to the floor and hold down. 3. While the accelerator pedal is depressed, depress the brake pedal 3 times in less than 8 seconds. 4. Release the accelerator pedal. 5. Start the engine. When the procedure is followed the engine idle speed will slowly increased to the calibrated high idle speed. This is 1,200 RPM for light duty, and 1,500 RPM for medium duty trucks. The idle speed will return to normal if any of the following conditions occur: * There is brake, clutch, or throttle input from the driver. * The automatic transmission is shifted out of Park or Neutral. * The air temperature is more than 7°C (45°F). * The engine coolant temperature (ECT) is more than 68°C (154°F). * The vehicle speed exceeds 0 km/h (0 mph). The high idle system will reactivate automatically when the following conditions occur: * The engine has been idling for more than 30 seconds. * The transmission is placed in Park or Neutral. * The vehicle speed is 0 km/h (0 mph). * The ambient air temperature is less than 3°C (37°F). * The ECT is less than 68°C (154°F). * The brake, clutch and throttle pedals are not depressed. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 5118 Engine Control Module: Service and Repair Engine Control Module Replacement Caution: * Turn the ignition OFF when installing or removing the control module connectors and disconnecting or reconnecting the power to the control module (battery cable, powertrain control module (PCM)/engine control module (ECM)/transaxle control module (TCM) pigtail, control module fuse, jumper cables, etc.) in order to prevent internal control module damage. * Control module damage may result when the metal case contacts battery voltage. DO NOT contact the control module metal case with battery voltage when servicing a control module, using battery booster cables, or when charging the vehicle battery. * In order to prevent any possible electrostatic discharge damage to the control module, do no touch the connector pins or the soldered components on the circuit board. * Remove any debris from around the control module connector surfaces before servicing the control module. Inspect the control module connector gaskets when diagnosing or replacing the control module. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant intrusion into the control module. * The replacement control module must be programmed. Note: Before removing the engine control module (ECM), use the scan tool to capture the ECM data. This captured data will then need to be restored into the NEW ECM. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning). Removal Procedure 1. Using a scan tool, capture the ECM data. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 3. Disconnect the ECM electrical connectors (2). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 5119 4. Release the ECM upper retaining tabs. 5. Remove the ECM from the bracket. Installation Procedure 1. Place the bottom edge of the ECM into the bracket lower retainers. 2. Push the ECM towards the bracket until the upper edge of the ECM snaps into place. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 5120 3. Connect the ECM electrical connectors (2). 4. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 5. If a NEW ECM was installed, program the ECM. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 5124 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 5125 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 5126 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 5127 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 5128 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 5129 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 5130 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations Accelerator Pedal Position Sensor: Locations Harness Routing Views Brake Clutch Harness Routing 1 - Driver Door Frame 2 - X205 3 - X102 (JL1) 4 - Accelerator Pedal Position (APP) Sensor Connector 5 - Junction Block - Left I/P (except MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 5135 Accelerator Pedal Position Sensor: Diagrams Component Connector End Views Accelerator Pedal Position (APP) Sensor Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 5136 Accelerator Pedal Position Sensor: Description and Operation Accelerator Pedal Position System Description The accelerator pedal position (APP) sensor is mounted inside the accelerator pedal control assembly. The sensor is made up of the two individual sensors within a single housing. Each sensor has a unique functionality to determine pedal position. The accelerator pedal position (APP) system along with the engine control module (ECM) is used to calculate and control the amount of acceleration and deceleration through fuel injector control. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 5137 Accelerator Pedal Position Sensor: Service and Repair Accelerator Pedal Position Sensor Replacement Removal Procedure Caution: Handle the electronic throttle control components carefully. Use cleanliness in order to prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the electronic throttle control components. Do not immerse the electronic throttle control components in cleaning solvents of any type. 1. Remove the connector position assurance (CPA) retainer. 2. Disconnect the accelerator pedal position (APP) sensor electrical connector (1). 3. Remove the accelerator pedal bolts. 4. Remove the accelerator pedal. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 5138 Installation Procedure 1. Position the accelerator pedal to the accelerator pedal bracket. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the accelerator pedal bolts and tighten to 9 Nm (80 lb in).. 3. Connect the APP sensor electrical connector (1). 4. Install the CPA retainer. 5. Connect a scan tool to the diagnostic port in order to test for proper throttle-opening and throttle-closing range. 6. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle, and a wide open throttle (WOT). 7. Verify that the vehicle meets the following conditions: * The vehicle is not in a reduced engine power mode. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 5139 * The ignition is ON. * The engine is OFF. 8. Inspect the carpet fit under the accelerator pedal. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations Air Flow Meter/Sensor: Locations Harness Routing Views Engine Harness Routing - Top (4.3L) 1 - Mega Fuse Ring Terminal 2 - X175 (M30) 3 - J128 4 - J105 5 - J106 6 - J130 (M30 with NQG/NQH) 7 - Engine Control Module (ECM) X1 8 - Engine Control Module (ECM) X2 9 - G103 10 - X112 11 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Connector Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 5143 Air Flow Meter/Sensor: Diagrams Component Connector End Views Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (Diesel) Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (Gas) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 5144 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 5145 Air Flow Meter/Sensor: Service and Repair Mass Airflow Sensor with Intake Air Temperature Sensor Replacement Removal Procedure 1. Disconnect the engine wiring harness electrical connector (1) from the mass air flow (MAF)/intake air temperature (IAT) sensor. 2. Remove the MAF/IAT sensor TORX(R) screws. 3. Remove the MAF/IAT sensor. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Locations > Page 5146 1. Install the MAF/IAT sensor. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the MAF/IAT sensor TORX(R) screws. Tighten the screws to 8 Nm (70 lb in). 3. Connect the engine wiring harness electrical connector (1) to the MAF/IAT sensor. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Current Sensor > Component Information > Diagrams Battery Current Sensor: Diagrams Component Connector End Views Battery Current Sensor (10 Series without MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Current Sensor > Component Information > Diagrams > Page 5150 Battery Current Sensor: Service and Repair Battery Current Sensor Replacement Removal Procedure 1. Remove the negative battery cable. Refer to Battery Negative Cable Replacement (V6) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Replacement (V8) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Replacement (Diesel) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 2. Mark the location of the battery current sensor on the battery cable with tape for reference during installation. 3. Remove the tape securing the battery current sensor to the negative battery cable. 4. Mark the location of the negative battery cable clips (1) and remove the clips from the cable. 5. Squeeze the negative battery cable branches together. Important: Note the orientation of the battery current sensor prior to removal. 6. Slide the battery current sensor (2) off of the negative battery cable. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Current Sensor > Component Information > Diagrams > Page 5151 1. Squeeze the negative battery cable branches together. Important: Ensure the battery current sensor is installed in the correct direction and location on the negative battery cable. 2. Slide the NEW battery current sensor (2) up onto the negative battery cable to the location previously marked during removal. 3. Wrap electrical tape around the battery current sensor leg in order to secure the sensor to the negative battery cable. 4. Install the negative battery cable clips (1) to the cable to the locations previously marked during removal. 5. Install the negative battery cable. Refer to Battery Negative Cable Replacement (V6) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Replacement (V8) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Replacement (Diesel) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Harness Routing Views Camshaft Position Sensor Jumper Harness Routing (4.8L/5.3L/6.0L/6.2L) 1 - X112 2 - Camshaft Position Sensor Jumper Harness Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 5155 Camshaft Position Sensor: Diagrams Component Connector End Views Camshaft Position (CMP) Actuator Solenoid Valve (LZ1, LY6, L96 or L9H) Camshaft Position (CMP) Sensor (LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 5156 Camshaft Position (CMP) Sensor (Gas except LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 5157 Camshaft Position (CMP) Sensor (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 5158 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 5159 Camshaft Position Sensor: Service Precautions Camshaft Position Actuator Removal and Installation Warning Warning Do not push or pull on the reluctor wheel of the camshaft position (CMP) actuator during removal or installation. The reluctor wheel is retained to the front of the CMP actuator by 3 roll pins. Pushing or pulling on the wheel may dislodge the wheel from the front of the actuator. The actuator return spring is under tension and may rotate the dislodged reluctor wheel, causing personal injury. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 5160 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor Replacement Removal Procedure 1. Remove the cooling fan pulley. Refer to Fan Pulley Replacement (See: Engine, Cooling and Exhaust/Cooling System/Radiator Cooling Fan/Service and Repair). 2. Remove the camshaft position (CMP) sensor bolt. 3. Remove the CMP sensor. Installation Procedure 1. Lubricate the CMP sensor O-ring with clean engine oil. 2. Install the CMP sensor. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 5161 3. Install the CMP sensor bolt. Tighten the bolt to 10 Nm (89 lb in). 4. Install the cooling fan pulley. Refer to Fan Pulley Replacement (See: Engine, Cooling and Exhaust/Cooling System/Radiator Cooling Fan/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Clutch Switch, ECM > Component Information > Diagrams Clutch Switch: Diagrams Component Connector End Views Clutch Pedal Position (CPP) Switch (TZ0) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps Coolant Temperature Sensor/Switch (For Computer): Customer Interest Engine - MIL ON P0116/P1400 Set In Very Cold Temps TECHNICAL Bulletin No.: 10-06-04-008A Date: January 24, 2011 Subject: Malfunction Indicator Lamp (MIL) Illuminated at Very Cold Ambient Temperatures When Using Engine Coolant Heater, DTC P0116 and/or P1400 Set (Relocate Engine Coolant Temperature (ECT) Sensor and Engine Coolant Heater Cord) Models: 2006-2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2006-2010 Cadillac Escalade 2006-2007 Chevrolet Monte Carlo 2006-2009 Chevrolet Impala SS, TrailBlazer 2006-2010 Chevrolet Avalanche, Express, Silverado Tahoe 2006-2009 GMC Envoy 2006-2010 GMC Savana, Sierra, Yukon 2006-2008 Pontiac Grand Prix 2006-2009 Saab 9-7X Equipped with V8 Engine RPO LC9, LH6, LH8, LH9, L76, LS2, LS4, LFA, LZ1, L92, L94, L9H or L20, L96, LMF, LMG, LY2, LY5, LY6 Please Refer to GMVIS Attention: To properly correct this condition, you must follow both of the procedures to relocate the ECT sensor and the engine coolant heater cord. Supercede: This bulletin is being revised to add cast iron block engine RPOs and to update the Warranty Information coverage period. Please discard Corporate Bulletin Number 10-06-04-008 (Section 06 - Engine/Propulsion System). Condition Some customers may comment that the malfunction indicator lamp (MIL) illuminates after starting the vehicle when they were using the engine coolant heater in very cold ambient temperatures. This usually occurs in a range of -23 to -40°C (-10 to -40°F) or colder. The technician may observe on a scan tool DTC P0116 and/or P1400 set as Current or in History. Cause This condition may be caused by the engine control module (ECM) determining that the ignition OFF time requirement has been met at start-up and interpreting the temperature difference between the engine coolant temperature (ECT) sensor and the intake air temperature (IAT) sensor as being outside of a calibrated range. Correction Important DO NOT replace the ECM for this condition. Relocating the ECT Sensor 1. Turn ON the ignition with the engine OFF. 2. Perform the diagnostic system check - vehicle. Refer to Diagnostic System Check - Vehicle in SI. ‹› If DTC P0116 and/or P1400 are set and the customer WAS using the engine coolant heater, proceed to Step 3. ‹› If DTC P0116 and/or P1400 are set and the customer WAS NOT using the engine coolant heater, refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. 3. Turn OFF the ignition. Warning To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 5173 under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator are still hot. 4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle. Refer to Cooling System Draining and Filling in SI. 7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor. 10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J 38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle. 13. Disconnect the wiring harness connector from the ECT sensor (2). 14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT sensor in the hole of the cylinder head where the plug was removed. Tighten Tighten to 20 Nm (15 lb ft). 18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was removed Tighten Tighten to 20 Nm (15 lb ft). Important Leave enough wire attached to the ECT sensor harness connector in order to create manageable splices that are at least 40 mm (1.5 in) away from the other splice. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 5174 20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit. Cut off the ECT sensor harness connector and wiring. 21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured TO or WITHIN an existing protective conduit. Note This step is to set up and verify the length of wiring that is required before cutting. 22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the appropriate length. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. 26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit using tie straps. Important You MUST run the engine at the specified RPM and until it reaches normal operating temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool down in order to top off the coolant level as needed. 28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI. 29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan tool to clear any DTCs. Relocating the Engine Coolant Heater Cord Important For reference, the procedure and graphics that are shown are from a Chevrolet Silverado, but are similar for the other vehicles listed above. 1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit from the engine compartment in order to determine the required extension cord length. 3. Obtain an extension cord with the following features: - 120 volt - 14/3 gauge - 15A capacity - Three prong - Polarized plug and receptacle - Chemical resistant - Grounded terminals - Designed for use in a cold outdoor environment - Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight - Maximum length of 2.5-3 m (8-10 ft) 4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N 12345579 (in Canada, use P/N 10953481) or an equivalent. 6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 5175 7. Wrap electrical tape around the connection as shown. 8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to the engine coolant crossover pipe as shown. 9. Continue to route the extension cord to the exit location desired by the customer as shown. 10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the engine coolant heater cord to the vehicle that were released to provide length. Part Information The extension cord may be obtained at any of the following outlets: - Lowes* - Home Depot* - Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number: CWRSJTOW3C14-10 USA: Cords should bear the UL symbol. Canada: Cords should bear the ULc symbol or CSA approval. *We believe these sources and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from these firms or for any such items that may be available from other sources. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Customer Interest for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 5176 Warranty Information (excluding Saab Models) For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps Coolant Temperature Sensor/Switch (For Computer): All Technical Service Bulletins Engine - MIL ON P0116/P1400 Set In Very Cold Temps TECHNICAL Bulletin No.: 10-06-04-008A Date: January 24, 2011 Subject: Malfunction Indicator Lamp (MIL) Illuminated at Very Cold Ambient Temperatures When Using Engine Coolant Heater, DTC P0116 and/or P1400 Set (Relocate Engine Coolant Temperature (ECT) Sensor and Engine Coolant Heater Cord) Models: 2006-2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2006-2010 Cadillac Escalade 2006-2007 Chevrolet Monte Carlo 2006-2009 Chevrolet Impala SS, TrailBlazer 2006-2010 Chevrolet Avalanche, Express, Silverado Tahoe 2006-2009 GMC Envoy 2006-2010 GMC Savana, Sierra, Yukon 2006-2008 Pontiac Grand Prix 2006-2009 Saab 9-7X Equipped with V8 Engine RPO LC9, LH6, LH8, LH9, L76, LS2, LS4, LFA, LZ1, L92, L94, L9H or L20, L96, LMF, LMG, LY2, LY5, LY6 Please Refer to GMVIS Attention: To properly correct this condition, you must follow both of the procedures to relocate the ECT sensor and the engine coolant heater cord. Supercede: This bulletin is being revised to add cast iron block engine RPOs and to update the Warranty Information coverage period. Please discard Corporate Bulletin Number 10-06-04-008 (Section 06 - Engine/Propulsion System). Condition Some customers may comment that the malfunction indicator lamp (MIL) illuminates after starting the vehicle when they were using the engine coolant heater in very cold ambient temperatures. This usually occurs in a range of -23 to -40°C (-10 to -40°F) or colder. The technician may observe on a scan tool DTC P0116 and/or P1400 set as Current or in History. Cause This condition may be caused by the engine control module (ECM) determining that the ignition OFF time requirement has been met at start-up and interpreting the temperature difference between the engine coolant temperature (ECT) sensor and the intake air temperature (IAT) sensor as being outside of a calibrated range. Correction Important DO NOT replace the ECM for this condition. Relocating the ECT Sensor 1. Turn ON the ignition with the engine OFF. 2. Perform the diagnostic system check - vehicle. Refer to Diagnostic System Check - Vehicle in SI. ‹› If DTC P0116 and/or P1400 are set and the customer WAS using the engine coolant heater, proceed to Step 3. ‹› If DTC P0116 and/or P1400 are set and the customer WAS NOT using the engine coolant heater, refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. 3. Turn OFF the ignition. Warning To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 5182 under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator are still hot. 4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle. Refer to Cooling System Draining and Filling in SI. 7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor. 10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J 38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle. 13. Disconnect the wiring harness connector from the ECT sensor (2). 14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT sensor in the hole of the cylinder head where the plug was removed. Tighten Tighten to 20 Nm (15 lb ft). 18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was removed Tighten Tighten to 20 Nm (15 lb ft). Important Leave enough wire attached to the ECT sensor harness connector in order to create manageable splices that are at least 40 mm (1.5 in) away from the other splice. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 5183 20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit. Cut off the ECT sensor harness connector and wiring. 21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured TO or WITHIN an existing protective conduit. Note This step is to set up and verify the length of wiring that is required before cutting. 22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the appropriate length. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. 26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit using tie straps. Important You MUST run the engine at the specified RPM and until it reaches normal operating temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool down in order to top off the coolant level as needed. 28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI. 29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan tool to clear any DTCs. Relocating the Engine Coolant Heater Cord Important For reference, the procedure and graphics that are shown are from a Chevrolet Silverado, but are similar for the other vehicles listed above. 1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit from the engine compartment in order to determine the required extension cord length. 3. Obtain an extension cord with the following features: - 120 volt - 14/3 gauge - 15A capacity - Three prong - Polarized plug and receptacle - Chemical resistant - Grounded terminals - Designed for use in a cold outdoor environment - Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight - Maximum length of 2.5-3 m (8-10 ft) 4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N 12345579 (in Canada, use P/N 10953481) or an equivalent. 6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 5184 7. Wrap electrical tape around the connection as shown. 8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to the engine coolant crossover pipe as shown. 9. Continue to route the extension cord to the exit location desired by the customer as shown. 10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the engine coolant heater cord to the vehicle that were released to provide length. Part Information The extension cord may be obtained at any of the following outlets: - Lowes* - Home Depot* - Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number: CWRSJTOW3C14-10 USA: Cords should bear the UL symbol. Canada: Cords should bear the ULc symbol or CSA approval. *We believe these sources and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from these firms or for any such items that may be available from other sources. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Temperature Sensor/Switch (For Computer): > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 5185 Warranty Information (excluding Saab Models) For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 5186 Coolant Temperature Sensor/Switch (For Computer): Diagrams Component Connector End Views Engine Coolant Temperature (ECT) Sensor (Diesel) Engine Coolant Temperature (ECT) Sensor (Gas) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Page 5187 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Engine Coolant Temperature Sensor Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams Crankshaft Position Sensor: Diagrams Component Connector End Views Crankshaft Position (CKP) Sensor (LU3) Crankshaft Position (CKP) Sensor (Gas except LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 5191 Crankshaft Position (CKP) Sensor (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 5192 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement Crankshaft Position Sensor Replacement Removal Procedure 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 2. Remove the right wheelhouse panel. Refer to Front Wheelhouse Liner Replacement - Right Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side)Front Wheelhouse Liner Replacement - Right Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side). 3. Disconnect the crankshaft position (CKP) sensor electrical connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 5195 4. Remove the CKP sensor bolt. 5. Remove the CKP sensor. 6. If necessary, remove the CKP sensor spacer bolts. 7. If necessary, remove the CKP sensor spacer. Installation Procedure 1. If necessary, lubricate a NEW CKP spacer O-ring with clean engine oil. 2. If necessary, install the NEW O-ring to the CKP sensor spacer. Note: The crankshaft position sensor spacers are machined with different timing positions. However, if the crankshaft position sensor spacer requires replacement, replace with a grade "C" spacer. 3. If necessary, install the CKP sensor spacer. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. If necessary, install the CKP sensor spacer bolts. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 5196 Tighten the bolts to 10 Nm (89 lb in). 5. Lubricate a NEW CKP sensor O-ring with clean engine oil. 6. Install the NEW O-ring to the CKP sensor. 7. Install the CKP sensor. 8. Install the CKP sensor bolt. Tighten the bolt to 10 Nm (89 lb in). 9. Connect the CKP sensor electrical connector. 10. Install the right wheelhouse panel. Refer to Front Wheelhouse Liner Replacement - Right Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side)Front Wheelhouse Liner Replacement - Right Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side). 11. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 5197 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Exciter Ring and Oil Pump Drive Gear Replacement Crankshaft Position Sensor Exciter Ring and Oil Pump Drive Gear Replacement Removal Procedure 1. Remove the engine front cover. Refer to Engine Front Cover Replacement (See: Engine, Cooling and Exhaust/Engine/Timing Components/Timing Cover/Service and Repair). 2. Remove the upper oil pan. Refer to Upper Oil Pan Replacement (See: Engine, Cooling and Exhaust/Engine/Engine Lubrication/Oil Pan/Service and Repair/Upper Oil Pan Replacement). Caution: Do not use an impact driver to remove or install the oil pump driven gear nut. Use of an impact driver may shear the oil pump drive gear pin in the crankshaft. 3. While holding the secondary oil pump shaft with a hex driver, remove the oil pump driven gear nut. 4. Remove the oil pump driven gear. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 5198 5. Remove the oil pump drive gear and crankshaft sensor reluctor. Do not damage the crankshaft reluctor teeth. Note: Do not remove the reluctor from the oil pump drive gear unless replacing the reluctor or the oil pump drive gear. The reluctor is timed to the gear and once removed the correct timing will be lost. 6. Remove the crankshaft reluctor to oil pump drive gear bolts. 7. Inspect the crankshaft reluctor for the damage, bent teeth, being bent or warped. 8. Inspect the oil pump drive gear for damaged or worn teeth. 9. Inspect the oil pump drive gear crankshaft pin for wear. 10. Inspect the groove of the crankshaft pin in the oil pump drive gear for wear. 11. Replace any parts that are damaged or worn. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 5199 Note: The crankshaft reluctor and the oil pump drive gear are timed at the factory. In order to re-establish proper timing, install knock pins in the oil pump drive gear if the crankshaft reluctor was removed from the oil pump drive gear. The knock pins are available through the parts department. 1. Install the knock pins in the oil pump drive gear to a height of 4.5-5.5 mm (0.177-0.217 in) 2. Install the crankshaft reluctor on the oil pump drive gear. Ensure the reluctor is aligned on the knock pins. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the crankshaft reluctor bolts and tighten to 8 Nm (71 lb in). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 5200 Note: Do not damage the teeth on the crankshaft reluctor. 4. Install the oil pump drive gear and reluctor to the crankshaft. 5. Install the oil pump driven gear. Caution: Do not use an impact driver to remove or install the oil pump driven gear nut. Use of an impact driver may shear the oil pump drive gear pin in the crankshaft. 6. While holding the secondary oil pump shaft with a hex driver, install the oil pump driven gear nut and tighten to 100 Nm (74 lb ft). 7. Install the upper oil pan. Refer to Upper Oil Pan Replacement (See: Engine, Cooling and Exhaust/Engine/Engine Lubrication/Oil Pan/Service and Repair/Upper Oil Pan Replacement). 8. Install the engine front cover. Refer to Engine Front Cover Replacement (See: Engine, Cooling and Exhaust/Engine/Timing Components/Timing Cover/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Technical Service Bulletins > Recalls for Exhaust Temperature Sensor: > 11054 > Apr > 11 > Recall - Replace Exhaust Gas Temperature Sensor Technical Service Bulletin # 11054 Date: 110412 Recall - Replace Exhaust Gas Temperature Sensor PRODUCT EMISSION Bulletin No.: 11054 Date: April 12, 2011 Subject: 11054 - Reduced Engine Performance and Emission Control - Replace Exhaust Gas Temperature Sensors Models: 2010 Chevrolet Express, Silverado HD 2010 GMC Savana, Sierra HD With 6.6L V8 Duramax Diesel Engine (LMM) 2007-2009 Chevrolet Express, Kodiak, Silverado HD 2007-2009 GMC Savana, Sierra HD, TopKick With 6.6L V8 Duramax Diesel Engine (LMM) Serviced with a Suspect EGT Sensor Condition General Motors has decided to conduct a Voluntary Emission Recall involving certain 2010 model year Chevrolet Express, Silverado HD; and GMC Savana, Sierra HD vehicles equipped with a 6.6L V8 Duramax diesel engine (LMM); and 2007-2009 model year Chevrolet Express, Kodiak, Silverado HD; and GMC Savana, Sierra HD, and TopKick vehicles equipped with a 6.6L V8 Duramax diesel engine (LMM) that may have been serviced with a suspect Exhaust Gas Temperature (EGT) sensor. On these vehicles, the circuit board welds on the EGT sensors in the exhaust system may not be to GM specification. If a weld fails, the Service Engine Soon light will illuminate in the instrument panel, the exhaust gas may not be filtered properly, and the engine power may be reduced. Correction Dealers are to replace both EGT sensors. Vehicles Involved Involved are certain 2010 model year Chevrolet Express, Silverado HD; and GMC Savana, Sierra HD vehicles equipped with a 6.6L V8 Duramax diesel engine (LMM); and 2007-2009 model year Chevrolet Express, Kodiak, Silverado HD; and GMC Savana, Sierra HD, and TopKick vehicles equipped with a 6.6L V8 Duramax diesel engine (LMM) that may have been serviced with a suspect EGT sensor. Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Required Field Actions section in the Global Warranty system. Not all vehicles may be involved. For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to US and Canadian dealers through the GM GlobalConnect Recall Reports, or sent directly to export dealers. Dealers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information Parts required to complete this recall are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Service Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Technical Service Bulletins > Recalls for Exhaust Temperature Sensor: > 11054 > Apr > 11 > Recall - Replace Exhaust Gas Temperature Sensor > Page 5209 1. Remove and replace position 1 and position 2 exhaust gas temperature sensors (1). Refer to Exhaust Temperature Sensor Replacement in SI. 2. CALIFORNIA, CONNECTICUT, MASSACHUSETTS, MAINE, OREGON, VERMONT, & WASHINGTON VEHICLES ONLY: Install a Recall Identification Label. Also, for California vehicles complete a "Proof of Correction" certificate upon recall completion. Recall Identification Label California/Connecticut/Massachusetts/Maine/Oregon/Vermont/Washington Vehicles Only) Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five-digit dealer code of the dealer performing the recall service. This information may be inserted with a ballpoint pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Recall Identification Label, be sure to pull the tab to allow adhesion of the clear protective covering. Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials by ordering on the web from DWD Store, www.gmdealerworld.com, and then click on the DWD Store link. Request Item Number S-1015 when ordering. Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a transaction using the table below. Customer Notification - For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter included with this bulletin). In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper maintenance. The vehicle may fail a state or local emission inspection test if the recall work is not completed. Customer Notification - For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the attached sample letter. In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Technical Service Bulletins > Recalls for Exhaust Temperature Sensor: > 11054 > Apr > 11 > Recall - Replace Exhaust Gas Temperature Sensor > Page 5210 maintenance. The vehicle may fail a state or local emission inspection test if the recall work is not completed. Dealer Recall Responsibility All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. ***THE FOLLOWING 2 PARAGRAPHS ARE NOT FOR CANADA OR EXPORT*** When a California emissions recall is completed by a GM dealer, the dealer must provide the vehicle owner a "Proof of Correction Certificate" which the owner may need to present to the California Department Of Motor Vehicles (DMV) when renewing their vehicle registration. Without this correction certificate, the owner may be unable to renew their vehicle registration. Additional Certificates can be obtained, at no charge, from Dealer Support Materials by ordering on the web from the DWD Store, www.gmdealerworld.com, and then click on the DWD Store link; request GM Item Number 1825 when ordering. Disclaimer Owner Letter Owner Letter Dear General Motors Customer: This notice is sent to inform you that General Motors is conducting a voluntary emission recall that includes your vehicle. Reason For This Recall: General Motors has decided to conduct a Voluntary Emission Recall involving certain 2010 model year Chevrolet Express, Silverado HD; and GMC Savana, Sierra HD vehicles equipped with a 6.6L V8 Duramax diesel engine; and 2007-2009 model year Chevrolet Express, Kodiak, Silverado HD; and GMC Savana, Sierra HD, and TopKick vehicles equipped with a 6.6L V8 Duramax diesel engine that may have been serviced with a suspect Exhaust Gas Temperature (EGT) sensor. The circuit board welds on the EGT sensors in the exhaust system may not be to GM specification. If a weld fails, the Service Engine Soon light will illuminate in the instrument panel, the exhaust gas may not be filtered properly, and the engine power may be reduced. What Will Be Done: Your GM dealer will replace both EGT sensors. This service will be performed for you at no charge. What You Should Do: Please contact your GM dealer as soon as possible to arrange a service date and to assure parts availability. Instructions for making this correction have been sent to your dealer. Please ask your dealer if you wish to know how much time will be needed to schedule, process, and repair your vehicle. If you have any questions or need any assistance, just contact your dealer or the appropriate Customer Assistance Center at the number listed below. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Technical Service Bulletins > Recalls for Exhaust Temperature Sensor: > 11054 > Apr > 11 > Recall - Replace Exhaust Gas Temperature Sensor > Page 5211 Emission Law Information: In order to ensure your full protection under the emission warranty made applicable to your vehicle by State and Federal Law, and your right to participate in future recalls, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could legally be determined to be lack of proper maintenance of your vehicle. Also, your vehicle may fail a state or local emission inspection if this recall is not accomplished. IMPORTANT MESSAGE FOR CALIFORNIA RESIDENTS The California Air Resources Board (CARB) requires vehicle emission recalls be completed prior to California registration renewal. Uncorrected emission recalls will result in the inability to renew your California vehicle registration. At the time of emission recall completion, your California dealer will issue a "Proof of Correction Certificate". Keep this certificate and, if required, present it to the Department of Motor Vehicles when renewing your California registration as proof of recall completion. We are sorry to cause you this inconvenience; however, we have taken this action in the interest of your continued satisfaction with our products. Jim Moloney General Director, Customer and Relationship Services 11054 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exhaust Temperature Sensor: > 11054 > Apr > 11 > Recall - Replace Exhaust Gas Temperature Sensor Technical Service Bulletin # 11054 Date: 110412 Recall - Replace Exhaust Gas Temperature Sensor PRODUCT EMISSION Bulletin No.: 11054 Date: April 12, 2011 Subject: 11054 - Reduced Engine Performance and Emission Control - Replace Exhaust Gas Temperature Sensors Models: 2010 Chevrolet Express, Silverado HD 2010 GMC Savana, Sierra HD With 6.6L V8 Duramax Diesel Engine (LMM) 2007-2009 Chevrolet Express, Kodiak, Silverado HD 2007-2009 GMC Savana, Sierra HD, TopKick With 6.6L V8 Duramax Diesel Engine (LMM) Serviced with a Suspect EGT Sensor Condition General Motors has decided to conduct a Voluntary Emission Recall involving certain 2010 model year Chevrolet Express, Silverado HD; and GMC Savana, Sierra HD vehicles equipped with a 6.6L V8 Duramax diesel engine (LMM); and 2007-2009 model year Chevrolet Express, Kodiak, Silverado HD; and GMC Savana, Sierra HD, and TopKick vehicles equipped with a 6.6L V8 Duramax diesel engine (LMM) that may have been serviced with a suspect Exhaust Gas Temperature (EGT) sensor. On these vehicles, the circuit board welds on the EGT sensors in the exhaust system may not be to GM specification. If a weld fails, the Service Engine Soon light will illuminate in the instrument panel, the exhaust gas may not be filtered properly, and the engine power may be reduced. Correction Dealers are to replace both EGT sensors. Vehicles Involved Involved are certain 2010 model year Chevrolet Express, Silverado HD; and GMC Savana, Sierra HD vehicles equipped with a 6.6L V8 Duramax diesel engine (LMM); and 2007-2009 model year Chevrolet Express, Kodiak, Silverado HD; and GMC Savana, Sierra HD, and TopKick vehicles equipped with a 6.6L V8 Duramax diesel engine (LMM) that may have been serviced with a suspect EGT sensor. Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Required Field Actions section in the Global Warranty system. Not all vehicles may be involved. For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to US and Canadian dealers through the GM GlobalConnect Recall Reports, or sent directly to export dealers. Dealers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information Parts required to complete this recall are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Service Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exhaust Temperature Sensor: > 11054 > Apr > 11 > Recall - Replace Exhaust Gas Temperature Sensor > Page 5217 1. Remove and replace position 1 and position 2 exhaust gas temperature sensors (1). Refer to Exhaust Temperature Sensor Replacement in SI. 2. CALIFORNIA, CONNECTICUT, MASSACHUSETTS, MAINE, OREGON, VERMONT, & WASHINGTON VEHICLES ONLY: Install a Recall Identification Label. Also, for California vehicles complete a "Proof of Correction" certificate upon recall completion. Recall Identification Label California/Connecticut/Massachusetts/Maine/Oregon/Vermont/Washington Vehicles Only) Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five-digit dealer code of the dealer performing the recall service. This information may be inserted with a ballpoint pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Recall Identification Label, be sure to pull the tab to allow adhesion of the clear protective covering. Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials by ordering on the web from DWD Store, www.gmdealerworld.com, and then click on the DWD Store link. Request Item Number S-1015 when ordering. Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a transaction using the table below. Customer Notification - For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter included with this bulletin). In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper maintenance. The vehicle may fail a state or local emission inspection test if the recall work is not completed. Customer Notification - For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the attached sample letter. In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exhaust Temperature Sensor: > 11054 > Apr > 11 > Recall - Replace Exhaust Gas Temperature Sensor > Page 5218 maintenance. The vehicle may fail a state or local emission inspection test if the recall work is not completed. Dealer Recall Responsibility All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. ***THE FOLLOWING 2 PARAGRAPHS ARE NOT FOR CANADA OR EXPORT*** When a California emissions recall is completed by a GM dealer, the dealer must provide the vehicle owner a "Proof of Correction Certificate" which the owner may need to present to the California Department Of Motor Vehicles (DMV) when renewing their vehicle registration. Without this correction certificate, the owner may be unable to renew their vehicle registration. Additional Certificates can be obtained, at no charge, from Dealer Support Materials by ordering on the web from the DWD Store, www.gmdealerworld.com, and then click on the DWD Store link; request GM Item Number 1825 when ordering. Disclaimer Owner Letter Owner Letter Dear General Motors Customer: This notice is sent to inform you that General Motors is conducting a voluntary emission recall that includes your vehicle. Reason For This Recall: General Motors has decided to conduct a Voluntary Emission Recall involving certain 2010 model year Chevrolet Express, Silverado HD; and GMC Savana, Sierra HD vehicles equipped with a 6.6L V8 Duramax diesel engine; and 2007-2009 model year Chevrolet Express, Kodiak, Silverado HD; and GMC Savana, Sierra HD, and TopKick vehicles equipped with a 6.6L V8 Duramax diesel engine that may have been serviced with a suspect Exhaust Gas Temperature (EGT) sensor. The circuit board welds on the EGT sensors in the exhaust system may not be to GM specification. If a weld fails, the Service Engine Soon light will illuminate in the instrument panel, the exhaust gas may not be filtered properly, and the engine power may be reduced. What Will Be Done: Your GM dealer will replace both EGT sensors. This service will be performed for you at no charge. What You Should Do: Please contact your GM dealer as soon as possible to arrange a service date and to assure parts availability. Instructions for making this correction have been sent to your dealer. Please ask your dealer if you wish to know how much time will be needed to schedule, process, and repair your vehicle. If you have any questions or need any assistance, just contact your dealer or the appropriate Customer Assistance Center at the number listed below. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exhaust Temperature Sensor: > 11054 > Apr > 11 > Recall - Replace Exhaust Gas Temperature Sensor > Page 5219 Emission Law Information: In order to ensure your full protection under the emission warranty made applicable to your vehicle by State and Federal Law, and your right to participate in future recalls, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could legally be determined to be lack of proper maintenance of your vehicle. Also, your vehicle may fail a state or local emission inspection if this recall is not accomplished. IMPORTANT MESSAGE FOR CALIFORNIA RESIDENTS The California Air Resources Board (CARB) requires vehicle emission recalls be completed prior to California registration renewal. Uncorrected emission recalls will result in the inability to renew your California vehicle registration. At the time of emission recall completion, your California dealer will issue a "Proof of Correction Certificate". Keep this certificate and, if required, present it to the Department of Motor Vehicles when renewing your California registration as proof of recall completion. We are sorry to cause you this inconvenience; however, we have taken this action in the interest of your continued satisfaction with our products. Jim Moloney General Director, Customer and Relationship Services 11054 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Exhaust Temperature Sensor Replacement - Position 1 Exhaust Temperature Sensor: Service and Repair Exhaust Temperature Sensor Replacement Position 1 Exhaust Temperature Sensor Replacement - Position 1 Removal Procedure Caution: The exhaust temperature sensor and exhaust pressure differential sensor line fittings may be difficult to remove when the engine exhaust system temperature is below 48°C (120°F). Excessive force may damage the threads in the exhaust manifold or exhaust pipe. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the exhaust temperature sensor electrical connector (1) from the chassis wiring harness electrical connector (2). 3. Remove the exhaust temperature sensor. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Exhaust Temperature Sensor Replacement - Position 1 > Page 5222 Note: A special anti-seize compound is used in the sensor or line fittings threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor or line fitting easier to remove. New, or service replacement sensors or line fittings already have the compound applied to the threads. If the sensor or line fittings are removed from an exhaust component and if for any reason the sensor or line fitting are reinstalled, the threads must have anti-seize compound applied before reinstallation. 1. If reinstalling the old temperature sensor or differential pressor sensor line fittings, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the exhaust temperature sensor. Tighten the sensor to 45 Nm (33 lb ft). 3. Connect the exhaust temperature sensor electrical connector (1) to the chassis wiring harness electrical connector (2). 4. Lower the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Exhaust Temperature Sensor Replacement - Position 1 > Page 5223 Exhaust Temperature Sensor: Service and Repair Exhaust Temperature Sensor Replacement Position 2 Exhaust Temperature Sensor Replacement - Position 2 Removal Procedure Caution: The exhaust temperature sensor and exhaust pressure differential sensor line fittings may be difficult to remove when the engine exhaust system temperature is below 48°C (120°F). Excessive force may damage the threads in the exhaust manifold or exhaust pipe. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the exhaust temperature sensor (3) electrical connector from the chassis wiring harness electrical connector (4). 3. Remove the exhaust temperature sensor. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Exhaust Temperature Sensor Replacement - Position 1 > Page 5224 Note: A special anti-seize compound is used in the sensor or line fittings threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor or line fitting easier to remove. New, or service replacement sensors or line fittings already have the compound applied to the threads. If the sensor or line fittings are removed from an exhaust component and if for any reason the sensor or line fitting are reinstalled, the threads must have anti-seize compound applied before reinstallation. 1. If reinstalling the old temperature sensor or differential pressor sensor line fittings, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the exhaust temperature sensor. Tighten the sensor to 45 Nm (33 lb ft). 3. Connect the exhaust temperature sensor (3) electrical connector to the chassis wiring harness electrical connector (4). 4. Lower the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Diagrams Fuel Level Sensor: Diagrams Component Connector End Views Fuel Level Sensor - Primary (Diesel) Fuel Level Sensor - Secondary (Diesel with 31 Series without NQZ) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Diagrams > Page 5228 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor (Cab/Chassis - Rear Tank) Fuel Level Sensor: Service and Repair Fuel Level Sensor (Cab/Chassis - Rear Tank) Fuel Level Sensor Replacement (Cab/Chassis - Rear Tank) Removal Procedure 1. Remove the sending unit. Refer to Fuel Sender Assembly Replacement (See: Fuel Delivery and Air Induction/Fuel Tank/Fuel Gauge Sender/Service and Repair). 2. Disconnect the fuel level sensor electrical connector (1). 3. Remove the sensor retaining clip (3). 4. Squeeze the locking tangs (2) and remove the fuel level sensor. Installation Procedure 1. Install the fuel level sensor. 2. Install the sensor retaining clip (3). 3. Connect the sensor electrical connector (1). 4. Install the sending unit. Refer to Fuel Sender Assembly Replacement (See: Fuel Delivery and Air Induction/Fuel Tank/Fuel Gauge Sender/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor (Cab/Chassis - Rear Tank) > Page 5231 Fuel Level Sensor: Service and Repair Fuel Level Sensor Replacement (35 Reg/Ext/Crew Cab With 34 gal Tank) Fuel Level Sensor Replacement (35 Reg/Ext/Crew Cab With 34 gal Tank) Removal Procedure 1. Remove the fuel tank module. Refer to Fuel Tank Fuel Pump Module Replacement (25 Ext/Crew Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15/25 Reg/Ext/Crw Cab With 34 Gal Tnk) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Ext/Crew Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Reg Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (35 Reg/Ext/Crew Cab With 34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair). 2. Disconnect the fuel level sensor wiring pigtail electrical connector (1) from the module cover. 3. Remove the fuel level sensor wiring pigtail from under the module clip (2). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor (Cab/Chassis - Rear Tank) > Page 5232 4. Gently push in the fuel level sensor retainers (1), disengaging them from the module reservoir. 5. Slide the fuel level sensor up, in order to remove the sensor from the module slot. Installation Procedure 1. Position the fuel level sensor over the slot in the reservoir and slide the sensor down into the slot. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor (Cab/Chassis - Rear Tank) > Page 5233 2. Ensure that the fuel level sensor retainers (1) engage the module reservoir. 3. Install the fuel level sensor wiring pigtail under the module clip (2) behind the fuel pump wires. 4. Connect the fuel level sensor wiring pigtail electrical connector (1) to the module cover. 5. Install the fuel tank module. Refer to Fuel Tank Fuel Pump Module Replacement (25 Ext/Crew Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15/25 Reg/Ext/Crw Cab With 34 Gal Tnk) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Ext/Crew Cab With 26 Gal Tank) ( See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (15 Reg Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair)Fuel Tank Fuel Pump Module Replacement (35 Reg/Ext/Crew Cab With 34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor (Cab/Chassis - Rear Tank) > Page 5234 Fuel Level Sensor: Service and Repair Fuel Sender Assembly Replacement Fuel Sender Assembly Replacement Special Tools J 45722 Fuel Sender Lock Ring Wrench Removal Procedure 1. Remove the fuel tank. Refer to Fuel Tank Replacement (Pickup) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (Cab/Chassis - Front) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (Cab/Chassis - Rear) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement). 2. Disconnect the fuel lines from the sending unit. Refer to Metal Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Metal Collar Quick Connect Fitting Service) or Plastic Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). Caution: Avoid damaging the lock ring. Use only J-45722 to prevent damage to the lock ring. Caution: Do Not handle the fuel sender assembly by the fuel pipes. The amount of leverage generated by handling the fuel pipes could damage the joints. Note: Do NOT use impact tools. Significant force will be required to release the lock ring. The use of a hammer and screwdriver is not recommended. Secure the fuel tank in order to prevent fuel tank rotation. 3. Use the J 45722 and a long breaker-bar in order to unlock the fuel sender lock ring. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor (Cab/Chassis - Rear Tank) > Page 5235 4. Remove the sending unit and seal. Discard the seal. 5. Clean the sending unit sealing surfaces. Note: Some lock rings were manufactured with "DO NOT REUSE" stamped into them. These lock rings may be reused if they are not damaged or warped. Note: Inspect the lock ring for damage due to improper removal or installation procedures. If damage is found, install a NEW lock ring. Note: Check the lock ring for flatness. 6. Place the lock ring on a flat surface. Measure the clearance between the lock ring and the flat surface using a feeler gauge at 7 points. 7. If warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement. 8. If warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Level Sensor (Cab/Chassis - Rear Tank) > Page 5236 1. Install the sending unit and a NEW seal. Note: Always replace the fuel sender seal when installing the fuel sender assembly. Replace the lock ring if necessary. DO NOT apply any type of lubrication in the seal groove. Ensure the lock ring is installed with the correct side facing upward. A correctly installed lock ring will only turn in a clockwise direction. 2. Use the J 45722 in order to install the fuel sender lock ring. Turn the fuel sender lock ring in a clockwise direction. 3. Connect the fuel lines to the sending unit. Refer to Metal Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Metal Collar Quick Connect Fitting Service) or Plastic Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). 4. Install the fuel tank. Refer to Fuel Tank Replacement (Pickup) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (Cab/Chassis - Front) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (Cab/Chassis - Rear) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Diagrams Fuel Tank Pressure Sensor: Diagrams Component Connector End Views Fuel Tank Pressure (FTP) Sensor (Gas) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Diagrams > Page 5240 Fuel Tank Pressure Sensor: Service and Repair Fuel Tank Pressure Sensor Replacement (35 Reg/Ext/Crew Cab With 34 Gal Tank) Removal Procedure 1. Remove the fuel tank. Refer to Fuel Tank Replacement (35 Reg/Ext/Crew Cab With 34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15 Ext/Crew Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15/25 Reg/Ext/Crw Cab With 34 Gal Tnk) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15 Rec Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (25 Ext/Crew Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement). 2. Remove the fuel tank pressure sensor by pulling straight up using a slight rocking motion. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Diagrams > Page 5241 1. Install the fuel tank pressure sensor. 2. Install the fuel tank pressure sensor cover. 3. Install the fuel tank. Refer to Fuel Tank Replacement (35 Reg/Ext/Crew Cab With 34 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15 Ext/Crew Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15/25 Reg/Ext/Crw Cab With 34 Gal Tnk) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (15 Rec Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (25 Ext/Crew Cab With 26 Gal Tank) (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > High Idle Switch > Component Information > Testing and Inspection High Idle Switch: Testing and Inspection High Idle Switch Diagnosis Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions )provide an overview of each diagnostic category. Diagnostic Fault Information Reference Information Schematic Reference Engine Controls Schematics (See: Diagrams/Electrical Diagrams) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning)for scan tool information Circuit/System Verification Ignition ON, observe the scan tool High Idle switch parameter while exercising the switch. The reading should change between ON/OFF. Circuit/System Testing 1. Ignition OFF, disconnect the harness connector at the high idle switch. 2. Test for less than 5 ohms between the ground circuit terminal A and ground. ‹› If greater than 5 ohms, test the ground circuit for an open/high resistance. 3. Ignition ON, verify the scan tool High Idle switch parameter is OFF. ‹› If not OFF, test the signal circuit for a short to ground. If the circuit tests normal, replace the ECM. 4. Install a 3A fused jumper wire between the signal circuit terminal C and ground. Verify the scan tool High Idle switch parameter is ON. ‹› If not ON, test the signal circuit for a short to voltage or an open/high resistance. If the circuit tests normal, replace the ECM. 5. If all circuits test normal, test or replace the high idle switch. Component Testing Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > High Idle Switch > Component Information > Testing and Inspection > Page 5245 1. Ignition OFF, disconnect the harness connector at the high idle switch. 2. Test for infinite resistance between the signal terminal C and the ground circuit terminal A with the switch in the open position. ‹› If less than infinite resistance, replace the high idle switch. 3. Test for less than 1 ohm between the signal terminal C and the ground terminal A with the switch in the closed position. ‹› If greater than 1 ohm, replace the high idle switch. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams Intake Air Temperature Sensor: Diagrams Component Connector End Views Intake Air Temperature (IAT) Sensor 2 (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Intake Air Temperature (IAT) Sensor 2 Replacement Intake Air Temperature Sensor: Service and Repair Intake Air Temperature (IAT) Sensor 2 Replacement Intake Air Temperature (IAT) Sensor 2 Replacement Removal Procedure 1. Remove the air intake pipe. Refer to Air Intake Pipe Replacement (See: Fuel Delivery and Air Induction/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair/Air Intake Pipe Replacement). 2. Disconnect the engine wiring harness electrical connector (1) from the intake air temperature (IAT) sensor pigtail. 3. Remove the IAT sensor (2) from the center intake manifold. Installation Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Intake Air Temperature (IAT) Sensor 2 Replacement > Page 5251 1. Install the IAT sensor (2) to the center intake manifold. Tighten the sensor to 25 Nm (18 lb ft). 2. Connect the engine wiring harness electrical connector (1) to the IAT sensor pigtail. 3. Install the air intake pipe. Refer to Air Intake Pipe Replacement (See: Fuel Delivery and Air Induction/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair/Air Intake Pipe Replacement). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Intake Air Temperature (IAT) Sensor 2 Replacement > Page 5252 Intake Air Temperature Sensor: Service and Repair Mass Airflow Sensor with Intake Air Temperature Sensor Replacement Mass Airflow Sensor with Intake Air Temperature Sensor Replacement Removal Procedure 1. Disconnect the engine wiring harness electrical connector (1) from the mass air flow (MAF)/intake air temperature (IAT) sensor. 2. Remove the MAF/IAT sensor TORX(R) screws. 3. Remove the MAF/IAT sensor. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Intake Air Temperature (IAT) Sensor 2 Replacement > Page 5253 1. Install the MAF/IAT sensor. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the MAF/IAT sensor TORX(R) screws. Tighten the screws to 8 Nm (70 lb in). 3. Connect the engine wiring harness electrical connector (1) to the MAF/IAT sensor. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams Knock Sensor: Diagrams Component Connector End Views Knock Sensor (KS) 1 (Gas) Knock Sensor (KS) 2 (Gas) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Page 5257 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams Manifold Pressure/Vacuum Sensor: Diagrams Component Connector End Views Manifold Absolute Pressure (MAP) Sensor (LU3) Manifold Absolute Pressure (MAP) Sensor (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Page 5261 Manifold Absolute Pressure (MAP) Sensor (Gas except LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Page 5262 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Page 5263 Manifold Pressure/Vacuum Sensor: Service and Repair Manifold Absolute Pressure Sensor Replacement Removal Procedure 1. Disconnect the engine wiring harness electrical connector (2) from the manifold absolute pressure (MAP) sensor. 2. Remove the MAP sensor bolt. 3. Remove the MAP sensor bracket and sensor. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Page 5264 1. Install the MAP sensor and bracket. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the MAP sensor bolt. Tighten the bolt to 10 Nm (89 lb in). 3. Connect the engine wiring harness electrical connector (2) to the MAP sensor. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams Oil Pressure Sensor: Diagrams Component Connector End Views Engine Oil Pressure (EOP) Sensor (Diesel) Engine Oil Pressure (EOP) Sensor (Gas except LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Page 5268 Engine Oil Pressure (EOP) Sensor (LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Page 5269 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Page 5270 Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement Special Tools DT-48827 Skip Shift Socket Removal Procedure 1. Remove the left wheelhouse inner panel. Refer to Front Wheelhouse Liner Replacement - Left Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Left Side)Front Wheelhouse Liner Replacement - Left Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Left Side). Note: Clean the area around the sensor. Do not allow debris to enter the engine. 2. Disconnect the oil pressure sensor electrical connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Page 5271 3. Using DT-48827 , remove the oil pressure sensor (1). Installation Procedure 1. Apply sealant to the threads of the oil pressure sensor. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Engine, Cooling and Exhaust/Engine/Specifications/Adhesives, Fluids, Lubricants, and Sealers) for the correct part number. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Using DT-48827 , install the oil pressure sensor (1). Tighten the sensor to 49 Nm (36 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams > Page 5272 3. Connect the oil pressure sensor electrical connector. 4. Install the left wheelhouse inner panel. Refer to Front Wheelhouse Liner Replacement - Left Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Left Side)Front Wheelhouse Liner Replacement - Left Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Left Side). 5. Check and add engine oil if necessary. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations Oxygen Sensor: Locations Harness Routing Views Heated Oxygen Sensor (HO2S) Jumper Harness Routing (LY6) 1 - X125 2 - Heated Oxygen Sensor (HO2S) Bank 2 Sensor 2 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 5276 Oxygen Sensor: Diagrams Component Connector End Views Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 (LU3) Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 (Gas except LU3 and except ZW9) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 5277 Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 (LY6 or L96 with ZW9) Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 2 (LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 5278 Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 2 (Gas except LU3) Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 (LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 5279 Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 (Gas except LU3 and except ZW9) Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 (LY6 or L96 with ZW9) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 5280 Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 2 (LU3) Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 2 (Gas except LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 5281 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service Precautions > Excessive Force and Oxygen Sensor Caution Oxygen Sensor: Service Precautions Excessive Force and Oxygen Sensor Caution Excessive Force and Oxygen Sensor Caution Caution: The oxygen sensor may be difficult to remove when the engine temperature is below 48°C (120°F). Excessive force may damage threads in the exhaust manifold or the exhaust pipe. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service Precautions > Excessive Force and Oxygen Sensor Caution > Page 5284 Oxygen Sensor: Service Precautions Heated Oxygen and Oxygen Sensor Caution Heated Oxygen and Oxygen Sensor Caution Caution: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen sensor (O2S). Removing the pigtail or the connector will affect sensor operation. Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical connector and the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of any type. Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring, connector, or terminal is damaged. This external clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air reference and degraded sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. * Do not damage the sensor pigtail and harness wires in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp bends or kinks could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire, where applicable. Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will cause poor engine performance. * Ensure that the peripheral seal remains intact on the vehicle harness connector in order to prevent damage due to water intrusion. The engine harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service Precautions > Excessive Force and Oxygen Sensor Caution > Page 5285 Oxygen Sensor: Service Precautions Heated Oxygen Sensor Resistance Learn Reset Caution Heated Oxygen Sensor Resistance Learn Reset Caution Caution: When replacing the HO2S perform the following: * A code clear with a scan tool, regardless of whether or not a DTC is set * HO2S heater resistance learn reset with a scan tool, where available Perform the above in order to reset the HO2S resistance learned value and avoid possible HO2S failure. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service Precautions > Excessive Force and Oxygen Sensor Caution > Page 5286 Oxygen Sensor: Service Precautions Silicon Contamination of Heated Oxygen Sensors Caution Silicon Contamination of Heated Oxygen Sensors Caution Caution: Contamination of the oxygen sensor can result from the use of an inappropriate RTV sealant (not oxygen sensor safe) or excessive engine coolant or oil consumption. Remove the HO2S and visually inspect the portion of the sensor exposed to the exhaust stream in order to check for contamination. If contaminated, the portion of the sensor exposed to the exhaust stream will have a white powdery coating. Silicon contamination causes a high but false HO2S signal voltage (rich exhaust indication). The control module will then reduce the amount of fuel delivered to the engine, causing a severe driveability problem. Eliminate the source of contamination before replacing the oxygen sensor. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Diagrams Pressure Feedback Exhaust Sensor: Diagrams Component Connector End Views Exhaust Pressure Differential Sensor (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams Transmission Position Switch/Sensor: Diagrams Component Connector End Views Park/Neutral Position (PNP) Switch (M30) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 5293 Transmission Position Switch/Sensor: Service and Repair Manual Shift Shaft, Detent Lever, and Position Switch Assembly Replacement Removal Procedure 1. Remove the control valve assembly from the transmission. Refer to Control Valve Body Replacement (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Valve Body/Service and Repair). Note: The detent lever/IMS retaining bolt contains patch lock material on the threads. Do not reuse the retaining bolt. 2. Remove the detent lever/IMS retaining bolt (1) using a T27 TORX(R) bit and discard the retaining bolt. Caution: DO NOT mar the transmission case surface around the spherical pin when removing or installing the spherical pin. An unmarred surface is required to maintain the seal between the control valve assembly and the transmission case. Caution: DO NOT twist the spherical pin when removing the pin from the transmission case. Damage to the transmission case can occur. 3. Place a protective plate on the transmission case surface around the spherical pin (3). Remove the spherical pin (3) from the transmission case. 4. Slide the manual shift shaft (5) through the detent lever/IMS assembly (4) and through the manual shift shaft seal. 5. Rotate the detent lever/IMS assembly to disengage the park pawl apply assembly (2). Remove the detent lever/IMS assembly (4). Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 5294 1. Place the new detent lever/IMS assembly (4) in position in the transmission case. Rotate the detent lever/IMS assembly to engage the park pawl apply assembly (2). Reinstall the manual shift shaft (5) through the manual shift shaft seal and through the detent lever/IMS assembly (4). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Push the manual shift shaft (5) into the final position in the transmission case. 3. Install the spherical pin (3) into the transmission case that retains the manual shift shaft. 4. Install the detent lever/IMS retaining bolt (1) using a T27 TORX(R) bit. Tighten the bolt (1) to 10 Nm (92 lb in). 5. Install the control valve assembly. Refer to Control Valve Body Replacement (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Valve Body/Service and Repair). Note: The FastLearn, adapt, procedure must be performed. This can be done in 1 step using a scan tool. If this procedure is not done, the TCM adaptive values will be at the settings that it learned for the old components and will be in slow adaptive mode. Under these conditions, it will take an unacceptably long time for the adaptive values to converge to levels suitable for the new transmission. 6. Perform the FastLearn procedure. Refer to FastLearn Procedure (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Testing and Inspection/Programming and Relearning). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Turbocharger Vane Position Sensor > Component Information > Technical Service Bulletins > Engine - Info on Duramax Turbo Vane Position Sensor Turbocharger Vane Position Sensor: Technical Service Bulletins Engine - Info on Duramax Turbo Vane Position Sensor INFORMATION Bulletin No.: 10-06-04-014 Date: November 03, 2010 Subject: Information on Duramax Turbo Vane Position Sensor Models: 2010-2011 Chevrolet Express Vans, Silverado 2010-2011 GMC Savana Vans, Sierra Equipped with Duramax(TM) Diesel Engine (RPOs LGH, LML) An improvement has been implemented to the turbocharger vane position sensor. Some turbochargers existing in inventory have the old style vane position sensor. If turbochargers, GM P/N 12635325 or 12635167 are being replaced, the original turbo vane sensor should be removed and replaced with the new style sensor, GM P/N 12643471. Turbochargers that are supersessions to these part numbers will have the new style vane position sensor and no action is necessary. Parts Information Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Turbocharger Vane Position Sensor > Component Information > Technical Service Bulletins > Page 5299 Turbocharger Vane Position Sensor: Diagrams Component Connector End Views Turbocharger Vane Position Sensor (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > A/T Shifting/Poor Performance Vehicle Speed Sensor: Technical Service Bulletins A/T - Shifting/Poor Performance INFORMATION Bulletin No.: 01-03-10-010G Date: July 22, 2009 Subject: Inspection of Tire and Wheel Size Prior to Diagnosis of Transmission Shifts, Poor Performance, Speedometer, Cruise Control Concerns Models: 2001-2007 Chevrolet Silverado Pickup (Classic) Models Equipped with Allison(R) Automatic Transmission Only 2001-2007 GMC Sierra Pickup (Classic) Models Equipped with Allison(R) Automatic Transmission Only 2007-2010 Chevrolet Silverado Pickup HD Models 2007-2010 GMC Sierra Pickup HD Models Supercede: This bulletin is being revised to add the 2008-2010 model years, update the tire size information and reference the vehicle tire information label locations. Please discard Corporate Bulletin Number 01-03-10-010F (Section 03 - Suspension). GM has developed and matched specific tires for your vehicle. The original equipment tires and their respective size installed on the vehicle when it was new, were designed to meet General Motors Tire Performance Criteria Specification (TPC Spec) system rating. GM's exclusive TPC Spec system considers over a dozen critical specifications that impact the overall performance of the vehicle. A truck that has different tires and wheels from the original equipment designed for that vehicle will have engine power/performance concerns, transmission shift concerns, speedometer registered speed concerns, cruise control concerns and increased steering effort, especially during parking lot maneuvers at slow speeds. The engine control module (ECM) and transmission control module (TCM) use engine speed (RPM) and vehicle speed sensor (VSS) inputs as operational parameters for engine torque, transmission shifting, cruise control operation and speedometer indicated vehicle speed. Calibrations for different tire/wheel combinations are not available. Therefore, changing of tire and/or wheel size should not be undertaken by dealerships or truck owners. Proper diagnosis of engine, transmission, speedometer and cruise control concerns MUST begin with an inspection of tire/wheel size. Important A vehicle specific Tire and Loading Information label is attached to the center pillar (B-pillar) of the vehicle. With the driver's door open, you will find the label attached below the door lock post (striker). The label shows the size of the original equipment tires and the recommended cold tire inflation pressures.A vehicle specific Certification/Tire label is found on the rear edge of the driver's door. The label shows the size of the original equipment tires and the recommended cold tire inflation pressures. 2001-2007 Pickups (Classic) Equipped with Allison(R) Automatic Transmission Only Inspect the vehicle for the proper tire size as indicated in the following information. - The 2500 series trucks have LT245/75R16E tires as standard equipment. - The 3500 series trucks with single rear wheels have LT265/75R16E tires as standard equipment. - The 3500 series trucks with dual rear wheels have LT215/85R16D tires as standard equipment. 2007 Pickups HD Models (New Design Pickups) Inspect the vehicle for the proper tire size as indicated in the following information. - The 2500 series trucks have LT245/75R16E tires as standard equipment. - The 3500 series trucks with single rear wheels have LT265/75R16E tires as standard equipment. - The 3500 series trucks with dual rear wheels have LT215/85R16E tires as standard equipment. 2008-2010 Pickups HD Models (New Design Pickups) Inspect the vehicle for the proper tire size as indicated in the following information. - The 2500 series trucks have LT245/75R16E tires as standard equipment. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > A/T Shifting/Poor Performance > Page 5304 - The 3500 series trucks with single rear wheels have LT265/75R16E tires as standard equipment. - The 3500 series trucks with dual rear wheels have LT225/75R17E tires as standard equipment. If a truck is found to have other than the above listed tire sizes, no further diagnosis should be undertaken until the original size tires and wheels are reinstalled on the truck. Warranty Information Reinstalling the proper wheels and tires on the vehicle, prior to performing any type of diagnosis of the truck, would be considered truck owner responsibility and not a warranty repair. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Page 5305 Vehicle Speed Sensor: Locations Harness Routing Views Engine Chassis Harness Routing - Rear (Diesel) 1 - X300 2 - G300 3 - Automatic Transmission Turbine Speed Sensor (MW7) 4 - Automatic Transmission (MW7) 5 - Vehicle Speed Sensor (VSS) (MW7) 6 - X124 (PTO) 7 - Power Take Off (PTO) Module (PTO) 8 - X175 (MW7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Page 5306 Vehicle Speed Sensor: Diagrams Component Connector End Views Vehicle Speed Sensor (VSS) (M30, TZ0, MYC and MW7or M99 with NQG or NQF) Vehicle Speed Sensor (VSS) (MW7 except NQG or NQF) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Page 5307 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Tremec 5-Speed (M96) - Manual Transmission Vehicle Speed Sensor: Service and Repair Tremec 5-Speed (M96) - Manual Transmission Vehicle Speed Sensor Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Tremec 5-Speed (M96) - Manual Transmission > Page 5310 Vehicle Speed Sensor: Service and Repair Tremec 5-Speed (TZ0) - Manual Transmission Vehicle Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the vehicle speed sensor (VSS) electrical connector (1). 3. Remove the VSS and O-ring seal. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Tremec 5-Speed (M96) - Manual Transmission > Page 5311 1. Coat a NEW O-ring seal with a thin film of Synchro-mesh transmission fluid GM P/N 12345349 (Canadian P/N 10953465), or equivalent. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the VSS and O-ring seal. Tighten the VSS to 16 Nm (12 lb ft). 3. Connect the VSS electrical connector (1). 4. Lower the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Tremec 5-Speed (M96) - Manual Transmission > Page 5312 Vehicle Speed Sensor: Service and Repair MP 1222/1225/1226-NQG - Transfer Case Vehicle Speed Sensor Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Tremec 5-Speed (M96) - Manual Transmission > Page 5313 Vehicle Speed Sensor: Service and Repair MP 1625/1626-NQF - Transfer Case Vehicle Speed Sensor Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Tremec 5-Speed (M96) - Manual Transmission > Page 5314 Vehicle Speed Sensor: Service and Repair MP 3023/3024-NQH - Transfer Case Vehicle Speed Sensor Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams Transmission Position Switch/Sensor: Diagrams Component Connector End Views Park/Neutral Position (PNP) Switch (M30) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 5318 Transmission Position Switch/Sensor: Service and Repair Manual Shift Shaft, Detent Lever, and Position Switch Assembly Replacement Removal Procedure 1. Remove the control valve assembly from the transmission. Refer to Control Valve Body Replacement (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Valve Body/Service and Repair). Note: The detent lever/IMS retaining bolt contains patch lock material on the threads. Do not reuse the retaining bolt. 2. Remove the detent lever/IMS retaining bolt (1) using a T27 TORX(R) bit and discard the retaining bolt. Caution: DO NOT mar the transmission case surface around the spherical pin when removing or installing the spherical pin. An unmarred surface is required to maintain the seal between the control valve assembly and the transmission case. Caution: DO NOT twist the spherical pin when removing the pin from the transmission case. Damage to the transmission case can occur. 3. Place a protective plate on the transmission case surface around the spherical pin (3). Remove the spherical pin (3) from the transmission case. 4. Slide the manual shift shaft (5) through the detent lever/IMS assembly (4) and through the manual shift shaft seal. 5. Rotate the detent lever/IMS assembly to disengage the park pawl apply assembly (2). Remove the detent lever/IMS assembly (4). Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 5319 1. Place the new detent lever/IMS assembly (4) in position in the transmission case. Rotate the detent lever/IMS assembly to engage the park pawl apply assembly (2). Reinstall the manual shift shaft (5) through the manual shift shaft seal and through the detent lever/IMS assembly (4). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Push the manual shift shaft (5) into the final position in the transmission case. 3. Install the spherical pin (3) into the transmission case that retains the manual shift shaft. 4. Install the detent lever/IMS retaining bolt (1) using a T27 TORX(R) bit. Tighten the bolt (1) to 10 Nm (92 lb in). 5. Install the control valve assembly. Refer to Control Valve Body Replacement (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Valve Body/Service and Repair). Note: The FastLearn, adapt, procedure must be performed. This can be done in 1 step using a scan tool. If this procedure is not done, the TCM adaptive values will be at the settings that it learned for the old components and will be in slow adaptive mode. Under these conditions, it will take an unacceptably long time for the adaptive values to converge to levels suitable for the new transmission. 6. Perform the FastLearn procedure. Refer to FastLearn Procedure (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Testing and Inspection/Programming and Relearning). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Turbocharger Vane Position Sensor > Component Information > Technical Service Bulletins > Engine - Info on Duramax Turbo Vane Position Sensor Turbocharger Vane Position Sensor: Technical Service Bulletins Engine - Info on Duramax Turbo Vane Position Sensor INFORMATION Bulletin No.: 10-06-04-014 Date: November 03, 2010 Subject: Information on Duramax Turbo Vane Position Sensor Models: 2010-2011 Chevrolet Express Vans, Silverado 2010-2011 GMC Savana Vans, Sierra Equipped with Duramax(TM) Diesel Engine (RPOs LGH, LML) An improvement has been implemented to the turbocharger vane position sensor. Some turbochargers existing in inventory have the old style vane position sensor. If turbochargers, GM P/N 12635325 or 12635167 are being replaced, the original turbo vane sensor should be removed and replaced with the new style sensor, GM P/N 12643471. Turbochargers that are supersessions to these part numbers will have the new style vane position sensor and no action is necessary. Parts Information Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Turbocharger Vane Position Sensor > Component Information > Technical Service Bulletins > Page 5324 Turbocharger Vane Position Sensor: Diagrams Component Connector End Views Turbocharger Vane Position Sensor (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Valve Deactivation Solenoid > Component Information > Diagrams Valve Deactivation Solenoid: Diagrams Component Connector End Views Valve Lifter Oil Manifold (VLOM) Assembly (LMG, LC9, LZ1 or L96) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > A/T - Shifting/Poor Performance Vehicle Speed Sensor: Technical Service Bulletins A/T - Shifting/Poor Performance INFORMATION Bulletin No.: 01-03-10-010G Date: July 22, 2009 Subject: Inspection of Tire and Wheel Size Prior to Diagnosis of Transmission Shifts, Poor Performance, Speedometer, Cruise Control Concerns Models: 2001-2007 Chevrolet Silverado Pickup (Classic) Models Equipped with Allison(R) Automatic Transmission Only 2001-2007 GMC Sierra Pickup (Classic) Models Equipped with Allison(R) Automatic Transmission Only 2007-2010 Chevrolet Silverado Pickup HD Models 2007-2010 GMC Sierra Pickup HD Models Supercede: This bulletin is being revised to add the 2008-2010 model years, update the tire size information and reference the vehicle tire information label locations. Please discard Corporate Bulletin Number 01-03-10-010F (Section 03 - Suspension). GM has developed and matched specific tires for your vehicle. The original equipment tires and their respective size installed on the vehicle when it was new, were designed to meet General Motors Tire Performance Criteria Specification (TPC Spec) system rating. GM's exclusive TPC Spec system considers over a dozen critical specifications that impact the overall performance of the vehicle. A truck that has different tires and wheels from the original equipment designed for that vehicle will have engine power/performance concerns, transmission shift concerns, speedometer registered speed concerns, cruise control concerns and increased steering effort, especially during parking lot maneuvers at slow speeds. The engine control module (ECM) and transmission control module (TCM) use engine speed (RPM) and vehicle speed sensor (VSS) inputs as operational parameters for engine torque, transmission shifting, cruise control operation and speedometer indicated vehicle speed. Calibrations for different tire/wheel combinations are not available. Therefore, changing of tire and/or wheel size should not be undertaken by dealerships or truck owners. Proper diagnosis of engine, transmission, speedometer and cruise control concerns MUST begin with an inspection of tire/wheel size. Important A vehicle specific Tire and Loading Information label is attached to the center pillar (B-pillar) of the vehicle. With the driver's door open, you will find the label attached below the door lock post (striker). The label shows the size of the original equipment tires and the recommended cold tire inflation pressures.A vehicle specific Certification/Tire label is found on the rear edge of the driver's door. The label shows the size of the original equipment tires and the recommended cold tire inflation pressures. 2001-2007 Pickups (Classic) Equipped with Allison(R) Automatic Transmission Only Inspect the vehicle for the proper tire size as indicated in the following information. - The 2500 series trucks have LT245/75R16E tires as standard equipment. - The 3500 series trucks with single rear wheels have LT265/75R16E tires as standard equipment. - The 3500 series trucks with dual rear wheels have LT215/85R16D tires as standard equipment. 2007 Pickups HD Models (New Design Pickups) Inspect the vehicle for the proper tire size as indicated in the following information. - The 2500 series trucks have LT245/75R16E tires as standard equipment. - The 3500 series trucks with single rear wheels have LT265/75R16E tires as standard equipment. - The 3500 series trucks with dual rear wheels have LT215/85R16E tires as standard equipment. 2008-2010 Pickups HD Models (New Design Pickups) Inspect the vehicle for the proper tire size as indicated in the following information. - The 2500 series trucks have LT245/75R16E tires as standard equipment. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > A/T - Shifting/Poor Performance > Page 5332 - The 3500 series trucks with single rear wheels have LT265/75R16E tires as standard equipment. - The 3500 series trucks with dual rear wheels have LT225/75R17E tires as standard equipment. If a truck is found to have other than the above listed tire sizes, no further diagnosis should be undertaken until the original size tires and wheels are reinstalled on the truck. Warranty Information Reinstalling the proper wheels and tires on the vehicle, prior to performing any type of diagnosis of the truck, would be considered truck owner responsibility and not a warranty repair. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Page 5333 Vehicle Speed Sensor: Locations Harness Routing Views Engine Chassis Harness Routing - Rear (Diesel) 1 - X300 2 - G300 3 - Automatic Transmission Turbine Speed Sensor (MW7) 4 - Automatic Transmission (MW7) 5 - Vehicle Speed Sensor (VSS) (MW7) 6 - X124 (PTO) 7 - Power Take Off (PTO) Module (PTO) 8 - X175 (MW7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Page 5334 Vehicle Speed Sensor: Diagrams Component Connector End Views Vehicle Speed Sensor (VSS) (M30, TZ0, MYC and MW7or M99 with NQG or NQF) Vehicle Speed Sensor (VSS) (MW7 except NQG or NQF) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Page 5335 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Tremec 5-Speed (M96) - Manual Transmission Vehicle Speed Sensor: Service and Repair Tremec 5-Speed (M96) - Manual Transmission Vehicle Speed Sensor Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Tremec 5-Speed (M96) - Manual Transmission > Page 5338 Vehicle Speed Sensor: Service and Repair Tremec 5-Speed (TZ0) - Manual Transmission Vehicle Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the vehicle speed sensor (VSS) electrical connector (1). 3. Remove the VSS and O-ring seal. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Tremec 5-Speed (M96) - Manual Transmission > Page 5339 1. Coat a NEW O-ring seal with a thin film of Synchro-mesh transmission fluid GM P/N 12345349 (Canadian P/N 10953465), or equivalent. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the VSS and O-ring seal. Tighten the VSS to 16 Nm (12 lb ft). 3. Connect the VSS electrical connector (1). 4. Lower the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Tremec 5-Speed (M96) - Manual Transmission > Page 5340 Vehicle Speed Sensor: Service and Repair MP 1222/1225/1226-NQG - Transfer Case Vehicle Speed Sensor Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Tremec 5-Speed (M96) - Manual Transmission > Page 5341 Vehicle Speed Sensor: Service and Repair MP 1625/1626-NQF - Transfer Case Vehicle Speed Sensor Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Service and Repair > Tremec 5-Speed (M96) - Manual Transmission > Page 5342 Vehicle Speed Sensor: Service and Repair MP 3023/3024-NQH - Transfer Case Vehicle Speed Sensor Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Technical Service Bulletins > Recalls for Exhaust Temperature Sensor: > 11054 > Apr > 11 > Recall - Replace Exhaust Gas Temperature Sensor Technical Service Bulletin # 11054 Date: 110412 Recall - Replace Exhaust Gas Temperature Sensor PRODUCT EMISSION Bulletin No.: 11054 Date: April 12, 2011 Subject: 11054 - Reduced Engine Performance and Emission Control - Replace Exhaust Gas Temperature Sensors Models: 2010 Chevrolet Express, Silverado HD 2010 GMC Savana, Sierra HD With 6.6L V8 Duramax Diesel Engine (LMM) 2007-2009 Chevrolet Express, Kodiak, Silverado HD 2007-2009 GMC Savana, Sierra HD, TopKick With 6.6L V8 Duramax Diesel Engine (LMM) Serviced with a Suspect EGT Sensor Condition General Motors has decided to conduct a Voluntary Emission Recall involving certain 2010 model year Chevrolet Express, Silverado HD; and GMC Savana, Sierra HD vehicles equipped with a 6.6L V8 Duramax diesel engine (LMM); and 2007-2009 model year Chevrolet Express, Kodiak, Silverado HD; and GMC Savana, Sierra HD, and TopKick vehicles equipped with a 6.6L V8 Duramax diesel engine (LMM) that may have been serviced with a suspect Exhaust Gas Temperature (EGT) sensor. On these vehicles, the circuit board welds on the EGT sensors in the exhaust system may not be to GM specification. If a weld fails, the Service Engine Soon light will illuminate in the instrument panel, the exhaust gas may not be filtered properly, and the engine power may be reduced. Correction Dealers are to replace both EGT sensors. Vehicles Involved Involved are certain 2010 model year Chevrolet Express, Silverado HD; and GMC Savana, Sierra HD vehicles equipped with a 6.6L V8 Duramax diesel engine (LMM); and 2007-2009 model year Chevrolet Express, Kodiak, Silverado HD; and GMC Savana, Sierra HD, and TopKick vehicles equipped with a 6.6L V8 Duramax diesel engine (LMM) that may have been serviced with a suspect EGT sensor. Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Required Field Actions section in the Global Warranty system. Not all vehicles may be involved. For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to US and Canadian dealers through the GM GlobalConnect Recall Reports, or sent directly to export dealers. Dealers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information Parts required to complete this recall are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Service Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Technical Service Bulletins > Recalls for Exhaust Temperature Sensor: > 11054 > Apr > 11 > Recall - Replace Exhaust Gas Temperature Sensor > Page 5353 1. Remove and replace position 1 and position 2 exhaust gas temperature sensors (1). Refer to Exhaust Temperature Sensor Replacement in SI. 2. CALIFORNIA, CONNECTICUT, MASSACHUSETTS, MAINE, OREGON, VERMONT, & WASHINGTON VEHICLES ONLY: Install a Recall Identification Label. Also, for California vehicles complete a "Proof of Correction" certificate upon recall completion. Recall Identification Label California/Connecticut/Massachusetts/Maine/Oregon/Vermont/Washington Vehicles Only) Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five-digit dealer code of the dealer performing the recall service. This information may be inserted with a ballpoint pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Recall Identification Label, be sure to pull the tab to allow adhesion of the clear protective covering. Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials by ordering on the web from DWD Store, www.gmdealerworld.com, and then click on the DWD Store link. Request Item Number S-1015 when ordering. Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a transaction using the table below. Customer Notification - For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter included with this bulletin). In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper maintenance. The vehicle may fail a state or local emission inspection test if the recall work is not completed. Customer Notification - For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the attached sample letter. In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Technical Service Bulletins > Recalls for Exhaust Temperature Sensor: > 11054 > Apr > 11 > Recall - Replace Exhaust Gas Temperature Sensor > Page 5354 maintenance. The vehicle may fail a state or local emission inspection test if the recall work is not completed. Dealer Recall Responsibility All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. ***THE FOLLOWING 2 PARAGRAPHS ARE NOT FOR CANADA OR EXPORT*** When a California emissions recall is completed by a GM dealer, the dealer must provide the vehicle owner a "Proof of Correction Certificate" which the owner may need to present to the California Department Of Motor Vehicles (DMV) when renewing their vehicle registration. Without this correction certificate, the owner may be unable to renew their vehicle registration. Additional Certificates can be obtained, at no charge, from Dealer Support Materials by ordering on the web from the DWD Store, www.gmdealerworld.com, and then click on the DWD Store link; request GM Item Number 1825 when ordering. Disclaimer Owner Letter Owner Letter Dear General Motors Customer: This notice is sent to inform you that General Motors is conducting a voluntary emission recall that includes your vehicle. Reason For This Recall: General Motors has decided to conduct a Voluntary Emission Recall involving certain 2010 model year Chevrolet Express, Silverado HD; and GMC Savana, Sierra HD vehicles equipped with a 6.6L V8 Duramax diesel engine; and 2007-2009 model year Chevrolet Express, Kodiak, Silverado HD; and GMC Savana, Sierra HD, and TopKick vehicles equipped with a 6.6L V8 Duramax diesel engine that may have been serviced with a suspect Exhaust Gas Temperature (EGT) sensor. The circuit board welds on the EGT sensors in the exhaust system may not be to GM specification. If a weld fails, the Service Engine Soon light will illuminate in the instrument panel, the exhaust gas may not be filtered properly, and the engine power may be reduced. What Will Be Done: Your GM dealer will replace both EGT sensors. This service will be performed for you at no charge. What You Should Do: Please contact your GM dealer as soon as possible to arrange a service date and to assure parts availability. Instructions for making this correction have been sent to your dealer. Please ask your dealer if you wish to know how much time will be needed to schedule, process, and repair your vehicle. If you have any questions or need any assistance, just contact your dealer or the appropriate Customer Assistance Center at the number listed below. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Technical Service Bulletins > Recalls for Exhaust Temperature Sensor: > 11054 > Apr > 11 > Recall - Replace Exhaust Gas Temperature Sensor > Page 5355 Emission Law Information: In order to ensure your full protection under the emission warranty made applicable to your vehicle by State and Federal Law, and your right to participate in future recalls, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could legally be determined to be lack of proper maintenance of your vehicle. Also, your vehicle may fail a state or local emission inspection if this recall is not accomplished. IMPORTANT MESSAGE FOR CALIFORNIA RESIDENTS The California Air Resources Board (CARB) requires vehicle emission recalls be completed prior to California registration renewal. Uncorrected emission recalls will result in the inability to renew your California vehicle registration. At the time of emission recall completion, your California dealer will issue a "Proof of Correction Certificate". Keep this certificate and, if required, present it to the Department of Motor Vehicles when renewing your California registration as proof of recall completion. We are sorry to cause you this inconvenience; however, we have taken this action in the interest of your continued satisfaction with our products. Jim Moloney General Director, Customer and Relationship Services 11054 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exhaust Temperature Sensor: > 11054 > Apr > 11 > Recall - Replace Exhaust Gas Temperature Sensor Technical Service Bulletin # 11054 Date: 110412 Recall - Replace Exhaust Gas Temperature Sensor PRODUCT EMISSION Bulletin No.: 11054 Date: April 12, 2011 Subject: 11054 - Reduced Engine Performance and Emission Control - Replace Exhaust Gas Temperature Sensors Models: 2010 Chevrolet Express, Silverado HD 2010 GMC Savana, Sierra HD With 6.6L V8 Duramax Diesel Engine (LMM) 2007-2009 Chevrolet Express, Kodiak, Silverado HD 2007-2009 GMC Savana, Sierra HD, TopKick With 6.6L V8 Duramax Diesel Engine (LMM) Serviced with a Suspect EGT Sensor Condition General Motors has decided to conduct a Voluntary Emission Recall involving certain 2010 model year Chevrolet Express, Silverado HD; and GMC Savana, Sierra HD vehicles equipped with a 6.6L V8 Duramax diesel engine (LMM); and 2007-2009 model year Chevrolet Express, Kodiak, Silverado HD; and GMC Savana, Sierra HD, and TopKick vehicles equipped with a 6.6L V8 Duramax diesel engine (LMM) that may have been serviced with a suspect Exhaust Gas Temperature (EGT) sensor. On these vehicles, the circuit board welds on the EGT sensors in the exhaust system may not be to GM specification. If a weld fails, the Service Engine Soon light will illuminate in the instrument panel, the exhaust gas may not be filtered properly, and the engine power may be reduced. Correction Dealers are to replace both EGT sensors. Vehicles Involved Involved are certain 2010 model year Chevrolet Express, Silverado HD; and GMC Savana, Sierra HD vehicles equipped with a 6.6L V8 Duramax diesel engine (LMM); and 2007-2009 model year Chevrolet Express, Kodiak, Silverado HD; and GMC Savana, Sierra HD, and TopKick vehicles equipped with a 6.6L V8 Duramax diesel engine (LMM) that may have been serviced with a suspect EGT sensor. Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Required Field Actions section in the Global Warranty system. Not all vehicles may be involved. For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to US and Canadian dealers through the GM GlobalConnect Recall Reports, or sent directly to export dealers. Dealers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information Parts required to complete this recall are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Service Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exhaust Temperature Sensor: > 11054 > Apr > 11 > Recall - Replace Exhaust Gas Temperature Sensor > Page 5361 1. Remove and replace position 1 and position 2 exhaust gas temperature sensors (1). Refer to Exhaust Temperature Sensor Replacement in SI. 2. CALIFORNIA, CONNECTICUT, MASSACHUSETTS, MAINE, OREGON, VERMONT, & WASHINGTON VEHICLES ONLY: Install a Recall Identification Label. Also, for California vehicles complete a "Proof of Correction" certificate upon recall completion. Recall Identification Label California/Connecticut/Massachusetts/Maine/Oregon/Vermont/Washington Vehicles Only) Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five-digit dealer code of the dealer performing the recall service. This information may be inserted with a ballpoint pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Recall Identification Label, be sure to pull the tab to allow adhesion of the clear protective covering. Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials by ordering on the web from DWD Store, www.gmdealerworld.com, and then click on the DWD Store link. Request Item Number S-1015 when ordering. Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a transaction using the table below. Customer Notification - For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter included with this bulletin). In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper maintenance. The vehicle may fail a state or local emission inspection test if the recall work is not completed. Customer Notification - For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the attached sample letter. In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exhaust Temperature Sensor: > 11054 > Apr > 11 > Recall - Replace Exhaust Gas Temperature Sensor > Page 5362 maintenance. The vehicle may fail a state or local emission inspection test if the recall work is not completed. Dealer Recall Responsibility All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. ***THE FOLLOWING 2 PARAGRAPHS ARE NOT FOR CANADA OR EXPORT*** When a California emissions recall is completed by a GM dealer, the dealer must provide the vehicle owner a "Proof of Correction Certificate" which the owner may need to present to the California Department Of Motor Vehicles (DMV) when renewing their vehicle registration. Without this correction certificate, the owner may be unable to renew their vehicle registration. Additional Certificates can be obtained, at no charge, from Dealer Support Materials by ordering on the web from the DWD Store, www.gmdealerworld.com, and then click on the DWD Store link; request GM Item Number 1825 when ordering. Disclaimer Owner Letter Owner Letter Dear General Motors Customer: This notice is sent to inform you that General Motors is conducting a voluntary emission recall that includes your vehicle. Reason For This Recall: General Motors has decided to conduct a Voluntary Emission Recall involving certain 2010 model year Chevrolet Express, Silverado HD; and GMC Savana, Sierra HD vehicles equipped with a 6.6L V8 Duramax diesel engine; and 2007-2009 model year Chevrolet Express, Kodiak, Silverado HD; and GMC Savana, Sierra HD, and TopKick vehicles equipped with a 6.6L V8 Duramax diesel engine that may have been serviced with a suspect Exhaust Gas Temperature (EGT) sensor. The circuit board welds on the EGT sensors in the exhaust system may not be to GM specification. If a weld fails, the Service Engine Soon light will illuminate in the instrument panel, the exhaust gas may not be filtered properly, and the engine power may be reduced. What Will Be Done: Your GM dealer will replace both EGT sensors. This service will be performed for you at no charge. What You Should Do: Please contact your GM dealer as soon as possible to arrange a service date and to assure parts availability. Instructions for making this correction have been sent to your dealer. Please ask your dealer if you wish to know how much time will be needed to schedule, process, and repair your vehicle. If you have any questions or need any assistance, just contact your dealer or the appropriate Customer Assistance Center at the number listed below. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exhaust Temperature Sensor: > 11054 > Apr > 11 > Recall - Replace Exhaust Gas Temperature Sensor > Page 5363 Emission Law Information: In order to ensure your full protection under the emission warranty made applicable to your vehicle by State and Federal Law, and your right to participate in future recalls, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could legally be determined to be lack of proper maintenance of your vehicle. Also, your vehicle may fail a state or local emission inspection if this recall is not accomplished. IMPORTANT MESSAGE FOR CALIFORNIA RESIDENTS The California Air Resources Board (CARB) requires vehicle emission recalls be completed prior to California registration renewal. Uncorrected emission recalls will result in the inability to renew your California vehicle registration. At the time of emission recall completion, your California dealer will issue a "Proof of Correction Certificate". Keep this certificate and, if required, present it to the Department of Motor Vehicles when renewing your California registration as proof of recall completion. We are sorry to cause you this inconvenience; however, we have taken this action in the interest of your continued satisfaction with our products. Jim Moloney General Director, Customer and Relationship Services 11054 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Service and Repair > Exhaust Temperature Sensor Replacement Position 1 Exhaust Temperature Sensor: Service and Repair Exhaust Temperature Sensor Replacement Position 1 Exhaust Temperature Sensor Replacement - Position 1 Removal Procedure Caution: The exhaust temperature sensor and exhaust pressure differential sensor line fittings may be difficult to remove when the engine exhaust system temperature is below 48°C (120°F). Excessive force may damage the threads in the exhaust manifold or exhaust pipe. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the exhaust temperature sensor electrical connector (1) from the chassis wiring harness electrical connector (2). 3. Remove the exhaust temperature sensor. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Service and Repair > Exhaust Temperature Sensor Replacement Position 1 > Page 5366 Note: A special anti-seize compound is used in the sensor or line fittings threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor or line fitting easier to remove. New, or service replacement sensors or line fittings already have the compound applied to the threads. If the sensor or line fittings are removed from an exhaust component and if for any reason the sensor or line fitting are reinstalled, the threads must have anti-seize compound applied before reinstallation. 1. If reinstalling the old temperature sensor or differential pressor sensor line fittings, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the exhaust temperature sensor. Tighten the sensor to 45 Nm (33 lb ft). 3. Connect the exhaust temperature sensor electrical connector (1) to the chassis wiring harness electrical connector (2). 4. Lower the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Service and Repair > Exhaust Temperature Sensor Replacement Position 1 > Page 5367 Exhaust Temperature Sensor: Service and Repair Exhaust Temperature Sensor Replacement Position 2 Exhaust Temperature Sensor Replacement - Position 2 Removal Procedure Caution: The exhaust temperature sensor and exhaust pressure differential sensor line fittings may be difficult to remove when the engine exhaust system temperature is below 48°C (120°F). Excessive force may damage the threads in the exhaust manifold or exhaust pipe. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the exhaust temperature sensor (3) electrical connector from the chassis wiring harness electrical connector (4). 3. Remove the exhaust temperature sensor. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Exhaust Temperature Sensor > Component Information > Service and Repair > Exhaust Temperature Sensor Replacement Position 1 > Page 5368 Note: A special anti-seize compound is used in the sensor or line fittings threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor or line fitting easier to remove. New, or service replacement sensors or line fittings already have the compound applied to the threads. If the sensor or line fittings are removed from an exhaust component and if for any reason the sensor or line fitting are reinstalled, the threads must have anti-seize compound applied before reinstallation. 1. If reinstalling the old temperature sensor or differential pressor sensor line fittings, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the exhaust temperature sensor. Tighten the sensor to 45 Nm (33 lb ft). 3. Connect the exhaust temperature sensor (3) electrical connector to the chassis wiring harness electrical connector (4). 4. Lower the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Continuous Trap Oxidizer, Diesel Emissions > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Exhaust Pressure Differential Sensor Replacement (Pickup) Exhaust Pressure Differential Sensor: Service and Repair Exhaust Pressure Differential Sensor Replacement (Pickup) Exhaust Pressure Differential Sensor Replacement (Pickup) Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the chassis wiring harness electrical connector (1) from the exhaust differential pressure sensor (2). 3. Reposition the exhaust differential pressure sensor pipe assembly hose clamps (3). 4. Remove the exhaust differential pressure sensor pipe assembly hoses from the sensor. 5. Remove the exhaust differential pressure sensor bracket bolts (1). 6. Remove the exhaust differential pressure sensor (2). Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Continuous Trap Oxidizer, Diesel Emissions > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Exhaust Pressure Differential Sensor Replacement (Pickup) > Page 5374 1. Position the exhaust differential pressure sensor (2) to the bracket. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the exhaust differential pressure sensor bracket bolts (1). Tighten the bolts to 9 Nm (80 lb in). 3. Install the exhaust differential pressure sensor pipe assembly hoses to the sensor. 4. Position the exhaust differential pressure sensor pipe assembly hose clamps (3). 5. Connect the chassis wiring harness electrical connector (1) to the exhaust differential pressure sensor (2). 6. Lower the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Continuous Trap Oxidizer, Diesel Emissions > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Exhaust Pressure Differential Sensor Replacement (Pickup) > Page 5375 Exhaust Pressure Differential Sensor: Service and Repair Exhaust Pressure Differential Sensor Replacement (Cab/Chassis) Exhaust Pressure Differential Sensor Replacement (Cab/Chassis) Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the chassis wiring harness electrical connector (1) from the exhaust differential pressure sensor (2). 3. Reposition the exhaust differential pressure sensor pipe assembly hose clamps (3). 4. Remove the exhaust differential pressure sensor pipe assembly hoses from the sensor. 5. Remove the exhaust differential pressure sensor bracket bolts (1). 6. Remove the exhaust differential pressure sensor (2). Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Continuous Trap Oxidizer, Diesel Emissions > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Exhaust Pressure Differential Sensor Replacement (Pickup) > Page 5376 1. Position the exhaust differential pressure sensor (2) to the bracket. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the exhaust differential pressure sensor bracket bolts (1). Tighten the bolts to 9 Nm (80 lb in). 3. Install the exhaust differential pressure sensor pipe assembly hoses to the sensor. 4. Position the exhaust differential pressure sensor pipe assembly hose clamps (3). 5. Connect the chassis wiring harness electrical connector (1) to the exhaust differential pressure sensor (2). 6. Lower the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Continuous Trap Oxidizer, Diesel Emissions > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Exhaust Pressure Differential Sensor Replacement (Pickup) > Page 5377 Exhaust Pressure Differential Sensor: Service and Repair Exhaust Pressure Differential Sensor Pipe Replacement (Pickup) Exhaust Pressure Differential Sensor Pipe Replacement (Pickup) Removal Procedure Caution: The exhaust temperature sensor and exhaust pressure differential sensor line fittings may be difficult to remove when the engine exhaust system temperature is below 48°C (120°F). Excessive force may damage the threads in the exhaust manifold or exhaust pipe. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Reposition the exhaust differential pressure sensor pipe assembly hose clamps (3). 3. Remove the exhaust differential pressure sensor pipe assembly hoses from the sensor. 4. Remove the exhaust differential pressure sensor pipe bracket bolt and nut. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Continuous Trap Oxidizer, Diesel Emissions > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Exhaust Pressure Differential Sensor Replacement (Pickup) > Page 5378 5. Loosen the exhaust differential pressure sensor pipe assembly fittings (1). 6. Remove the exhaust differential pressure sensor pipe assembly. Installation Procedure Note: A special anti-seize compound is used in the sensor or line fittings threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor or line fitting easier to remove. New, or service replacement sensors or line fittings already have the compound applied to the threads. If the sensor or line fittings are removed from an exhaust component and if for any reason the sensor or line fitting are reinstalled, the threads must have anti-seize compound applied before reinstallation. 1. If reinstalling the old temperature sensor or differential pressor sensor line fittings, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Continuous Trap Oxidizer, Diesel Emissions > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Exhaust Pressure Differential Sensor Replacement (Pickup) > Page 5379 Note: Ensure to route the pipe assembly over the frame crossmember. 2. Position and install the exhaust differential pressure sensor pipe assembly to the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Tighten the exhaust differential pressure sensor pipe assembly fittings (1). Tighten the fittings to 45 Nm (33 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Continuous Trap Oxidizer, Diesel Emissions > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Exhaust Pressure Differential Sensor Replacement (Pickup) > Page 5380 4. Position the exhaust differential pressure sensor pipe bracket to the exhaust hanger and install the bolt and nut. Tighten the bracket bolt/nut to 9 Nm (80 lb in). 5. Install the exhaust differential pressure sensor pipe assembly hoses to the sensor. 6. Position the exhaust differential pressure sensor pipe assembly hose clamps (3). 7. Lower the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Continuous Trap Oxidizer, Diesel Emissions > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Exhaust Pressure Differential Sensor Replacement (Pickup) > Page 5381 Exhaust Pressure Differential Sensor: Service and Repair Exhaust Pressure Differential Sensor Pipe Replacement (Cab/Chassis) Exhaust Pressure Differential Sensor Pipe Replacement (Cab/Chassis) Removal Procedure Caution: The exhaust temperature sensor and exhaust pressure differential sensor line fittings may be difficult to remove when the engine exhaust system temperature is below 48°C (120°F). Excessive force may damage the threads in the exhaust manifold or exhaust pipe. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Reposition the exhaust differential pressure sensor pipe assembly hose clamps (3). 3. Remove the exhaust differential pressure sensor pipe assembly hoses from the sensor. 4. Remove the exhaust differential pressure sensor pipe bracket bolt and nut. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Continuous Trap Oxidizer, Diesel Emissions > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Exhaust Pressure Differential Sensor Replacement (Pickup) > Page 5382 5. Loosen the exhaust differential pressure sensor pipe assembly fittings (1). 6. Remove the exhaust differential pressure sensor pipe assembly. Installation Procedure Note: A special anti-seize compound is used in the sensor or line fittings threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor or line fitting easier to remove. New, or service replacement sensors or line fittings already have the compound applied to the threads. If the sensor or line fittings are removed from an exhaust component and if for any reason the sensor or line fitting are reinstalled, the threads must have anti-seize compound applied before reinstallation. 1. If reinstalling the old temperature sensor or differential pressor sensor line fittings, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Continuous Trap Oxidizer, Diesel Emissions > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Exhaust Pressure Differential Sensor Replacement (Pickup) > Page 5383 Note: Ensure to route the pipe assembly over the frame crossmember. 2. Position and install the exhaust differential pressure sensor pipe assembly to the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Tighten the exhaust differential pressure sensor pipe assembly fittings (1). Tighten the fittings to 45 Nm (33 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Continuous Trap Oxidizer, Diesel Emissions > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Exhaust Pressure Differential Sensor Replacement (Pickup) > Page 5384 4. Position the exhaust differential pressure sensor pipe bracket to the exhaust hanger and install the bolt and nut. Tighten the bracket bolt/nut to 9 Nm (80 lb in). 5. Install the exhaust differential pressure sensor pipe assembly hoses to the sensor. 6. Position the exhaust differential pressure sensor pipe assembly hose clamps (3). 7. Lower the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Diesel Emissions Fluid (DEF) System > Diesel Emissions Fluid > Component Information > Specifications > Capacity Specifications Diesel Emissions Fluid: Capacity Specifications Diesel Exhaust Fluid (DEF) .............................................................................................................................................................. 22.0 liters (5.8 gallons) NOTE: All capacities are approximate. When adding, be sure to fill to the approximate level. Recheck fluid level after filling. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Diesel Emissions Fluid (DEF) System > Diesel Emissions Fluid > Component Information > Specifications > Capacity Specifications > Page 5390 Diesel Emissions Fluid: Fluid Type Specifications DIESEL EXHAUST AFTERTREATMENT SYSTEM Diesel Exhaust Fluid (GM Part No. U.S. 88862659, in Canada 88862660) or diesel exhaust fluid that meets ISO 22241-1 and displays the API Diesel Exhaust Fluid Certification Mark. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Diesel Particle Filter (DPF) > Component Information > Technical Service Bulletins > Exhaust System - DIC Clean Exhaust Filter Mssg/DTC P2463 Diesel Particle Filter (DPF): Technical Service Bulletins Exhaust System - DIC Clean Exhaust Filter Mssg/DTC P2463 INFORMATION Bulletin No.: 10-06-05-002 Date: March 04, 2010 Subject: "Clean Exhaust Filter See Owners Manual Now" Message Displayed on Driver Information Center (DIC), DTC P2463 May Be Set - Inform Customer on Driving Conditions Required for a Self Cleaning of Diesel Particulate Filter (DPF) Models: 2007-2009 Chevrolet Kodiak 2007-2010 Chevrolet Express, Silverado 2007-2009 GMC TopKick 2007-2010 GMC Savana, Sierra Equipped With Duramax(TM) Diesel Engine RPO LMM Please Refer to GMVIS The "CLEAN EXHAUST FILTER SEE OWNERS MANUAL NOW" message may be displayed on the driver information center (DIC) with a DTC P2463 set. This is a result of the customer NOT DRIVING the vehicle at the required speed and necessary amount of time for a self cleaning (regeneration) of the diesel particulate filter (DPF) to occur when the message is displayed. CLEAN EXHAUST FILTER SEE OWNERS MANUAL NOW The "CLEAN EXHAUST FILTER SEE OWNERS MANUAL NOW", message will appear on the driver information center (DIC) when a DPF regeneration is required. This message is displayed to NOTIFY the DRIVER that the status of the vehicle has changed and ACTION is required by the DRIVER to correct the condition. The message is not a onetime display and will occur periodically through the lifetime of the vehicle when a DPF regeneration is required based on engine run time, fuel consumed and distance traveled since the last DPF regeneration. 1. Perform the Diagnostic System Check - Vehicle. 2. Is DTC P2463 set? ‹› If DTC P2463 is set, refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. After following the diagnostic procedure return to this bulletin and PROCEED to Step 3. ‹› If DTC P2463 is not set, then proceed to Step 3 and inform the customer as indicated. Important ADVISE THE CUSTOMER ABOUT ALL OF THE FOLLOWING INFORMATION: 3. The importance of the message and responding to it immediately. Clearing the message will only make the message disappear temporarily and not correct the problem. 4. Guide the customer to their Duramax(TM) Diesel Engine Owners Manual Supplement and review the information titled: "Diesel Particulate Filter", in order to familiarize them with the operation of the system. 5. Extended idle time should be avoided while the "Clean Exhaust Filter" message is displayed because the DPF system is not capable of self cleaning at idle. 6. Instruct the customer that the most efficient way to clean the filter is to DRIVE the vehicle at more than 50 km/h (30 mph) for approximately 20-30 minutes, UNTIL the warning message goes OFF. 7. Ignoring the message and continuing to drive with the DPF warning message ON and the exhaust filter not being cleaned as required will eventually result in the following: 1. The malfunction indicator lamp (MIL) will illuminate at which point the DPF warning message will be displayed and a chime will also sound. 2. Diagnostic Trouble Code DTC P2463 will be set as a result of excessive soot loading in the DPF. 3. The Engine Power Is Reduced message will be displayed. The engine WILL operate in reduced engine power when this occurs. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Diesel Particle Filter (DPF) > Component Information > Technical Service Bulletins > Exhaust System - DIC Clean Exhaust Filter Mssg/DTC P2463 > Page 5395 4. Once this occurs, self cleaning of the DPF is no longer possible and dealer service will be necessary. 5. Possible irreversible damage to the DPF may occur, requiring repair or replacement. 6. Advise the customer that if following the diagnostic procedure for DTC P2463 in SI results in a DPF system malfunction NOT BEING found, the Diesel Particulate Filter (DPF) Service Regeneration SHOULD NOT BE CHARGED TO GM WARRANTY. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Diesel Particle Filter (DPF) > Component Information > Service and Repair > Diesel Particulate Filter (DPF) Service Regeneration Diesel Particle Filter (DPF): Service and Repair Diesel Particulate Filter (DPF) Service Regeneration Diesel Particulate Filter (DPF) Service Regeneration Warning Tailpipe outlet exhaust temperature will be greater than 300°C (572°F) during service regeneration. To help prevent personal injury or property damage from fire or burns, perform the following: 1. Do not connect any shop exhaust removal hoses to the vehicle's tailpipe. 2. Park the vehicle outdoors and keep people, other vehicles, and combustible material away during service regeneration. 3. Do not leave the vehicle unattended. Warning To avoid extremely elevated exhaust temperatures, inspect and remove any debris or mud build up at the exhaust cooler located at the tailpipe. Caution: Due to the elevated engine temperatures created while performing this procedure it is imperative to keep the front of vehicle in an open environment, with the hood open, away from any walls or buildings. This will ensure proper airflow across the radiator. Note: If you were not referred to this document from another diagnostic, DO NOT perform this procedure. Conditions for Running The following conditions must be met in order to enable DPF Service Regeneration: Note: Do not refuel the vehicle during DPF Service Regeneration. * DTCs P2463 or P244B are the only active DTCs displayed. * The battery voltage is greater than 10 volts. * The engine speed is between 600-1,250 RPM. * The exhaust gas temperature (EGT) sensors 1 and 2 are less than 400°C (752°F). * The engine coolant temperature (ECT) sensor 1 is between 70-115°C (158-239°F). * The brake pedal and accelerator pedal are in the released position. * The transmission is in Park or Neutral. Test Procedure 1. Clear all DTCs with a scan tool before proceeding with DPF Service Regeneration. 2. Observe the scan tool DPF Regenerations Completed parameter and record the value. 3. Check the following fluid levels before and after this procedure: * Engine oil * Engine coolant * Power steering * Transmission * Fuel level should be over 15 percent to ensure a successful regeneration. 4. Park the vehicle outside the facility, away from any obstacles, place the transmission in Park and apply the parking brake. 5. Ensure the hood is open. 6. Select DPF Service Regeneration in the Output Controls menu and follow the instruction on the scan tool. 7. Command the DPF Service Regeneration ON with a scan tool. ‹› If the service regeneration failed to start, repair the vehicle for the condition indicated by the scan tool DPF Regen Inhibit Reason parameter. Refer to the Service Regeneration Unsuccessful table. 8. The DPF Service Regeneration will take approximately 35 minutes consisting of the following: 1. 8 minutes for the exhaust system to warm up, with the engine speed slowly increasing to 1,600 RPM, then 2,200 RPM and finally 2,500 RPM 2. 20 minutes for the DPF to regenerate at an engine speed between 2,200-2,500 RPM 3. 3 minutes for the exhaust system to cool down with the engine speed will slowly returning to 1,400 RPM 4. 3 minutes at 800 RPM, then idle speed of 680 RPM 9. The DPF Service Regeneration will be terminated if any of the following actions are performed: Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Diesel Particle Filter (DPF) > Component Information > Service and Repair > Diesel Particulate Filter (DPF) Service Regeneration > Page 5398 * Applying the brake pedal * Applying the accelerator pedal * Selecting Drive or Reverse * Commanding DPF Service Regeneration OFF using the scan tool or disconnecting the scan tool from the vehicle Note: * The DPF Service Regeneration will terminate if the DPF or ECT temperatures exceed a calibrated threshold. * Temporary blue, gray, or white smoke during this procedure may be an indication of a fuel with high sulfur content. 10. After the service regeneration completes, clear all DTCs and turn the ignition OFF for 90 seconds. ‹› If the service regeneration did not complete or aborted, replace the Exhaust Particulate Filter. 11. Engine running, perform the following within 10 minutes of a successful service regeneration. Operate the vehicle within the following Conditions for Running DTC P2002. Refer to DTC P2002 (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P2002). ‹› If DTC P2002 or P244B sets, replace the Exhaust Particulate Filter. 12. Verify that the scan tool DPF Regenerations Completed parameter has increased by one. ‹› If the value has not increased by one, refer to Service Regeneration Unsuccessful. Service Regeneration Unsuccessful The scan tool DPF Regeneration Inhibit reason parameter will display a reason for not enabling or aborting the DPF service regeneration. Refer to the reasons that are displayed and the corrective action for each reason. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Diesel Particle Filter (DPF) > Component Information > Service and Repair > Diesel Particulate Filter (DPF) Service Regeneration > Page 5399 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Diesel Particle Filter (DPF) > Component Information > Service and Repair > Diesel Particulate Filter (DPF) Service Regeneration > Page 5400 Diesel Particle Filter (DPF): Service and Repair Diesel Particulate Filter (DPF) Regeneration Enable Diesel Particulate Filter (DPF) Regeneration Enable Important: The DPF Regeneration Enable is required when specific service procedures have been performed. Do not perform a DPF Regeneration Enable unless instructed to in the Repair Instruction section of the service procedure. After the system repair perform the following to avoid possible damage to the DPF. 1. Ignition ON, clear all DTCs with a scan tool. 2. Select DPF Regeneration Enable within the Special Function menu. 3. Select ON. ‹› The selection can be confirmed by the DPF Regeneration Reason parameter indicating Device Control. 4. Exit the Special Function Menu. The scan tool can now be removed. The vehicle will perform an active Regeneration as soon as the engine running conditions are met. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Diagrams Canister Purge Solenoid: Diagrams Component Connector End Views Evaporative Emission (EVAP) Canister Purge Solenoid Valve (Gas) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Diagrams Canister Vent Valve: Diagrams Component Connector End Views Evaporative Emission (EVAP) Canister Vent Solenoid Valve (Gas) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Technical Service Bulletins > Emissions - EGR Cooler Pressure Tester Adapter EGR Cooler: Technical Service Bulletins Emissions - EGR Cooler Pressure Tester Adapter INFORMATION Bulletin No.: 08-06-04-003B Date: April 18, 2011 Subject: New Tool Availability - EN-48974 - EGR Cooler Pressure Tester Adapter Set to Diagnose Duramax(TM) Diesel Engine EGR Cooler Engine Coolant Leaks into Combustion Chamber Models: 2002-2012 Chevrolet Silverado 2004-2009 Chevrolet Kodiak C4500-C5500 Series 2006-2012 Chevrolet Express Vans 2002-2012 GMC Sierra 2004-2009 GMC TopKick C4500-C5500 Series 2006-2012 GMC Savana Vans Equipped with 6.6L Duramax(TM) Diesel Engine (VINs 1, 2, D, 6, L, 8 - RPOs LB7 (CA Emissions), LLY, LBZ, LMM, LML, LGH) Please Refer to GWM/IVH Attention: The graphics contained in this bulletin for clarity show the EGR cooler connections to J-46091 and EN-48974 on a workbench. The connections are the same with on-vehicle service. Supercede: This bulletin is being revised to add supplemental kit EN-48974-20, 2011-2012 model year vehicles, add graphics and update the EGR cooler testing information. Please discard Corporate Bulletin Number 08-06-04-003A (Section 06 - Engine/Propulsion System). An EGR Cooler Pressure Tester Adapter Set, EN-48974, was shipped essential to dealers in December 2007 to diagnose EGR cooler engine coolant leaks on all Duramax(TM) engines equipped with an EGR system. This adapter set is designed to be used with J-46091-1 - Charge Air Cooler Tester Regulator to pressurize the EGR cooler with shop air and monitor it for leakage. Important Leaks from the EGR cooler may allow coolant to pass through the exhaust system and enter the combustion chambers on the right bank cylinders. Failure to inspect the EGR cooler for leaks may lead to a misdiagnosis for coolant in the combustion chamber. EN-48974 - EGR Cooler Pressure Tester Adapter Set 544259 (Qty 2) 19 mm (3/4 Inch) Hose Clamps EN-48974-3 (Qty 1) 19 mm (3/4 Inch) EGR Cooler Hose Adapter EN-48974-4 (Qty 1) 19 mm (3/4 Inch) Cap Plug EN-48974-1 (Qty 1) 15.9 mm (5/8 Inch) EGR Cooler Hose Adapter EN-48974-2 (Qty 1) 15.9 mm (5/8 Inch) Cap Plug 544258 (Qty 2) 15.9 mm (5/8 Inch) Hose Clamps In December 2010 another supplement to the EGR Cooler Pressure Tester Adapter Set, EN-48974-20, was shipped essential to dealers to diagnose EGR cooler engine coolant leaks on all 2010-2011 Duramax(TM) 6.6L engines equipped with multiple cooler EGR system. This supplement gives the test adapter set a larger variety of sizes to accommodate the newer style coolers that have multiple ports. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Technical Service Bulletins > Emissions - EGR Cooler Pressure Tester Adapter > Page 5414 EN-48974-20 - EGR Cooler Pressure Tester Adapter Set EN-48974-21 (Qty 1) 12.7 mm (1/2 Inch) EGR Cooler Hose Adapter EN-48974-22 (Qty 1) 8 mm (5/16 Inch) EGR Cooler Hose Adapter 544259 (Qty 2) 19 mm (3/4 Inch) Hose Clamps 553016 (Qty 1) 12.7 mm (1/2 Inch) Cap Plug 544258 (Qty 3) 15.9 mm (5/8 Inch) Hose Clamps 553015 (Qty 1) 8 mm (5/16 Inch) Cap Plug 553017 (Qty 1) 22.2 mm (7/8 Inch) Cap Plug Important If an investigation of loss of engine coolant leads to coolant found in one or multiple cylinders on the right bank, YOU MUST test the EGR cooler for leakage BEFORE attempting any engine repair. The cylinders affected will depend on which exhaust valves were open at the time of engine shutdown. 1. Partially drain the engine coolant to allow removal of the EGR cooler coolant hoses. Refer to Cooling System Draining and Filling in SI. 2. Select the appropriate size EGR Cooler Hose Adapter from the EN-48974 - EGR Cooler Pressure Tester Adapter Set. 3. Install the EGR Cooler Hose Adapter (1) and tighten the clamp (2) on the EGR cooler hose barb as shown. 4. Select the appropriate size Cap Plug(s) from the EN-48974 - EGR Cooler Pressure Tester Adapter Set. 5. Install the Cap Plug(s) (1) and tighten the clamp(s) (2) on the EGR cooler hose barb(s) as shown. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Technical Service Bulletins > Emissions - EGR Cooler Pressure Tester Adapter > Page 5415 6. Connect the hose fitting (1) of pressure tester J-46091-1 Charge Air Cooler Tester Regulator to the EGR Cooler Hose Adapter (2) on the EGR cooler as shown. Important SOME J-46091-1 REGULATORS MAY BE PRESET AT 30 PSI WITH THE ADJUSTING KNOB RIVETED IN PLACE. THE RIVET HEAD MUST BE DRILLED OUT WITH A 5/16" DRILL BIT BEFORE ADJUSTMENT. DO NOT DRILL MORE THAN 1/8" IN DEPTH, OR JUST ENOUGH TO REMOVE THE RIVET HEAD. THE RIVET SHAFT DOES NOT HAVE TO BE REMOVED FROM THE REGULATOR. 7. Back off the regulator on J-46091-1 - Charge Air Cooler Tester Regulator by turning counterclockwise until it stops. 8. Connect J-46091-1 - Charge Air Cooler Tester Regulator to the shop air supply. 9. Open the shutoff valve, then slowly turn the regulator on J-46091-1 clockwise until the gauge reads 42 psi. 10. Close the shutoff valve on J-46091-1 and monitor the gauge for pressure decay for 5 minutes. ‹› If the gauge indicates pressure decay, replace the EGR cooler. ‹› If the gauge does not indicate pressure decay, proceed to Step 11. 11. Continue performing the engine diagnosis to determine the source of the coolant leak. 12. Install the EGR cooler. Refer to Exhaust Gas Recirculation Valve and Cooler Installation in SI. 13. Fill the engine coolant to the proper level. Refer to Cooling System Draining and Filling in SI. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Service and Repair > Exhaust Gas Recirculation Valve Cooler Replacement EGR Cooler: Service and Repair Exhaust Gas Recirculation Valve Cooler Replacement Exhaust Gas Recirculation Valve Cooler Replacement Removal Procedure 1. Drain the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair). 2. Remove the charger air outlet pipe. Refer to Charge Air Cooler Outlet Pipe Replacement (See: Fuel Delivery and Air Induction/Turbocharger/Intercooler/Intercooler Duct/Service and Repair/Charge Air Cooler Outlet Pipe Replacement). 3. Remove the air intake pipe. Refer to Air Intake Pipe Replacement (See: Fuel Delivery and Air Induction/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair/Air Intake Pipe Replacement). 4. Open the intake air heater (IAH) harness lead cover (2). 5. Remove the engine wiring harness lead nut (1) from the IAH stud. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Service and Repair > Exhaust Gas Recirculation Valve Cooler Replacement > Page 5418 6. Remove the engine wiring harness lead (3) from the IAH stud. 7. Remove the electrical harness bolts (1). 8. Reposition the harness clip from the intake manifold tube, as needed. 9. Remove the air inlet tube to intake manifold tube bolt and nut. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Service and Repair > Exhaust Gas Recirculation Valve Cooler Replacement > Page 5419 10. Disconnect the intake air heater electrical connector. 11. Disconnect the manifold absolute pressure (MAP) sensor electrical connector. 12. Remove the engine harness clip from the air inlet tube. 13. Remove the air inlet tube nuts and bolt. 14. Remove the air inlet tube. 15. Reposition the heater inlet hose clamp (1) at the exhaust gas recirculation (EGR) valve cooler. 16. Remove the heater inlet hose from the EGR valve cooler and reposition out of the way. 17. Remove the EGR valve cooler coolant hose clamp nut (2). 18. Reposition the EGR valve cooler coolant hose clamp (1). 19. Remove the EGR valve cooler coolant hose from the EGR valve cooler. Reposition the hose out of the way. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Service and Repair > Exhaust Gas Recirculation Valve Cooler Replacement > Page 5420 20. Remove the right exhaust pipe to EGR valve cooler nuts (2). 21. Remove the rear EGR valve cooler bolts (1). 22. Remove the outside bolt (2) of the EGR cooler heat shield. 23. Loosen the inside EGR cooler heat shield bolt (1) and rotate the heat shield counter-clockwise. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Service and Repair > Exhaust Gas Recirculation Valve Cooler Replacement > Page 5421 24. Remove the front EGR valve cooler bolts (1). 25. Remove the EGR temperature sensors (3). Refer to Exhaust Gas Recirculation Valve Temperature Sensor Replacement - Position 1 (See: EGR Temperature Sensor/Service and Repair/Exhaust Gas Recirculation Valve Temperature Sensor Replacement - Position 1) or Exhaust Gas Recirculation Valve Temperature Sensor Replacement Position 2 (See: EGR Temperature Sensor/Service and Repair/Exhaust Gas Recirculation Valve Temperature Sensor Replacement - Position 2). 26. Remove the EGR valve cooler (2) and gasket (1). Discard the gasket. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Service and Repair > Exhaust Gas Recirculation Valve Cooler Replacement > Page 5422 27. If necessary, perform the following steps in order to remove the EGR brackets: 1. Remove the fuel injection fuel feed manifold bolt (3). 2. Remove the fuel feed pipe nut (1) and reposition the clip. 3. Remove the EGR bracket bolt (2). 4. Remove the EGR brackets (4). 28. If replacing the EGR valve cooler, perform the following steps: 1. Reposition the EGR valve cooler hose clamp and remove the hose (4). 2. Remove the EGR valve bolts (2). 3. Remove the EGR valve (3). 4. Remove and discard the EGR valve gaskets (1). Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Service and Repair > Exhaust Gas Recirculation Valve Cooler Replacement > Page 5423 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. If the EGR valve cooler was replaced, perform the following steps: 1. Position the EGR valve (3) to the cooler. 2. Install the EGR valve bolts (2). Tighten the bolts to 20 Nm (15 lb ft). 3. Install the EGR valve cooler hose (4) and position the hose clamp. 4. Install NEW EGR valve gaskets (1). 2. If necessary, perform the following steps in order to install the EGR brackets: 1. Position the EGR brackets (4). 2. Install the EGR bracket bolt (2). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Service and Repair > Exhaust Gas Recirculation Valve Cooler Replacement > Page 5424 Tighten the bolt to 25 Nm (18 lb ft). 3. Position the clip and install the fuel feed pipe nut (1). Tighten the nut to 25 Nm (18 lb ft). 4. Install the fuel injection fuel feed manifold bolt (3). Tighten the bolt to 25 Nm (18 lb ft). 3. Install a NEW EGR valve cooler gasket (1) onto the cooler studs, and install the EGR cooler (2) to the engine. 4. Install the EGR temperature sensors (3). Refer to Exhaust Gas Recirculation Valve Temperature Sensor Replacement - Position 1 (See: EGR Temperature Sensor/Service and Repair/Exhaust Gas Recirculation Valve Temperature Sensor Replacement - Position 1) or Exhaust Gas Recirculation Valve Temperature Sensor Replacement Position 2 (See: EGR Temperature Sensor/Service and Repair/Exhaust Gas Recirculation Valve Temperature Sensor Replacement - Position 2). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Service and Repair > Exhaust Gas Recirculation Valve Cooler Replacement > Page 5425 5. Install the front EGR valve cooler bolts (1). Tighten the bolts to 50 Nm (37 lb ft). 6. Rotate the EGR cooler heat shield clock-wise and align the outside bolt hole. 7. Tighten the inside EGR cooler heat shield bolt (1) to 25 Nm (18 lb ft). 8. Connect the electrical connector to the fuel rail pressure sensor and tighten the outside bolt (2) to 25 Nm (18 lb ft). 9. Install the rear EGR valve cooler bolts (1). Tighten the bolts to 25 Nm (18 lb ft). 10. Install the right exhaust pipe to EGR valve cooler nuts (2). Tighten the nuts to 53 Nm (39 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Service and Repair > Exhaust Gas Recirculation Valve Cooler Replacement > Page 5426 11. Position the EGR valve cooler coolant hose, and install the hose to the EGR valve cooler. 12. Position the EGR valve cooler coolant hose clamp (1). 13. Install the EGR valve cooler coolant hose clamp nut (2). Tighten the nut to 24 Nm (18 lb ft). 14. Position the heater inlet hose and install the hose to the EGR valve cooler. 15. Position the heater inlet hose clamp (1) at the EGR valve cooler. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Service and Repair > Exhaust Gas Recirculation Valve Cooler Replacement > Page 5427 16. Install the air inlet tube and NEW gaskets. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) 17. Install the air inlet tube nuts and bolt. Tighten the nuts to 25 Nm (18 lb ft). 18. Connect the intake air heater electrical connector. 19. Connect the MAP sensor electrical connector. 20. Install the engine harness clip to the air inlet tube. 21. Install the air inlet tube to intake manifold tube bolt and nut. Tighten the bolt/nut to 10 Nm (89 lb in). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Service and Repair > Exhaust Gas Recirculation Valve Cooler Replacement > Page 5428 22. Install the electrical harness bolts (1). Tighten the bolts to 4 Nm (35 lb in). 23. Install the engine wiring harness lead (3) to the IAH stud. 24. Install the engine wiring harness lead nut (1) to the IAH stud. Tighten the nut to 10 Nm (89 lb in). 25. Close the IAH harness lead cover (2). 26. Install the air intake pipe. Refer to Air Intake Pipe Replacement (See: Fuel Delivery and Air Induction/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair/Air Intake Pipe Replacement). 27. Install the charger air outlet pipe. Refer to Charge Air Cooler Outlet Pipe Replacement (See: Fuel Delivery and Air Induction/Turbocharger/Intercooler/Intercooler Duct/Service and Repair/Charge Air Cooler Outlet Pipe Replacement). 28. Fill the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Service and Repair > Exhaust Gas Recirculation Valve Cooler Replacement > Page 5429 EGR Cooler: Service and Repair Exhaust Gas Recirculation Coolant Hoses/Pipes Replacement Exhaust Gas Recirculation Coolant Hoses/Pipes Replacement Removal Procedure Warning To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam under pressure if radiator cap or surge tank cap is removed while the engine and radiator are still hot. 1. Drain the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair). 2. Reposition the EGR cooler pipe clamp and remove the EGR cooler pipe hose (4) from the EGR cooler tube. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Service and Repair > Exhaust Gas Recirculation Valve Cooler Replacement > Page 5430 3. Remove the upper EGR cooler pipe bolt (2). 4. Remove the lower EGR cooler pipe bolt (1). 5. Remove the EGR cooler pipe from the engine. Installation Procedure 1. Inspect EGR cooling hose (4) and replace as necessary. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Position the EGR cooler pipe and hose (3) to the engine. Tighten the lower bolt (1) to 9 Nm (80 lb in). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Cooler > Component Information > Service and Repair > Exhaust Gas Recirculation Valve Cooler Replacement > Page 5431 3. Install the EGR cooler pipe hose (4) to the EGR cooler tube and reposition the EGR cooler pipe clamp (3). 4. Tighten the clamp bolt (2) to 9 Nm (80 lb in). 5. Fill the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Temperature Sensor > Component Information > Diagrams EGR Temperature Sensor: Diagrams Component Connector End Views Exhaust Gas Recirculation (EGR) Temperature Sensor 1 (Diesel) Exhaust Gas Recirculation (EGR) Temperature Sensor 2 (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Temperature Sensor > Component Information > Diagrams > Page 5435 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Temperature Sensor > Component Information > Service and Repair > Exhaust Gas Recirculation Valve Temperature Sensor Replacement - Position 1 EGR Temperature Sensor: Service and Repair Exhaust Gas Recirculation Valve Temperature Sensor Replacement - Position 1 Exhaust Gas Recirculation Valve Temperature Sensor Replacement - Position 1 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Temperature Sensor > Component Information > Service and Repair > Exhaust Gas Recirculation Valve Temperature Sensor Replacement - Position 1 > Page 5438 EGR Temperature Sensor: Service and Repair Exhaust Gas Recirculation Valve Temperature Sensor Replacement - Position 2 Exhaust Gas Recirculation Valve Temperature Sensor Replacement - Position 2 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Diagrams EGR Valve: Diagrams Component Connector End Views Exhaust Gas Recirculation (EGR) Valve (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Diagrams > Page 5442 EGR Valve: Service and Repair Exhaust Gas Recirculation Valve Replacement Removal Procedure 1. Remove the exhaust gas recirculation (EGR) valve cooler. Refer to Exhaust Gas Recirculation Valve Cooler Replacement (See: EGR Cooler/Service and Repair/Exhaust Gas Recirculation Valve Cooler Replacement). 2. Remove the EGR valve gaskets (1), if required. 3. Remove the EGR valve bolts (2). 4. Remove the EGR valve (3). 5. Remove and discard the EGR valve to valve cooler gasket. Installation Procedure Note: Use a NEW EGR valve gasket when installing the EGR valve. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Diagrams > Page 5443 1. Position a NEW EGR valve to valve cooler gasket to the valve cooler. 2. Position the EGR valve (3) to the valve cooler. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the EGR valve bolts (2). Tighten the bolts to 25 Nm (18 lb ft). 4. Install NEW EGR valve gaskets (1) onto the EGR valve, if required. 5. Install the EGR valve cooler. Refer to Exhaust Gas Recirculation Valve Cooler Replacement (See: EGR Cooler/Service and Repair/Exhaust Gas Recirculation Valve Cooler Replacement). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Actuator > Component Information > Service and Repair EGR Valve Actuator: Service and Repair Exhaust Gas Recirculation Valve Motor Replacement Removal Procedure Note: There is no gasket between the motor and the valve. However, some vehicles may have a thin metal spacer between the motor and the valve that appears to be a gasket. This spacer is used to correct for production variances in some valves and should be reinstalled with the new motor. 1. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (See: Fuel Delivery and Air Induction/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair/Air Cleaner Outlet Duct Replacement). 2. Disconnect the engine wiring harness electrical connector (1) from the exhaust gas recirculation (EGR) valve motor. 3. Remove the EGR valve motor screws. 4. Remove the EGR valve motor, and spacer (if equipped) from the EGR valve. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Actuator > Component Information > Service and Repair > Page 5447 Installation Procedure 1. Position the EGR spacer (if equipped), and NEW EGR valve motor to the EGR valve. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the EGR valve motor screws. Tighten the screws to 2 Nm (18 lb in). 3. Connect the engine wiring harness electrical connector (1) to the EGR valve motor. 4. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (See: Fuel Delivery and Air Induction/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair/Air Cleaner Outlet Duct Replacement). 5. Cycle the ignition to relearn the new EGR valve motor pintle position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Diagrams Pressure Feedback Exhaust Sensor: Diagrams Component Connector End Views Exhaust Pressure Differential Sensor (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > PCV Valve Hose > Component Information > Service and Repair PCV Valve Hose: Service and Repair Positive Crankcase Ventilation Hose/Pipe/Tube Replacement Removal Procedure 1. Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair/Intake Manifold Cover Replacement). Note: After removing the charged air cooler duct, cover the turbocharger opening with tape in order to prevent entry of objects. 2. Loosen the charged air cooler inlet duct connector to turbocharger clamp (1). Note: Do not use a screwdriver or other tool to pry the hose loose. The hose can be torn or damaged. Loosen the hose by twisting. 3. Remove the charged air cooler inlet duct connector (4) from the turbocharger. 4. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (See: Fuel Delivery and Air Induction/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair/Air Cleaner Outlet Duct Replacement). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > PCV Valve Hose > Component Information > Service and Repair > Page 5455 5. Reposition the positive crankcase ventilation (PCV) hose clamp. 6. Remove the PCV hose from the air inlet pipe. 7. Remove the PCV hose from the clip on the top of the turbocharger. 8. Remove the left PCV hose/pipe bolt. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > PCV Valve Hose > Component Information > Service and Repair > Page 5456 9. Remove the right PCV hose/pipe bolt. 10. Remove the PCV hose/pipe. Installation Procedure 1. Install the PCV hose/pipe. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the right PCV hose/pipe bolt. Tighten the bolt to 18 Nm (13 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > PCV Valve Hose > Component Information > Service and Repair > Page 5457 3. Install the left PCV hose/pipe bolt. Tighten the bolt to 18 Nm (13 lb ft). 4. Install the PCV hose to the air inlet pipe. 5. Position the PCV hose clamp. 6. Install the PCV hose to the clip on the top of the turbocharger. 7. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (See: Fuel Delivery and Air Induction/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair/Air Cleaner Outlet Duct Replacement). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > PCV Valve Hose > Component Information > Service and Repair > Page 5458 8. Remove the tape from the turbocharger openings. Note: Lubricate the end of the duct prior to installation. 9. Install the charged air cooler inlet duct connector (4) to the turbocharger. 10. Tighten the charged air cooler inlet duct connector to turbocharger clamp (1). Tighten the clamp to 6 Nm (53 lb in). 11. Install the intake manifold cover. Refer to Intake Manifold Cover Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair/Intake Manifold Cover Replacement). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Service and Repair > Positive Crankcase Ventilation Valve Replacement (Driver Side) Positive Crankcase Ventilation Valve: Service and Repair Positive Crankcase Ventilation Valve Replacement (Driver Side) Positive Crankcase Ventilation Valve Replacement (Driver Side) Removal Procedure Note: After removing the charged air cooler duct, cover the turbocharger opening with tape in order to prevent entry of objects. 1. Loosen the charged air cooler inlet duct connector to turbocharger clamp (1). Note: Do not use a screwdriver or other tool to pry the hose loose. The hose can be torn or damaged. Loosen the hose by twisting. 2. Remove the charged air cooler inlet duct connector (4) from the turbocharger. 3. Remove the positive crankcase ventilation (PCV) cover screws. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Service and Repair > Positive Crankcase Ventilation Valve Replacement (Driver Side) > Page 5463 4. Remove the PCV cover, diaphragm, and spring. 5. Clean and inspect the cover, diaphragm, and spring. 6. Discard the diaphragm if damage is found. Installation Procedure 1. Install the spring, diaphragm, and cover. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the PCV cover screws. Tighten the screws to 4 Nm (35 lb in). 3. Remove the tape from the turbocharger openings. Note: Lubricate the end of the duct prior to installation. 4. Install the charged air cooler inlet duct connector (4) to the turbocharger. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Service and Repair > Positive Crankcase Ventilation Valve Replacement (Driver Side) > Page 5464 5. Tighten the charged air cooler inlet duct connector to turbocharger clamp (1). Tighten the clamp to 6 Nm (53 lb in). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Service and Repair > Positive Crankcase Ventilation Valve Replacement (Driver Side) > Page 5465 Positive Crankcase Ventilation Valve: Service and Repair Positive Crankcase Ventilation Valve Replacement (Passenger Side) Positive Crankcase Ventilation Valve Replacement (Passenger Side) Removal Procedure 1. Remove the air cleaner outlet duct. Refer to Air Cleaner Assembly Replacement (See: Fuel Delivery and Air Induction/Air Cleaner Housing/Service and Repair). 2. Remove the fuel filter bracket bolts. 3. Position the fuel filter assembly out of the way. 4. Remove the positive crankcase ventilation (PCV) cover screws. 5. Remove the PCV cover, diaphragm, and spring. 6. Clean and inspect the cover, diaphragm and spring. 7. Discard the diaphragm if damage is found. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Service and Repair > Positive Crankcase Ventilation Valve Replacement (Driver Side) > Page 5466 Installation Procedure 1. Install the spring, diaphragm and cover. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the PCV cover screws. Tighten the screws to 4 Nm (35 lb in). 3. Position the fuel filter assembly to the engine. 4. Install the fuel filter bracket bolts. Tighten the bolts to 21 Nm (15 lb ft). 5. Install the air cleaner outlet duct. Refer to Air Cleaner Assembly Replacement (See: Fuel Delivery and Air Induction/Air Cleaner Housing/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Technical Service Bulletins > Recalls for Exhaust Temperature Sensor: > 11054 > Apr > 11 > Recall - Replace Exhaust Gas Temperature Sensor Technical Service Bulletin # 11054 Date: 110412 Recall - Replace Exhaust Gas Temperature Sensor PRODUCT EMISSION Bulletin No.: 11054 Date: April 12, 2011 Subject: 11054 - Reduced Engine Performance and Emission Control - Replace Exhaust Gas Temperature Sensors Models: 2010 Chevrolet Express, Silverado HD 2010 GMC Savana, Sierra HD With 6.6L V8 Duramax Diesel Engine (LMM) 2007-2009 Chevrolet Express, Kodiak, Silverado HD 2007-2009 GMC Savana, Sierra HD, TopKick With 6.6L V8 Duramax Diesel Engine (LMM) Serviced with a Suspect EGT Sensor Condition General Motors has decided to conduct a Voluntary Emission Recall involving certain 2010 model year Chevrolet Express, Silverado HD; and GMC Savana, Sierra HD vehicles equipped with a 6.6L V8 Duramax diesel engine (LMM); and 2007-2009 model year Chevrolet Express, Kodiak, Silverado HD; and GMC Savana, Sierra HD, and TopKick vehicles equipped with a 6.6L V8 Duramax diesel engine (LMM) that may have been serviced with a suspect Exhaust Gas Temperature (EGT) sensor. On these vehicles, the circuit board welds on the EGT sensors in the exhaust system may not be to GM specification. If a weld fails, the Service Engine Soon light will illuminate in the instrument panel, the exhaust gas may not be filtered properly, and the engine power may be reduced. Correction Dealers are to replace both EGT sensors. Vehicles Involved Involved are certain 2010 model year Chevrolet Express, Silverado HD; and GMC Savana, Sierra HD vehicles equipped with a 6.6L V8 Duramax diesel engine (LMM); and 2007-2009 model year Chevrolet Express, Kodiak, Silverado HD; and GMC Savana, Sierra HD, and TopKick vehicles equipped with a 6.6L V8 Duramax diesel engine (LMM) that may have been serviced with a suspect EGT sensor. Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Required Field Actions section in the Global Warranty system. Not all vehicles may be involved. For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to US and Canadian dealers through the GM GlobalConnect Recall Reports, or sent directly to export dealers. Dealers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information Parts required to complete this recall are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Service Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Technical Service Bulletins > Recalls for Exhaust Temperature Sensor: > 11054 > Apr > 11 > Recall - Replace Exhaust Gas Temperature Sensor > Page 5476 1. Remove and replace position 1 and position 2 exhaust gas temperature sensors (1). Refer to Exhaust Temperature Sensor Replacement in SI. 2. CALIFORNIA, CONNECTICUT, MASSACHUSETTS, MAINE, OREGON, VERMONT, & WASHINGTON VEHICLES ONLY: Install a Recall Identification Label. Also, for California vehicles complete a "Proof of Correction" certificate upon recall completion. Recall Identification Label California/Connecticut/Massachusetts/Maine/Oregon/Vermont/Washington Vehicles Only) Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five-digit dealer code of the dealer performing the recall service. This information may be inserted with a ballpoint pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Recall Identification Label, be sure to pull the tab to allow adhesion of the clear protective covering. Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials by ordering on the web from DWD Store, www.gmdealerworld.com, and then click on the DWD Store link. Request Item Number S-1015 when ordering. Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a transaction using the table below. Customer Notification - For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter included with this bulletin). In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper maintenance. The vehicle may fail a state or local emission inspection test if the recall work is not completed. Customer Notification - For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the attached sample letter. In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Technical Service Bulletins > Recalls for Exhaust Temperature Sensor: > 11054 > Apr > 11 > Recall - Replace Exhaust Gas Temperature Sensor > Page 5477 maintenance. The vehicle may fail a state or local emission inspection test if the recall work is not completed. Dealer Recall Responsibility All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. ***THE FOLLOWING 2 PARAGRAPHS ARE NOT FOR CANADA OR EXPORT*** When a California emissions recall is completed by a GM dealer, the dealer must provide the vehicle owner a "Proof of Correction Certificate" which the owner may need to present to the California Department Of Motor Vehicles (DMV) when renewing their vehicle registration. Without this correction certificate, the owner may be unable to renew their vehicle registration. Additional Certificates can be obtained, at no charge, from Dealer Support Materials by ordering on the web from the DWD Store, www.gmdealerworld.com, and then click on the DWD Store link; request GM Item Number 1825 when ordering. Disclaimer Owner Letter Owner Letter Dear General Motors Customer: This notice is sent to inform you that General Motors is conducting a voluntary emission recall that includes your vehicle. Reason For This Recall: General Motors has decided to conduct a Voluntary Emission Recall involving certain 2010 model year Chevrolet Express, Silverado HD; and GMC Savana, Sierra HD vehicles equipped with a 6.6L V8 Duramax diesel engine; and 2007-2009 model year Chevrolet Express, Kodiak, Silverado HD; and GMC Savana, Sierra HD, and TopKick vehicles equipped with a 6.6L V8 Duramax diesel engine that may have been serviced with a suspect Exhaust Gas Temperature (EGT) sensor. The circuit board welds on the EGT sensors in the exhaust system may not be to GM specification. If a weld fails, the Service Engine Soon light will illuminate in the instrument panel, the exhaust gas may not be filtered properly, and the engine power may be reduced. What Will Be Done: Your GM dealer will replace both EGT sensors. This service will be performed for you at no charge. What You Should Do: Please contact your GM dealer as soon as possible to arrange a service date and to assure parts availability. Instructions for making this correction have been sent to your dealer. Please ask your dealer if you wish to know how much time will be needed to schedule, process, and repair your vehicle. If you have any questions or need any assistance, just contact your dealer or the appropriate Customer Assistance Center at the number listed below. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Technical Service Bulletins > Recalls for Exhaust Temperature Sensor: > 11054 > Apr > 11 > Recall - Replace Exhaust Gas Temperature Sensor > Page 5478 Emission Law Information: In order to ensure your full protection under the emission warranty made applicable to your vehicle by State and Federal Law, and your right to participate in future recalls, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could legally be determined to be lack of proper maintenance of your vehicle. Also, your vehicle may fail a state or local emission inspection if this recall is not accomplished. IMPORTANT MESSAGE FOR CALIFORNIA RESIDENTS The California Air Resources Board (CARB) requires vehicle emission recalls be completed prior to California registration renewal. Uncorrected emission recalls will result in the inability to renew your California vehicle registration. At the time of emission recall completion, your California dealer will issue a "Proof of Correction Certificate". Keep this certificate and, if required, present it to the Department of Motor Vehicles when renewing your California registration as proof of recall completion. We are sorry to cause you this inconvenience; however, we have taken this action in the interest of your continued satisfaction with our products. Jim Moloney General Director, Customer and Relationship Services 11054 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exhaust Temperature Sensor: > 11054 > Apr > 11 > Recall - Replace Exhaust Gas Temperature Sensor Technical Service Bulletin # 11054 Date: 110412 Recall - Replace Exhaust Gas Temperature Sensor PRODUCT EMISSION Bulletin No.: 11054 Date: April 12, 2011 Subject: 11054 - Reduced Engine Performance and Emission Control - Replace Exhaust Gas Temperature Sensors Models: 2010 Chevrolet Express, Silverado HD 2010 GMC Savana, Sierra HD With 6.6L V8 Duramax Diesel Engine (LMM) 2007-2009 Chevrolet Express, Kodiak, Silverado HD 2007-2009 GMC Savana, Sierra HD, TopKick With 6.6L V8 Duramax Diesel Engine (LMM) Serviced with a Suspect EGT Sensor Condition General Motors has decided to conduct a Voluntary Emission Recall involving certain 2010 model year Chevrolet Express, Silverado HD; and GMC Savana, Sierra HD vehicles equipped with a 6.6L V8 Duramax diesel engine (LMM); and 2007-2009 model year Chevrolet Express, Kodiak, Silverado HD; and GMC Savana, Sierra HD, and TopKick vehicles equipped with a 6.6L V8 Duramax diesel engine (LMM) that may have been serviced with a suspect Exhaust Gas Temperature (EGT) sensor. On these vehicles, the circuit board welds on the EGT sensors in the exhaust system may not be to GM specification. If a weld fails, the Service Engine Soon light will illuminate in the instrument panel, the exhaust gas may not be filtered properly, and the engine power may be reduced. Correction Dealers are to replace both EGT sensors. Vehicles Involved Involved are certain 2010 model year Chevrolet Express, Silverado HD; and GMC Savana, Sierra HD vehicles equipped with a 6.6L V8 Duramax diesel engine (LMM); and 2007-2009 model year Chevrolet Express, Kodiak, Silverado HD; and GMC Savana, Sierra HD, and TopKick vehicles equipped with a 6.6L V8 Duramax diesel engine (LMM) that may have been serviced with a suspect EGT sensor. Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Required Field Actions section in the Global Warranty system. Not all vehicles may be involved. For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to US and Canadian dealers through the GM GlobalConnect Recall Reports, or sent directly to export dealers. Dealers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information Parts required to complete this recall are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Service Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exhaust Temperature Sensor: > 11054 > Apr > 11 > Recall - Replace Exhaust Gas Temperature Sensor > Page 5484 1. Remove and replace position 1 and position 2 exhaust gas temperature sensors (1). Refer to Exhaust Temperature Sensor Replacement in SI. 2. CALIFORNIA, CONNECTICUT, MASSACHUSETTS, MAINE, OREGON, VERMONT, & WASHINGTON VEHICLES ONLY: Install a Recall Identification Label. Also, for California vehicles complete a "Proof of Correction" certificate upon recall completion. Recall Identification Label California/Connecticut/Massachusetts/Maine/Oregon/Vermont/Washington Vehicles Only) Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five-digit dealer code of the dealer performing the recall service. This information may be inserted with a ballpoint pen. Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Recall Identification Label, be sure to pull the tab to allow adhesion of the clear protective covering. Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials by ordering on the web from DWD Store, www.gmdealerworld.com, and then click on the DWD Store link. Request Item Number S-1015 when ordering. Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a transaction using the table below. Customer Notification - For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter included with this bulletin). In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper maintenance. The vehicle may fail a state or local emission inspection test if the recall work is not completed. Customer Notification - For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the attached sample letter. In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exhaust Temperature Sensor: > 11054 > Apr > 11 > Recall - Replace Exhaust Gas Temperature Sensor > Page 5485 maintenance. The vehicle may fail a state or local emission inspection test if the recall work is not completed. Dealer Recall Responsibility All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. ***THE FOLLOWING 2 PARAGRAPHS ARE NOT FOR CANADA OR EXPORT*** When a California emissions recall is completed by a GM dealer, the dealer must provide the vehicle owner a "Proof of Correction Certificate" which the owner may need to present to the California Department Of Motor Vehicles (DMV) when renewing their vehicle registration. Without this correction certificate, the owner may be unable to renew their vehicle registration. Additional Certificates can be obtained, at no charge, from Dealer Support Materials by ordering on the web from the DWD Store, www.gmdealerworld.com, and then click on the DWD Store link; request GM Item Number 1825 when ordering. Disclaimer Owner Letter Owner Letter Dear General Motors Customer: This notice is sent to inform you that General Motors is conducting a voluntary emission recall that includes your vehicle. Reason For This Recall: General Motors has decided to conduct a Voluntary Emission Recall involving certain 2010 model year Chevrolet Express, Silverado HD; and GMC Savana, Sierra HD vehicles equipped with a 6.6L V8 Duramax diesel engine; and 2007-2009 model year Chevrolet Express, Kodiak, Silverado HD; and GMC Savana, Sierra HD, and TopKick vehicles equipped with a 6.6L V8 Duramax diesel engine that may have been serviced with a suspect Exhaust Gas Temperature (EGT) sensor. The circuit board welds on the EGT sensors in the exhaust system may not be to GM specification. If a weld fails, the Service Engine Soon light will illuminate in the instrument panel, the exhaust gas may not be filtered properly, and the engine power may be reduced. What Will Be Done: Your GM dealer will replace both EGT sensors. This service will be performed for you at no charge. What You Should Do: Please contact your GM dealer as soon as possible to arrange a service date and to assure parts availability. Instructions for making this correction have been sent to your dealer. Please ask your dealer if you wish to know how much time will be needed to schedule, process, and repair your vehicle. If you have any questions or need any assistance, just contact your dealer or the appropriate Customer Assistance Center at the number listed below. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exhaust Temperature Sensor: > 11054 > Apr > 11 > Recall - Replace Exhaust Gas Temperature Sensor > Page 5486 Emission Law Information: In order to ensure your full protection under the emission warranty made applicable to your vehicle by State and Federal Law, and your right to participate in future recalls, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could legally be determined to be lack of proper maintenance of your vehicle. Also, your vehicle may fail a state or local emission inspection if this recall is not accomplished. IMPORTANT MESSAGE FOR CALIFORNIA RESIDENTS The California Air Resources Board (CARB) requires vehicle emission recalls be completed prior to California registration renewal. Uncorrected emission recalls will result in the inability to renew your California vehicle registration. At the time of emission recall completion, your California dealer will issue a "Proof of Correction Certificate". Keep this certificate and, if required, present it to the Department of Motor Vehicles when renewing your California registration as proof of recall completion. We are sorry to cause you this inconvenience; however, we have taken this action in the interest of your continued satisfaction with our products. Jim Moloney General Director, Customer and Relationship Services 11054 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Exhaust Temperature Sensor Replacement - Position 1 Exhaust Temperature Sensor: Service and Repair Exhaust Temperature Sensor Replacement Position 1 Exhaust Temperature Sensor Replacement - Position 1 Removal Procedure Caution: The exhaust temperature sensor and exhaust pressure differential sensor line fittings may be difficult to remove when the engine exhaust system temperature is below 48°C (120°F). Excessive force may damage the threads in the exhaust manifold or exhaust pipe. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the exhaust temperature sensor electrical connector (1) from the chassis wiring harness electrical connector (2). 3. Remove the exhaust temperature sensor. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Exhaust Temperature Sensor Replacement - Position 1 > Page 5489 Note: A special anti-seize compound is used in the sensor or line fittings threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor or line fitting easier to remove. New, or service replacement sensors or line fittings already have the compound applied to the threads. If the sensor or line fittings are removed from an exhaust component and if for any reason the sensor or line fitting are reinstalled, the threads must have anti-seize compound applied before reinstallation. 1. If reinstalling the old temperature sensor or differential pressor sensor line fittings, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the exhaust temperature sensor. Tighten the sensor to 45 Nm (33 lb ft). 3. Connect the exhaust temperature sensor electrical connector (1) to the chassis wiring harness electrical connector (2). 4. Lower the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Exhaust Temperature Sensor Replacement - Position 1 > Page 5490 Exhaust Temperature Sensor: Service and Repair Exhaust Temperature Sensor Replacement Position 2 Exhaust Temperature Sensor Replacement - Position 2 Removal Procedure Caution: The exhaust temperature sensor and exhaust pressure differential sensor line fittings may be difficult to remove when the engine exhaust system temperature is below 48°C (120°F). Excessive force may damage the threads in the exhaust manifold or exhaust pipe. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the exhaust temperature sensor (3) electrical connector from the chassis wiring harness electrical connector (4). 3. Remove the exhaust temperature sensor. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Temperature Sensor > Component Information > Service and Repair > Exhaust Temperature Sensor Replacement - Position 1 > Page 5491 Note: A special anti-seize compound is used in the sensor or line fittings threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor or line fitting easier to remove. New, or service replacement sensors or line fittings already have the compound applied to the threads. If the sensor or line fittings are removed from an exhaust component and if for any reason the sensor or line fitting are reinstalled, the threads must have anti-seize compound applied before reinstallation. 1. If reinstalling the old temperature sensor or differential pressor sensor line fittings, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the exhaust temperature sensor. Tighten the sensor to 45 Nm (33 lb ft). 3. Connect the exhaust temperature sensor (3) electrical connector to the chassis wiring harness electrical connector (4). 4. Lower the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Temperature Sensor > Component Information > Diagrams EGR Temperature Sensor: Diagrams Component Connector End Views Exhaust Gas Recirculation (EGR) Temperature Sensor 1 (Diesel) Exhaust Gas Recirculation (EGR) Temperature Sensor 2 (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Temperature Sensor > Component Information > Diagrams > Page 5495 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Temperature Sensor > Component Information > Service and Repair > Exhaust Gas Recirculation Valve Temperature Sensor Replacement - Position 1 EGR Temperature Sensor: Service and Repair Exhaust Gas Recirculation Valve Temperature Sensor Replacement - Position 1 Exhaust Gas Recirculation Valve Temperature Sensor Replacement - Position 1 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Temperature Sensor > Component Information > Service and Repair > Exhaust Gas Recirculation Valve Temperature Sensor Replacement - Position 1 > Page 5498 EGR Temperature Sensor: Service and Repair Exhaust Gas Recirculation Valve Temperature Sensor Replacement - Position 2 Exhaust Gas Recirculation Valve Temperature Sensor Replacement - Position 2 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Exhaust Pressure Differential Sensor Replacement (Pickup) Exhaust Pressure Differential Sensor: Service and Repair Exhaust Pressure Differential Sensor Replacement (Pickup) Exhaust Pressure Differential Sensor Replacement (Pickup) Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the chassis wiring harness electrical connector (1) from the exhaust differential pressure sensor (2). 3. Reposition the exhaust differential pressure sensor pipe assembly hose clamps (3). 4. Remove the exhaust differential pressure sensor pipe assembly hoses from the sensor. 5. Remove the exhaust differential pressure sensor bracket bolts (1). 6. Remove the exhaust differential pressure sensor (2). Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Exhaust Pressure Differential Sensor Replacement (Pickup) > Page 5503 1. Position the exhaust differential pressure sensor (2) to the bracket. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the exhaust differential pressure sensor bracket bolts (1). Tighten the bolts to 9 Nm (80 lb in). 3. Install the exhaust differential pressure sensor pipe assembly hoses to the sensor. 4. Position the exhaust differential pressure sensor pipe assembly hose clamps (3). 5. Connect the chassis wiring harness electrical connector (1) to the exhaust differential pressure sensor (2). 6. Lower the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Exhaust Pressure Differential Sensor Replacement (Pickup) > Page 5504 Exhaust Pressure Differential Sensor: Service and Repair Exhaust Pressure Differential Sensor Replacement (Cab/Chassis) Exhaust Pressure Differential Sensor Replacement (Cab/Chassis) Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the chassis wiring harness electrical connector (1) from the exhaust differential pressure sensor (2). 3. Reposition the exhaust differential pressure sensor pipe assembly hose clamps (3). 4. Remove the exhaust differential pressure sensor pipe assembly hoses from the sensor. 5. Remove the exhaust differential pressure sensor bracket bolts (1). 6. Remove the exhaust differential pressure sensor (2). Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Exhaust Pressure Differential Sensor Replacement (Pickup) > Page 5505 1. Position the exhaust differential pressure sensor (2) to the bracket. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the exhaust differential pressure sensor bracket bolts (1). Tighten the bolts to 9 Nm (80 lb in). 3. Install the exhaust differential pressure sensor pipe assembly hoses to the sensor. 4. Position the exhaust differential pressure sensor pipe assembly hose clamps (3). 5. Connect the chassis wiring harness electrical connector (1) to the exhaust differential pressure sensor (2). 6. Lower the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Exhaust Pressure Differential Sensor Replacement (Pickup) > Page 5506 Exhaust Pressure Differential Sensor: Service and Repair Exhaust Pressure Differential Sensor Pipe Replacement (Pickup) Exhaust Pressure Differential Sensor Pipe Replacement (Pickup) Removal Procedure Caution: The exhaust temperature sensor and exhaust pressure differential sensor line fittings may be difficult to remove when the engine exhaust system temperature is below 48°C (120°F). Excessive force may damage the threads in the exhaust manifold or exhaust pipe. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Reposition the exhaust differential pressure sensor pipe assembly hose clamps (3). 3. Remove the exhaust differential pressure sensor pipe assembly hoses from the sensor. 4. Remove the exhaust differential pressure sensor pipe bracket bolt and nut. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Exhaust Pressure Differential Sensor Replacement (Pickup) > Page 5507 5. Loosen the exhaust differential pressure sensor pipe assembly fittings (1). 6. Remove the exhaust differential pressure sensor pipe assembly. Installation Procedure Note: A special anti-seize compound is used in the sensor or line fittings threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor or line fitting easier to remove. New, or service replacement sensors or line fittings already have the compound applied to the threads. If the sensor or line fittings are removed from an exhaust component and if for any reason the sensor or line fitting are reinstalled, the threads must have anti-seize compound applied before reinstallation. 1. If reinstalling the old temperature sensor or differential pressor sensor line fittings, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Exhaust Pressure Differential Sensor Replacement (Pickup) > Page 5508 Note: Ensure to route the pipe assembly over the frame crossmember. 2. Position and install the exhaust differential pressure sensor pipe assembly to the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Tighten the exhaust differential pressure sensor pipe assembly fittings (1). Tighten the fittings to 45 Nm (33 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Exhaust Pressure Differential Sensor Replacement (Pickup) > Page 5509 4. Position the exhaust differential pressure sensor pipe bracket to the exhaust hanger and install the bolt and nut. Tighten the bracket bolt/nut to 9 Nm (80 lb in). 5. Install the exhaust differential pressure sensor pipe assembly hoses to the sensor. 6. Position the exhaust differential pressure sensor pipe assembly hose clamps (3). 7. Lower the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Exhaust Pressure Differential Sensor Replacement (Pickup) > Page 5510 Exhaust Pressure Differential Sensor: Service and Repair Exhaust Pressure Differential Sensor Pipe Replacement (Cab/Chassis) Exhaust Pressure Differential Sensor Pipe Replacement (Cab/Chassis) Removal Procedure Caution: The exhaust temperature sensor and exhaust pressure differential sensor line fittings may be difficult to remove when the engine exhaust system temperature is below 48°C (120°F). Excessive force may damage the threads in the exhaust manifold or exhaust pipe. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Reposition the exhaust differential pressure sensor pipe assembly hose clamps (3). 3. Remove the exhaust differential pressure sensor pipe assembly hoses from the sensor. 4. Remove the exhaust differential pressure sensor pipe bracket bolt and nut. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Exhaust Pressure Differential Sensor Replacement (Pickup) > Page 5511 5. Loosen the exhaust differential pressure sensor pipe assembly fittings (1). 6. Remove the exhaust differential pressure sensor pipe assembly. Installation Procedure Note: A special anti-seize compound is used in the sensor or line fittings threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor or line fitting easier to remove. New, or service replacement sensors or line fittings already have the compound applied to the threads. If the sensor or line fittings are removed from an exhaust component and if for any reason the sensor or line fitting are reinstalled, the threads must have anti-seize compound applied before reinstallation. 1. If reinstalling the old temperature sensor or differential pressor sensor line fittings, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Exhaust Pressure Differential Sensor Replacement (Pickup) > Page 5512 Note: Ensure to route the pipe assembly over the frame crossmember. 2. Position and install the exhaust differential pressure sensor pipe assembly to the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Tighten the exhaust differential pressure sensor pipe assembly fittings (1). Tighten the fittings to 45 Nm (33 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Exhaust Pressure Differential Sensor > Component Information > Service and Repair > Exhaust Pressure Differential Sensor Replacement (Pickup) > Page 5513 4. Position the exhaust differential pressure sensor pipe bracket to the exhaust hanger and install the bolt and nut. Tighten the bracket bolt/nut to 9 Nm (80 lb in). 5. Install the exhaust differential pressure sensor pipe assembly hoses to the sensor. 6. Position the exhaust differential pressure sensor pipe assembly hose clamps (3). 7. Lower the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Diagrams Pressure Feedback Exhaust Sensor: Diagrams Component Connector End Views Exhaust Pressure Differential Sensor (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications During engine cranking, the pressure should be at least 10 MPa. With the engine running at idle the pressure should be close to the Desired Fuel Rail Pressure. As the engine speed increase, the Desired Fuel Rail Pressure and the Actual Fuel Rail Pressure should be within 2 MPa of each other. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications > Page 5521 Fuel Pressure: Service Precautions Relieving Fuel Pressure Warning Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis Fuel Pressure: Testing and Inspection Fuel System Diagnosis Fuel System Diagnosis Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Circuit/System Description Fuel is drawn by the fuel injection pump from the tank to the engine through the fuel supply lines. Fuel flows to the fuel filter/heater element housing , which combines a water separator, a prime pump, fuel heater element and a filter element. A mechanical fuel injection pump at the front of the engine valley includes the fuel supply pump and the high-pressure pump. The small section of the fuel pump assembly is the supply pump, which creates a vacuum to pull fuel from the fuel tank to the high-pressure pump. The vacuum varies with engine load and speed as indicated by the table below. The pump is engine-driven by the camshaft gear. From the high-pressure pump, the pressurized fuel flows to the left fuel rail. A balance pipe from the center of the left rail then feeds the right fuel rail. Each fuel rail supplies one bank of 4 fuel injectors. The fuel rail pressure sensor is mounted in the end of the right fuel rail. Fuel is used to cool and lubricate the fuel injectors and fuel injection pump. The fuel return system is designed to return this fuel to the fuel tank. If the high side fuel pressure becomes excessive, the fuel rail pressure relief valve releases the fuel into the fuel return system. The return fuel travels through the fuel cooler and then to the fuel tank. Diagnostic Aids An Engine Cranks but Will Not Run or Hard Start symptom may exist if air is being drawn into the fuel injection system due to the following conditions: * Fuel contamination-Refer to Contaminants-in-Fuel Diagnosis (See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Contaminants-in-Fuel Diagnosis). * Deformed or cut O-rings at the fuel supply line connections * Improperly seated fuel supply line fittings * Porous or weathered rubber fuel supply lines * Fuel filter vent screw not tighten or cross threaded * Fuel filter not tighten properly Reference Information Special Tools * J-23738-A MityVac * EN-47969 Fuel Supply Diagnostic Hose * CH-48027 Digital Pressure Gauge * J 44581 Fuel Line Disconnect Tool Circuit/System Verification Observe the Actual Fuel Rail Pressure parameter with a scan tool. During engine cranking, the pressure should be at least 10 MPa. With the engine running at idle the pressure should be close to the Desired Fuel Rail Pressure. As the engine speed increase, the Desired Fuel Rail Pressure and the Actual Fuel Rail Pressure should be within 2 MPa of each other. Circuit/System Testing Note: Ensure that a sufficient amount of fuel is in the fuel tank to run the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis > Page 5524 1. Install the CH-48027 to the fuel system service port on the right front side of the engine. 2. Prime the fuel system until 10 psi is indicated on the CH-48027 . Fuel pressure should not drop below 2 psi in less than one minute. ‹› If fuel pressure drops below 2 psi in less than one minute, go to step 4. Note: It may be necessary to remove engine components for the visual inspections. 3. Attempt to start and idle the engine. Observe the CH-48027 during idle. The vacuum should be between 1-3 in Hg. ‹› If more than 3 in Hg is observed at idle, visually inspect the following items: * Fuel filter element for a restriction * Hoses and lines that are flattening when the engine is running, or have kinks that would restrict the flow of fuel ‹› If engine did not start and no vacuum was observed, refer to Fuel Injection Pump Replacement (See: Fuel Pump/Service and Repair). 4. Disconnect the fuel supply line at the engine and install a J-23738-A using the J 44581 to the engine side of the fuel supply line. 5. Apply vacuum to the fuel supply pipe until 25 in Hg has been reached. Wait for at least one minute to allow the fuel system to stabilize. Vacuum should not drop below 8 in Hg within 10 minutes. ‹› If vacuum cannot be obtained or the vacuum drops below 8 in Hg within 10 minutes, repair the air leak at fuel filter/heater element housing connections or at the fuel hoses/pipes on the engine supply line. 6. Remove both hoses from the fuel filter/heater element housing assembly. Cap the suction side port of the fuel filter/heater element housing assembly. Apply 25 in Hg to the discharge port of the fuel filter/heater element housing assembly. Vacuum should not drop below 8 in Hg within 10 minutes. ‹› If vacuum drops below 8 in Hg within 10 minutes, replace the fuel filter/heater element housing assembly. Note: The engine may start and then stall after briefly running. 7. Remove the J-23738-A from the fuel filter/heater element housing assembly. Install the removed fuel filter/heater element housing assembly, and cap off the fuel supply pipe on the engine. Crank the engine in 15-second intervals while observing the CH-48027 . More than 5 in Hg vacuum should be observed during cranking. ‹› If less than 5 in Hg was observed on the vacuum gauge during cranking, replace the fuel injection pump. Note: The engine may start, and then stall after briefly running. 8. Install the fuel supply line at the engine, and disconnect the chassis fuel supply line at the fuel tank. Install a J-23738-A to the supply hose at the fuel tank using the J 44581 . 9. Apply vacuum to the supply hose at the fuel tank until 25 in Hg has been reached. Wait for a least one minute for the fuel system to stabilize. Vacuum should not drop below 8 in Hg within 10 minutes. ‹› If vacuum cannot be obtained, or the vacuum drops below 8 in Hg within 10 minutes, repair the air leak in the fuel supply line between the engine and fuel tank, or the connection of the supply line to the engine. 10. Install all components and lines that were previously removed or disconnected. 11. Install the EN-47969 on the fuel supply line at the engine. Create a vertical loop in the hose to observe the incoming fuel for air bubbles. 12. Open the bleed screw on top of the fuel filter/heater element housing. Prime the system until fuel appears at the bleed screw. Continue to prime the fuel system until the engine starts and runs. 13. Run the engine for at least 10 minutes to allow the fuel system to stabilize, and purge any air from the system. Note: Changes in engine speed can cause an increase of air bubbles that enter the EN-47969 . An air pocket at the top of the EN-47969 loop is considered a normal condition. 14. At a stabilized idle, observe the fuel entering the EN-47969 for air bubbles. ‹› If air bubbles were observed entering the transparent hose, test the fuel sender for leaks. Refer to Fuel Sender Assembly Replacement (See: Fuel Tank/Fuel Gauge Sender/Service and Repair). 15. Install the fuel sender, fuel tank, and all fuel system connections and components that were previously disconnected. Leave the EN-47969 connected to the fuel supply line. Prime the fuel system 30 times to remove the air from the fuel hoses. Continue to prime the fuel system until the engine starts and runs. Observe the fuel entering the transparent hose. ‹› If air bubbles are still present, refer to Diagnostic Aids. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis > Page 5525 ‹› If no air bubbles are present , remove the EN-47969 and run the engine to ensure no fuel leaks exist. Repair Instructions Perform the Diagnostic Repair Verification (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. * Fuel Injection Pump Replacement (See: Fuel Pump/Service and Repair) * Fuel Sender Assembly Replacement (See: Fuel Tank/Fuel Gauge Sender/Service and Repair) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis > Page 5526 Fuel Pressure: Testing and Inspection Fuel System Diagnosis - High Pressure Side Fuel System Diagnosis - High Pressure Side Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Circuit/System Description High Pressure System The fuel injection pump at the front of the engine valley includes a fuel supply pump and a high-pressure pump. Fuel is drawn by the fuel supply pump from the primary fuel tank and delivered to the high-pressure pump. The pump is engine-driven by the camshaft gear. High pressure fuel is regulated by the fuel pressure regulator mounted on the fuel injection pump. From the high-pressure pump, the fuel moves to the left and right fuel rails through high pressure metal lines. Each fuel rail distributes high pressure fuel to one bank of 4 fuel injectors. The fuel pressure relief valve is location on the left rail, and relieves excessive fuel pressure which returns to the fuel tank. Return System The fuel return system routes fuel from the fuel injectors, the pressure relief valve, and the fuel injection pump. The return fuel travels to the fuel cooler and then to the fuel tank. This fuel is used to cool and lubricate the injection pump and the injectors. Diagnostic Aids * The fuel return volumes vary based on the American Petroleum Institute (API) rating of the diesel fuel. * A fuel injector may have high fuel return flow only at higher engine temperatures. Reference Information Special Tools * J 45873 Fuel Return Volume Test Kit * J-45873-30 Injector Flow Test Adapter Circuit/System Verification With the engine running at idle the Actual Fuel Pressure should be close to the Desired Fuel Rail Pressure. During engine cranking the Actual Fuel Pressure should be at least 10 MPa. Inspect the fuel return hoses and lines for external leaks or damage. Circuit/System Testing Important: If you were not referred to this test from another diagnostic, do not perform this procedure. Only perform this test when the fuel is more than 18°C (65°F). Important: Before replacing the fuel pressure relief valve, ensure that the break-away torque is within specifications. Refer to Fastener Tightening Specifications (See: Specifications). 1. Remove the fuel pressure relief valve return hose and plug the hose to prevent fuel leakage. 2. Install a section of rubber fuel hose on the fuel pressure relief valve connection and place loose end of hose into a clean fuel container. Important: Fuel that is contaminated with gasoline may cause permanent damage to the fuel pressure relief valve. Refer to Contaminants-in-Fuel Diagnosis (See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Contaminants-in-Fuel Diagnosis). * If the engine cranks but does not start, crank engine for 15 seconds. Observe for fuel leaking from fuel pressure relief valve. ‹› If fuel leaks from the fuel pressure relief valve, replace the pressure relief valve. Refer to Fuel Pressure Relief Valve Replacement (See: Fuel Filter/Fuel Pressure Release/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis > Page 5527 * If the engine starts and runs, idle the engine while commanding the fuel rail pressure to 180 MPa with a scan tool. Observe for fuel leaking from fuel pressure relief valve. ‹› If fuel leaks from the fuel pressure relief valve, replace the pressure relief valve. Refer to Fuel Pressure Relief Valve Replacement (See: Fuel Filter/Fuel Pressure Release/Service and Repair). Important: Always replace the fuel return hose retaining clips on the fuel injectors with new clips after removing. 3. Remove the fuel return hose from the fuel injectors of the right cylinder bank. Refer to Fuel Injection Fuel Return Pipe Replacement - Right Side (See: Fuel Return Line/Service and Repair/Fuel Injection Fuel Return Pipe Replacement - Right Side). 4. Connect the yellow hoses from the J 45873 to the J-45873-30 . 5. Connect the J-45873-30 with yellow hoses to each fuel injector return port of the right cylinder bank, and install the retaining clips. 6. Install the 4 yellow hoses in the J 45873 graduated cylinders in numerical order. 7. Connect the fuel return hoses to the J-45873-30 to prevent leakage. ‹› If the engine starts and runs, idle the engine until fuel start dripping into all the graduated cylinders and yellow hoses are full of fuel. Important: The engine cranking speed must be more than 150 RPM during the cranking portion of this test. ‹› If the engine does not start, crank the engine in 15-second intervals, with 1 minute cooling time between intervals, until fuel starts to flow into all of the graduated cylinders. 8. Elevate the 4 yellow hoses to retain the fuel in the hoses, and empty the 4 graduated cylinders into a suitable container. 9. Install the 4 yellow hoses in the J 45873 graduated cylinders in numerical order. ‹› If the engine starts and runs, idle the engine for 15 seconds. ‹› If the engine does not start, crank the engine for 15 seconds. Important: During replacement of the injectors, inspect the inlet and outlet fittings for corrosion or contamination. Refer to Contaminants-in-Fuel Diagnosis (See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Contaminants-in-Fuel Diagnosis). 10. Measure the quantity of fuel in each of the graduated cylinders. Refer to Fuel System Specifications (See: Specifications) for the desired quantities. ‹› If high return flows were recorded, replace those fuel injectors that had high return flow and retest the fuel return flow, referring to Fuel System Specifications (See: Specifications). Replace any additional high return flow injectors and proceed to the next number step. 11. Install and connect all fuel system components that were previously removed or disconnected. 12. Remove the fuel return pipes from the fuel injectors of the left cylinder bank and repeat the fuel return flow test previously preformed on the right cylinder bank. ‹› If high return flows were recorded, replace those fuel injectors that had high return flow and retest the fuel return flow, referring to Fuel System Specifications (See: Specifications). Replace any additional high return flow injectors and proceed to the next number step. 13. Install and connect all fuel system components that were previously removed or disconnected. 14. Start and idle the engine. You may have to prime the fuel system before the engine will start. Command the fuel pressure control to 180 MPa with a scan tool. The actual fuel pressure should be the same as the commanded pressure. ‹› If the engine does not start or the fuel pressure is less than 145 MPa when commanded, replace the fuel injection pump. 15. Command the fuel pressure control to 180 MPa with a scan tool. The fuel pressure should be able to reach 145 MPa when commanded. ‹› If the fuel pressure is less than the specified value, refer to Fuel System Diagnosis (See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Fuel System Diagnosis). 16. Operate the vehicle in order to verify the repairs. Repair Instructions Perform the Diagnostic Repair Verification (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. * Fuel Injection Pump Replacement (See: Fuel Pump/Service and Repair) * Fuel Pressure Relief Valve Replacement (See: Fuel Filter/Fuel Pressure Release/Service and Repair) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis > Page 5528 * Fuel Injector Replacement (Right) (See: Fuel Injector/Service and Repair/Removal and Replacement/Fuel Injector Replacement (Right))Fuel Injector Replacement (Left) (See: Fuel Injector/Service and Repair/Removal and Replacement/Fuel Injector Replacement (Left)) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair Fuel Pressure Relief Valve Replacement Removal Procedure 1. Remove the glow plug module and bracket. Refer to Glow Plug Control Module Replacement (See: Glow Plug System/Glow Plug Control Module/Service and Repair). 2. Remove the fuel pressure relief valve from the left fuel rail. Installation Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the fuel pressure relief valve to the left fuel rail. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service and Repair > Page 5532 Tighten the valve to 100 Nm (74 lb ft). 2. Install the glow plug module and bracket. Refer to Glow Plug Control Module Replacement (See: Glow Plug System/Glow Plug Control Module/Service and Repair). 3. Prime the fuel system. Refer to Fuel System Priming (See: Service and Repair/Fuel System Priming). 4. Start the engine. If the engine stalls, repeat the above step. 5. Once the engine starts, inspect for fuel leaks. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications Idle Speed: Specifications Idle Speed............................................................................................................................................ ......................................................................680 RPM Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications > Page 5536 Idle Speed: Service and Repair High Idle Switch Programming Before Programming a Control Module Important: DO NOT program a control module unless you are directed by a service procedure or you are directed by a General Motors Corporation service bulletin. Programming a control module at any other time will not permanently correct a customer's concern. Ensure the following conditions are met before programming a control module: * Vehicle system voltage - There is no charging system concern. All charging system concerns must be repaired before programming a control module. - Battery voltage is greater than 12 volts but less than 16 volts. The battery must be charged before programming the control module if the battery voltage is low. - A battery charger is NOT connected to the vehicle's battery. Incorrect system voltage or voltage fluctuations from a battery charger, may cause programming failure or control module damage. - Turn OFF or disable any system that may put a load on the vehicle's battery. * Twilight sentinel * Interior lights * Daytime running lights (DRL)-Applying the parking brake, on most vehicles, disables the DRL system. Refer to the Owner's Manual. * HVAC systems * Engine cooling fans, etc. * The ignition switch is in the proper position. The scan tool prompts you to turn ON the ignition, with the engine OFF. DO NOT change the position of the ignition switch during the programming procedure, unless instructed to do so. * All tool connections are secure. - The connection at the data link connector (DLC) - Voltage supply circuits * DO NOT disturb the tool harnesses while programming. If an interruption occurs during the programming procedure, programming failure or control module damage may occur. High Idle Switch Programming * Using the Tech 2, select Module Setup/PTO Options * Use soft keys to select desired settings. * When setting selections are complete, select Reprogram. Important: The ECM will not operate under the new value until the it has powered down once. * Turn OFF the ignition until communication with the ECM is lost, as indicated on the scan tool. * Start the vehicle and confirm the new settings by operating the high idle switch. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations Accelerator Pedal Position Sensor: Locations Harness Routing Views Brake Clutch Harness Routing 1 - Driver Door Frame 2 - X205 3 - X102 (JL1) 4 - Accelerator Pedal Position (APP) Sensor Connector 5 - Junction Block - Left I/P (except MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 5540 Accelerator Pedal Position Sensor: Diagrams Component Connector End Views Accelerator Pedal Position (APP) Sensor Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 5541 Accelerator Pedal Position Sensor: Description and Operation Accelerator Pedal Position System Description The accelerator pedal position (APP) sensor is mounted inside the accelerator pedal control assembly. The sensor is made up of the two individual sensors within a single housing. Each sensor has a unique functionality to determine pedal position. The accelerator pedal position (APP) system along with the engine control module (ECM) is used to calculate and control the amount of acceleration and deceleration through fuel injector control. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 5542 Accelerator Pedal Position Sensor: Service and Repair Accelerator Pedal Position Sensor Replacement Removal Procedure Caution: Handle the electronic throttle control components carefully. Use cleanliness in order to prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the electronic throttle control components. Do not immerse the electronic throttle control components in cleaning solvents of any type. 1. Remove the connector position assurance (CPA) retainer. 2. Disconnect the accelerator pedal position (APP) sensor electrical connector (1). 3. Remove the accelerator pedal bolts. 4. Remove the accelerator pedal. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 5543 Installation Procedure 1. Position the accelerator pedal to the accelerator pedal bracket. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the accelerator pedal bolts and tighten to 9 Nm (80 lb in).. 3. Connect the APP sensor electrical connector (1). 4. Install the CPA retainer. 5. Connect a scan tool to the diagnostic port in order to test for proper throttle-opening and throttle-closing range. 6. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle, and a wide open throttle (WOT). 7. Verify that the vehicle meets the following conditions: * The vehicle is not in a reduced engine power mode. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 5544 * The ignition is ON. * The engine is OFF. 8. Inspect the carpet fit under the accelerator pedal. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > Customer Interest for Air Cleaner Fresh Air Duct/Hose: > 08-06-04-054B > Jan > 11 > Diesel Engine - Low Power/MIL ON/DTC P0101 Air Cleaner Fresh Air Duct/Hose: Customer Interest Diesel Engine - Low Power/MIL ON/DTC P0101 TECHNICAL Bulletin No.: 08-06-04-054B Date: January 24, 2011 Subject: Snow or Ice Ingestion into Air Cleaner Element, Malfunction Indicator Lamp (MIL) Illuminated, Engine Power is Reduced Message Displayed, DTC P0101 Set (Perform Repair as Outlined) Models: 2007-2010 Chevrolet Silverado 2500/3500 Series 2007-2010 GMC Sierra 2500/3500 Series Equipped with Duramax(TM) Diesel Engine (RPO LMM) Supercede: This bulletin is being revised to provide a procedure to relocate the OAT sensor, if equipped with RPO CJ2. Please discard Corporate Bulletin 08-06-04-054A (Section 06 - Engine / Propulsion System). Condition Some customers may comment on the malfunction indicator lamp (MIL) being illuminated and an Engine Power is Reduced message being displayed. The technician may observe DTC P0101 set as current or in history. Cause This condition may be caused by snow being ingested into the air cleaner housing and accumulating in the air cleaner element, resulting in restricted airflow into the engine. Correction 1. Verify the condition by questioning the customer as to when the condition occurs (such as during or right after a snow storm). ‹› If the condition occurs as described above, proceed to Step 2. ‹› If the condition does not occur as described above, refer to Diagnostic Trouble Code (DTC) List Vehicle in SI. 2. Remove the air cleaner element. Refer to Air Cleaner Element Replacement in SI. 3. Inspect the air cleaner element for the following conditions: 1. Packed snow 2. Frozen ice 3. A soaking wet condition that would indicate previous snow ingestion 4. Excessive debris and contamination as a result of the ingestion ‹› If any of the above conditions are observed, replace the air cleaner element. Remove any snow or ice that may have accumulated in the air intake duct. Note Winter covers for trucks that are equipped with the Duramax(TM) Diesel Engine are included with vehicle orders that ship to the following areas: All of Canada, and the following states: Alaska, Colorado, Idaho, Maine, Michigan, Minnesota, Montana, New Hampshire, New York, North Dakota, South Dakota, Vermont, Wisconsin, Wyoming. These vehicles should not need a new cover. 4. Install the grille opening section ONLY (if using the 2 piece cover) of the winter front cover following the usage guidelines provided in the Owners Manual for the appropriate type winter cover. ‹› If the customer does not have a cover, obtain and install the grille opening section ONLY , GM P/N 25822811 (GMC) or GM P/N 25822812 (Chevrolet). 5. The grille opening cover MUST BE installed to ensure a complete repair, BEFORE ENCOUNTERING SNOW. This repair allows warm air to be circulated into the air cleaner. Additional Information to Advise Customer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > Customer Interest for Air Cleaner Fresh Air Duct/Hose: > 08-06-04-054B > Jan > 11 > Diesel Engine - Low Power/MIL ON/DTC P0101 > Page 5554 Important If the vehicle is driven in a snow storm before installing the winter cover and the customer chooses to resolve the issue, they must follow this procedure using the following steps: 1. Remove ANY ice or snow that may have accumulated in the air intake duct, BEFORE REPLACING the air cleaner element. 2. INSTALL the winter cover BEFORE continuing to drive the truck. 3. Turn OFF the ignition, and all electrical accessories and components. 4. Remove the key from the vehicle, THEN open and close the door. 5. WAIT for 2 minutes to allow the engine control module (ECM) to power down. This can be verified by watching for the instrument panel cluster (IPC) gage needles to drop slightly. 1. Allowing the ECM to power down will let DTC P0101 revert to a History DTC and the vehicle should return to full power if the issue has been eliminated. 2. Advise the customer to take the vehicle to the dealer as soon as possible to verify the condition has been eliminated. Ambient (Outside) Air Temperature Sensor Relocation For vehicles equipped with Automatic Temperature Control HVAC (RPO CJ2), the ambient (outside) air temperature sensor needs to be relocated using the following procedure: 1. Remove the radiator grille. Refer to the Radiator Grille Replacement procedure in SI. 2. Remove the ambient air sensor from its current location by carefully lifting the sensor from the radiator support cross bar. 3. Remove the harness clip nearest to the sensor. 4. Reinstall the ambient air sensor to the new location using the existing hole (1) in the lower section of the radiator support. 5. Reinstall the harness clip to the existing hole (2) in the radiator support. 6. Reinstall the radiator grille. Parts Information Warranty Information Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > Customer Interest for Air Cleaner Fresh Air Duct/Hose: > 08-06-04-054B > Jan > 11 > Diesel Engine - Low Power/MIL ON/DTC P0101 > Page 5555 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > Customer Interest for Air Cleaner Fresh Air Duct/Hose: > 08-06-04-054A > Jan > 10 > Engine - Reduced Power/MIL ON/DTC P0101 Air Cleaner Fresh Air Duct/Hose: Customer Interest Engine - Reduced Power/MIL ON/DTC P0101 TECHNICAL Bulletin No.: 08-06-04-054A Date: January 07, 2010 Subject: Snow or Ice Ingestion into Air Cleaner Element, Malfunction Indicator Lamp (MIL) Illuminated, Engine Power is Reduced Message Displayed, DTC P0101 Set (Perform Repair as Outlined) Models: 2007-2010 Chevrolet Silverado 2500/3500 Series 2007-2010 GMC Sierra 2500/3500 Series Equipped with Duramax(TM) Diesel Engine (RPO LMM) Please Refer to GMVIS Supercede: This bulletin is being revised to remove the graphic, update the Parts and Correction information and add information to advise a customer. Please discard Corporate Bulletin 08-06-04-054 (Section 06 - Engine / Propulsion System). Condition Some customers may comment on the malfunction indicator lamp (MIL) being illuminated and an Engine Power is Reduced message being displayed. The technician may observe DTC P0101 set as current or in history. Cause This condition may be caused by snow being ingested into the air cleaner housing and accumulating in the air cleaner element, resulting in restricted airflow into the engine. Correction 1. Verify the condition by questioning the customer as to when the condition occurs (such as during or right after a snow storm). ‹› If the condition occurs as described above, proceed to Step 2. ‹› If the condition does not occur as described above, refer to Diagnostic Trouble Code (DTC) List Vehicle in SI. 2. Remove the air cleaner element. Refer to Air Cleaner Element Replacement in SI. 3. Inspect the air cleaner element for the following conditions: 1. Packed snow 2. Frozen ice 3. A soaking wet condition that would indicate previous snow ingestion 4. Excessive debris and contamination as a result of the ingestion ‹› If any of the above conditions are observed, replace the air cleaner element. Remove any snow or ice that may have accumulated in the air intake duct. Note Winter covers for trucks that are equipped with the Duramax(TM) Diesel Engine are included with vehicle orders that ship to the following areas: All of Canada, and the following states: Alaska, Colorado, Idaho, Maine, Michigan, Minnesota, Montana, New Hampshire, New York, North Dakota, South Dakota, Vermont, Wisconsin, Wyoming. These vehicles should not need a new cover. 4. Install the grille opening section ONLY (if using the 2 piece cover) of the winter front cover following the usage guidelines provided in the Owners Manual for the appropriate type winter cover. ‹› If the customer does not have a cover, obtain and install the grille opening section ONLY, GM P/N 25822811 (GMC) or GM P/N 25822812 (Chevrolet). 5. The grille opening cover MUST BE installed to ensure a complete repair, BEFORE ENCOUNTERING SNOW. This repair allows warm air to be circulated into the air cleaner. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > Customer Interest for Air Cleaner Fresh Air Duct/Hose: > 08-06-04-054A > Jan > 10 > Engine - Reduced Power/MIL ON/DTC P0101 > Page 5560 Additional Information to Advise Customer Important If the vehicle is driven in a snow storm before installing the winter cover and the customer chooses to resolve the issue, they must follow this procedure using the following steps: 1. Remove ANY ice or snow that may have accumulated in the air intake duct, BEFORE REPLACING the air cleaner element. 2. INSTALL the winter cover BEFORE continuing to drive the truck. 3. Turn OFF the ignition, and all electrical accessories and components. 4. Remove the key from the vehicle, THEN open and close the door. 5. WAIT for 2 minutes to allow the engine control module (ECM) to power down. This can be verified by watching for the instrument panel cluster (IPC) gage needles to drop slightly. 1. Allowing the ECM to power down will let DTC P0101 revert to a History DTC and the vehicle should return to full power if the issue has been eliminated. 2. Advise the customer to take the vehicle to the dealer as soon as possible to verify the condition has been eliminated. Parts Information Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Cleaner Fresh Air Duct/Hose: > 08-06-04-054B > Jan > 11 > Diesel Engine - Low Power/MIL ON/DTC P0101 Air Cleaner Fresh Air Duct/Hose: All Technical Service Bulletins Diesel Engine - Low Power/MIL ON/DTC P0101 TECHNICAL Bulletin No.: 08-06-04-054B Date: January 24, 2011 Subject: Snow or Ice Ingestion into Air Cleaner Element, Malfunction Indicator Lamp (MIL) Illuminated, Engine Power is Reduced Message Displayed, DTC P0101 Set (Perform Repair as Outlined) Models: 2007-2010 Chevrolet Silverado 2500/3500 Series 2007-2010 GMC Sierra 2500/3500 Series Equipped with Duramax(TM) Diesel Engine (RPO LMM) Supercede: This bulletin is being revised to provide a procedure to relocate the OAT sensor, if equipped with RPO CJ2. Please discard Corporate Bulletin 08-06-04-054A (Section 06 - Engine / Propulsion System). Condition Some customers may comment on the malfunction indicator lamp (MIL) being illuminated and an Engine Power is Reduced message being displayed. The technician may observe DTC P0101 set as current or in history. Cause This condition may be caused by snow being ingested into the air cleaner housing and accumulating in the air cleaner element, resulting in restricted airflow into the engine. Correction 1. Verify the condition by questioning the customer as to when the condition occurs (such as during or right after a snow storm). ‹› If the condition occurs as described above, proceed to Step 2. ‹› If the condition does not occur as described above, refer to Diagnostic Trouble Code (DTC) List Vehicle in SI. 2. Remove the air cleaner element. Refer to Air Cleaner Element Replacement in SI. 3. Inspect the air cleaner element for the following conditions: 1. Packed snow 2. Frozen ice 3. A soaking wet condition that would indicate previous snow ingestion 4. Excessive debris and contamination as a result of the ingestion ‹› If any of the above conditions are observed, replace the air cleaner element. Remove any snow or ice that may have accumulated in the air intake duct. Note Winter covers for trucks that are equipped with the Duramax(TM) Diesel Engine are included with vehicle orders that ship to the following areas: All of Canada, and the following states: Alaska, Colorado, Idaho, Maine, Michigan, Minnesota, Montana, New Hampshire, New York, North Dakota, South Dakota, Vermont, Wisconsin, Wyoming. These vehicles should not need a new cover. 4. Install the grille opening section ONLY (if using the 2 piece cover) of the winter front cover following the usage guidelines provided in the Owners Manual for the appropriate type winter cover. ‹› If the customer does not have a cover, obtain and install the grille opening section ONLY , GM P/N 25822811 (GMC) or GM P/N 25822812 (Chevrolet). 5. The grille opening cover MUST BE installed to ensure a complete repair, BEFORE ENCOUNTERING SNOW. This repair allows warm air to be circulated into the air cleaner. Additional Information to Advise Customer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Cleaner Fresh Air Duct/Hose: > 08-06-04-054B > Jan > 11 > Diesel Engine - Low Power/MIL ON/DTC P0101 > Page 5566 Important If the vehicle is driven in a snow storm before installing the winter cover and the customer chooses to resolve the issue, they must follow this procedure using the following steps: 1. Remove ANY ice or snow that may have accumulated in the air intake duct, BEFORE REPLACING the air cleaner element. 2. INSTALL the winter cover BEFORE continuing to drive the truck. 3. Turn OFF the ignition, and all electrical accessories and components. 4. Remove the key from the vehicle, THEN open and close the door. 5. WAIT for 2 minutes to allow the engine control module (ECM) to power down. This can be verified by watching for the instrument panel cluster (IPC) gage needles to drop slightly. 1. Allowing the ECM to power down will let DTC P0101 revert to a History DTC and the vehicle should return to full power if the issue has been eliminated. 2. Advise the customer to take the vehicle to the dealer as soon as possible to verify the condition has been eliminated. Ambient (Outside) Air Temperature Sensor Relocation For vehicles equipped with Automatic Temperature Control HVAC (RPO CJ2), the ambient (outside) air temperature sensor needs to be relocated using the following procedure: 1. Remove the radiator grille. Refer to the Radiator Grille Replacement procedure in SI. 2. Remove the ambient air sensor from its current location by carefully lifting the sensor from the radiator support cross bar. 3. Remove the harness clip nearest to the sensor. 4. Reinstall the ambient air sensor to the new location using the existing hole (1) in the lower section of the radiator support. 5. Reinstall the harness clip to the existing hole (2) in the radiator support. 6. Reinstall the radiator grille. Parts Information Warranty Information Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Cleaner Fresh Air Duct/Hose: > 08-06-04-054B > Jan > 11 > Diesel Engine - Low Power/MIL ON/DTC P0101 > Page 5567 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Cleaner Fresh Air Duct/Hose: > 08-06-04-054A > Jan > 10 > Engine - Reduced Power/MIL ON/DTC P0101 Air Cleaner Fresh Air Duct/Hose: All Technical Service Bulletins Engine - Reduced Power/MIL ON/DTC P0101 TECHNICAL Bulletin No.: 08-06-04-054A Date: January 07, 2010 Subject: Snow or Ice Ingestion into Air Cleaner Element, Malfunction Indicator Lamp (MIL) Illuminated, Engine Power is Reduced Message Displayed, DTC P0101 Set (Perform Repair as Outlined) Models: 2007-2010 Chevrolet Silverado 2500/3500 Series 2007-2010 GMC Sierra 2500/3500 Series Equipped with Duramax(TM) Diesel Engine (RPO LMM) Please Refer to GMVIS Supercede: This bulletin is being revised to remove the graphic, update the Parts and Correction information and add information to advise a customer. Please discard Corporate Bulletin 08-06-04-054 (Section 06 - Engine / Propulsion System). Condition Some customers may comment on the malfunction indicator lamp (MIL) being illuminated and an Engine Power is Reduced message being displayed. The technician may observe DTC P0101 set as current or in history. Cause This condition may be caused by snow being ingested into the air cleaner housing and accumulating in the air cleaner element, resulting in restricted airflow into the engine. Correction 1. Verify the condition by questioning the customer as to when the condition occurs (such as during or right after a snow storm). ‹› If the condition occurs as described above, proceed to Step 2. ‹› If the condition does not occur as described above, refer to Diagnostic Trouble Code (DTC) List Vehicle in SI. 2. Remove the air cleaner element. Refer to Air Cleaner Element Replacement in SI. 3. Inspect the air cleaner element for the following conditions: 1. Packed snow 2. Frozen ice 3. A soaking wet condition that would indicate previous snow ingestion 4. Excessive debris and contamination as a result of the ingestion ‹› If any of the above conditions are observed, replace the air cleaner element. Remove any snow or ice that may have accumulated in the air intake duct. Note Winter covers for trucks that are equipped with the Duramax(TM) Diesel Engine are included with vehicle orders that ship to the following areas: All of Canada, and the following states: Alaska, Colorado, Idaho, Maine, Michigan, Minnesota, Montana, New Hampshire, New York, North Dakota, South Dakota, Vermont, Wisconsin, Wyoming. These vehicles should not need a new cover. 4. Install the grille opening section ONLY (if using the 2 piece cover) of the winter front cover following the usage guidelines provided in the Owners Manual for the appropriate type winter cover. ‹› If the customer does not have a cover, obtain and install the grille opening section ONLY, GM P/N 25822811 (GMC) or GM P/N 25822812 (Chevrolet). 5. The grille opening cover MUST BE installed to ensure a complete repair, BEFORE ENCOUNTERING SNOW. This repair allows warm air to be circulated into the air cleaner. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Cleaner Fresh Air Duct/Hose: > 08-06-04-054A > Jan > 10 > Engine - Reduced Power/MIL ON/DTC P0101 > Page 5572 Additional Information to Advise Customer Important If the vehicle is driven in a snow storm before installing the winter cover and the customer chooses to resolve the issue, they must follow this procedure using the following steps: 1. Remove ANY ice or snow that may have accumulated in the air intake duct, BEFORE REPLACING the air cleaner element. 2. INSTALL the winter cover BEFORE continuing to drive the truck. 3. Turn OFF the ignition, and all electrical accessories and components. 4. Remove the key from the vehicle, THEN open and close the door. 5. WAIT for 2 minutes to allow the engine control module (ECM) to power down. This can be verified by watching for the instrument panel cluster (IPC) gage needles to drop slightly. 1. Allowing the ECM to power down will let DTC P0101 revert to a History DTC and the vehicle should return to full power if the issue has been eliminated. 2. Advise the customer to take the vehicle to the dealer as soon as possible to verify the condition has been eliminated. Parts Information Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Air Cleaner Outlet Duct Replacement Air Cleaner Fresh Air Duct/Hose: Service and Repair Air Cleaner Outlet Duct Replacement Air Cleaner Outlet Duct Replacement Removal Procedure 1. Loosen the outlet duct clamps at the air cleaner assembly and the turbocharger. 2. Remove the air cleaner outlet duct. Installation Procedure Note: The air cleaner outlet duct must be fully seated against the positive stop feature on the turbocharger inlet and also must be fully seated against the positive stop features on both sides of the air cleaner assembly. 1. Install the air cleaner outlet duct. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Air Cleaner Outlet Duct Replacement > Page 5575 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Tighten the outlet duct clamps at the turbocharger and the air cleaner assembly. Tighten the clamps to 4 Nm (35 lb in). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Air Cleaner Outlet Duct Replacement > Page 5576 Air Cleaner Fresh Air Duct/Hose: Service and Repair Air Intake Pipe Replacement Air Intake Pipe Replacement Removal Procedure 1. Remove the water outlet tube. Refer to Water Outlet Tube Replacement (LU3) (See: Engine, Cooling and Exhaust/Cooling System/Coolant Outlet/Service and Repair)Water Outlet Tube Replacement (LMM) (See: Engine, Cooling and Exhaust/Cooling System/Coolant Outlet/Service and Repair). 2. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (See: Air Cleaner Outlet Duct Replacement). Note: It is not necessary to completely remove the PCV hose/pipe from the engine when removing the air intake pipe. 3. Remove the positive crankcase ventilation (PCV) hose/pipe from the air intake pipe. Refer to Positive Crankcase Ventilation Hose/Pipe/Tube Replacement (See: Emission Control Systems/Positive Crankcase Ventilation/PCV Valve Hose/Service and Repair). 4. Disconnect the engine wiring harness electrical connector from the turbocharger control solenoid valve. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Air Cleaner Outlet Duct Replacement > Page 5577 5. Remove the engine wiring harness clip (1) from the bracket on the turbocharger. 6. Reposition the turbocharger control solenoid valve wiring harness extension out of the way. Note: The clamp for the air intake pipe uses reverse threads. 7. Loosen the air intake pipe to turbocharger clamp (1). 8. Remove the air intake pipe (2) from the turbocharger. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Air Cleaner Outlet Duct Replacement > Page 5578 1. Clean the mating surfaces on the air intake pipe and the turbocharger. 2. Align the arrow (2) on the air intake pipe to the arrow (1) on the turbocharger. 3. Install the air intake pipe (2) into the turbocharger. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Note: The clamp for the air intake pipe uses reverse threads. 4. Tighten the air intake pipe to turbocharger clamp (1). Tighten the clamp to 4.6 Nm (41 lb in). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Air Cleaner Outlet Duct Replacement > Page 5579 5. Route the turbocharger control solenoid valve wiring harness extension into position. 6. Install the engine wiring harness clip (1) to the bracket on the turbocharger. 7. Connect the engine wiring harness electrical connector to the turbocharger control solenoid valve. 8. Install the PCV hose/pipe to the air intake pipe. Refer to Positive Crankcase Ventilation Hose/Pipe/Tube Replacement (See: Emission Control Systems/Positive Crankcase Ventilation/PCV Valve Hose/Service and Repair). 9. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (See: Air Cleaner Outlet Duct Replacement). 10. Install the water outlet tube. Refer to Water Outlet Tube Replacement (LU3) (See: Engine, Cooling and Exhaust/Cooling System/Coolant Outlet/Service and Repair)Water Outlet Tube Replacement (LMM) (See: Engine, Cooling and Exhaust/Cooling System/Coolant Outlet/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 08-06-04-054B > Jan > 11 > Diesel Engine - Low Power/MIL ON/DTC P0101 Air Filter Element: Customer Interest Diesel Engine - Low Power/MIL ON/DTC P0101 TECHNICAL Bulletin No.: 08-06-04-054B Date: January 24, 2011 Subject: Snow or Ice Ingestion into Air Cleaner Element, Malfunction Indicator Lamp (MIL) Illuminated, Engine Power is Reduced Message Displayed, DTC P0101 Set (Perform Repair as Outlined) Models: 2007-2010 Chevrolet Silverado 2500/3500 Series 2007-2010 GMC Sierra 2500/3500 Series Equipped with Duramax(TM) Diesel Engine (RPO LMM) Supercede: This bulletin is being revised to provide a procedure to relocate the OAT sensor, if equipped with RPO CJ2. Please discard Corporate Bulletin 08-06-04-054A (Section 06 - Engine / Propulsion System). Condition Some customers may comment on the malfunction indicator lamp (MIL) being illuminated and an Engine Power is Reduced message being displayed. The technician may observe DTC P0101 set as current or in history. Cause This condition may be caused by snow being ingested into the air cleaner housing and accumulating in the air cleaner element, resulting in restricted airflow into the engine. Correction 1. Verify the condition by questioning the customer as to when the condition occurs (such as during or right after a snow storm). ‹› If the condition occurs as described above, proceed to Step 2. ‹› If the condition does not occur as described above, refer to Diagnostic Trouble Code (DTC) List Vehicle in SI. 2. Remove the air cleaner element. Refer to Air Cleaner Element Replacement in SI. 3. Inspect the air cleaner element for the following conditions: 1. Packed snow 2. Frozen ice 3. A soaking wet condition that would indicate previous snow ingestion 4. Excessive debris and contamination as a result of the ingestion ‹› If any of the above conditions are observed, replace the air cleaner element. Remove any snow or ice that may have accumulated in the air intake duct. Note Winter covers for trucks that are equipped with the Duramax(TM) Diesel Engine are included with vehicle orders that ship to the following areas: All of Canada, and the following states: Alaska, Colorado, Idaho, Maine, Michigan, Minnesota, Montana, New Hampshire, New York, North Dakota, South Dakota, Vermont, Wisconsin, Wyoming. These vehicles should not need a new cover. 4. Install the grille opening section ONLY (if using the 2 piece cover) of the winter front cover following the usage guidelines provided in the Owners Manual for the appropriate type winter cover. ‹› If the customer does not have a cover, obtain and install the grille opening section ONLY , GM P/N 25822811 (GMC) or GM P/N 25822812 (Chevrolet). 5. The grille opening cover MUST BE installed to ensure a complete repair, BEFORE ENCOUNTERING SNOW. This repair allows warm air to be circulated into the air cleaner. Additional Information to Advise Customer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 08-06-04-054B > Jan > 11 > Diesel Engine - Low Power/MIL ON/DTC P0101 > Page 5588 Important If the vehicle is driven in a snow storm before installing the winter cover and the customer chooses to resolve the issue, they must follow this procedure using the following steps: 1. Remove ANY ice or snow that may have accumulated in the air intake duct, BEFORE REPLACING the air cleaner element. 2. INSTALL the winter cover BEFORE continuing to drive the truck. 3. Turn OFF the ignition, and all electrical accessories and components. 4. Remove the key from the vehicle, THEN open and close the door. 5. WAIT for 2 minutes to allow the engine control module (ECM) to power down. This can be verified by watching for the instrument panel cluster (IPC) gage needles to drop slightly. 1. Allowing the ECM to power down will let DTC P0101 revert to a History DTC and the vehicle should return to full power if the issue has been eliminated. 2. Advise the customer to take the vehicle to the dealer as soon as possible to verify the condition has been eliminated. Ambient (Outside) Air Temperature Sensor Relocation For vehicles equipped with Automatic Temperature Control HVAC (RPO CJ2), the ambient (outside) air temperature sensor needs to be relocated using the following procedure: 1. Remove the radiator grille. Refer to the Radiator Grille Replacement procedure in SI. 2. Remove the ambient air sensor from its current location by carefully lifting the sensor from the radiator support cross bar. 3. Remove the harness clip nearest to the sensor. 4. Reinstall the ambient air sensor to the new location using the existing hole (1) in the lower section of the radiator support. 5. Reinstall the harness clip to the existing hole (2) in the radiator support. 6. Reinstall the radiator grille. Parts Information Warranty Information Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 08-06-04-054B > Jan > 11 > Diesel Engine - Low Power/MIL ON/DTC P0101 > Page 5589 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 08-06-04-054A > Jan > 10 > Engine - Reduced Power/MIL ON/DTC P0101 Air Filter Element: Customer Interest Engine - Reduced Power/MIL ON/DTC P0101 TECHNICAL Bulletin No.: 08-06-04-054A Date: January 07, 2010 Subject: Snow or Ice Ingestion into Air Cleaner Element, Malfunction Indicator Lamp (MIL) Illuminated, Engine Power is Reduced Message Displayed, DTC P0101 Set (Perform Repair as Outlined) Models: 2007-2010 Chevrolet Silverado 2500/3500 Series 2007-2010 GMC Sierra 2500/3500 Series Equipped with Duramax(TM) Diesel Engine (RPO LMM) Please Refer to GMVIS Supercede: This bulletin is being revised to remove the graphic, update the Parts and Correction information and add information to advise a customer. Please discard Corporate Bulletin 08-06-04-054 (Section 06 - Engine / Propulsion System). Condition Some customers may comment on the malfunction indicator lamp (MIL) being illuminated and an Engine Power is Reduced message being displayed. The technician may observe DTC P0101 set as current or in history. Cause This condition may be caused by snow being ingested into the air cleaner housing and accumulating in the air cleaner element, resulting in restricted airflow into the engine. Correction 1. Verify the condition by questioning the customer as to when the condition occurs (such as during or right after a snow storm). ‹› If the condition occurs as described above, proceed to Step 2. ‹› If the condition does not occur as described above, refer to Diagnostic Trouble Code (DTC) List Vehicle in SI. 2. Remove the air cleaner element. Refer to Air Cleaner Element Replacement in SI. 3. Inspect the air cleaner element for the following conditions: 1. Packed snow 2. Frozen ice 3. A soaking wet condition that would indicate previous snow ingestion 4. Excessive debris and contamination as a result of the ingestion ‹› If any of the above conditions are observed, replace the air cleaner element. Remove any snow or ice that may have accumulated in the air intake duct. Note Winter covers for trucks that are equipped with the Duramax(TM) Diesel Engine are included with vehicle orders that ship to the following areas: All of Canada, and the following states: Alaska, Colorado, Idaho, Maine, Michigan, Minnesota, Montana, New Hampshire, New York, North Dakota, South Dakota, Vermont, Wisconsin, Wyoming. These vehicles should not need a new cover. 4. Install the grille opening section ONLY (if using the 2 piece cover) of the winter front cover following the usage guidelines provided in the Owners Manual for the appropriate type winter cover. ‹› If the customer does not have a cover, obtain and install the grille opening section ONLY, GM P/N 25822811 (GMC) or GM P/N 25822812 (Chevrolet). 5. The grille opening cover MUST BE installed to ensure a complete repair, BEFORE ENCOUNTERING SNOW. This repair allows warm air to be circulated into the air cleaner. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 08-06-04-054A > Jan > 10 > Engine - Reduced Power/MIL ON/DTC P0101 > Page 5594 Additional Information to Advise Customer Important If the vehicle is driven in a snow storm before installing the winter cover and the customer chooses to resolve the issue, they must follow this procedure using the following steps: 1. Remove ANY ice or snow that may have accumulated in the air intake duct, BEFORE REPLACING the air cleaner element. 2. INSTALL the winter cover BEFORE continuing to drive the truck. 3. Turn OFF the ignition, and all electrical accessories and components. 4. Remove the key from the vehicle, THEN open and close the door. 5. WAIT for 2 minutes to allow the engine control module (ECM) to power down. This can be verified by watching for the instrument panel cluster (IPC) gage needles to drop slightly. 1. Allowing the ECM to power down will let DTC P0101 revert to a History DTC and the vehicle should return to full power if the issue has been eliminated. 2. Advise the customer to take the vehicle to the dealer as soon as possible to verify the condition has been eliminated. Parts Information Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 08-06-04-054B > Jan > 11 > Diesel Engine - Low Power/MIL ON/DTC P0101 Air Filter Element: All Technical Service Bulletins Diesel Engine - Low Power/MIL ON/DTC P0101 TECHNICAL Bulletin No.: 08-06-04-054B Date: January 24, 2011 Subject: Snow or Ice Ingestion into Air Cleaner Element, Malfunction Indicator Lamp (MIL) Illuminated, Engine Power is Reduced Message Displayed, DTC P0101 Set (Perform Repair as Outlined) Models: 2007-2010 Chevrolet Silverado 2500/3500 Series 2007-2010 GMC Sierra 2500/3500 Series Equipped with Duramax(TM) Diesel Engine (RPO LMM) Supercede: This bulletin is being revised to provide a procedure to relocate the OAT sensor, if equipped with RPO CJ2. Please discard Corporate Bulletin 08-06-04-054A (Section 06 - Engine / Propulsion System). Condition Some customers may comment on the malfunction indicator lamp (MIL) being illuminated and an Engine Power is Reduced message being displayed. The technician may observe DTC P0101 set as current or in history. Cause This condition may be caused by snow being ingested into the air cleaner housing and accumulating in the air cleaner element, resulting in restricted airflow into the engine. Correction 1. Verify the condition by questioning the customer as to when the condition occurs (such as during or right after a snow storm). ‹› If the condition occurs as described above, proceed to Step 2. ‹› If the condition does not occur as described above, refer to Diagnostic Trouble Code (DTC) List Vehicle in SI. 2. Remove the air cleaner element. Refer to Air Cleaner Element Replacement in SI. 3. Inspect the air cleaner element for the following conditions: 1. Packed snow 2. Frozen ice 3. A soaking wet condition that would indicate previous snow ingestion 4. Excessive debris and contamination as a result of the ingestion ‹› If any of the above conditions are observed, replace the air cleaner element. Remove any snow or ice that may have accumulated in the air intake duct. Note Winter covers for trucks that are equipped with the Duramax(TM) Diesel Engine are included with vehicle orders that ship to the following areas: All of Canada, and the following states: Alaska, Colorado, Idaho, Maine, Michigan, Minnesota, Montana, New Hampshire, New York, North Dakota, South Dakota, Vermont, Wisconsin, Wyoming. These vehicles should not need a new cover. 4. Install the grille opening section ONLY (if using the 2 piece cover) of the winter front cover following the usage guidelines provided in the Owners Manual for the appropriate type winter cover. ‹› If the customer does not have a cover, obtain and install the grille opening section ONLY , GM P/N 25822811 (GMC) or GM P/N 25822812 (Chevrolet). 5. The grille opening cover MUST BE installed to ensure a complete repair, BEFORE ENCOUNTERING SNOW. This repair allows warm air to be circulated into the air cleaner. Additional Information to Advise Customer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 08-06-04-054B > Jan > 11 > Diesel Engine - Low Power/MIL ON/DTC P0101 > Page 5600 Important If the vehicle is driven in a snow storm before installing the winter cover and the customer chooses to resolve the issue, they must follow this procedure using the following steps: 1. Remove ANY ice or snow that may have accumulated in the air intake duct, BEFORE REPLACING the air cleaner element. 2. INSTALL the winter cover BEFORE continuing to drive the truck. 3. Turn OFF the ignition, and all electrical accessories and components. 4. Remove the key from the vehicle, THEN open and close the door. 5. WAIT for 2 minutes to allow the engine control module (ECM) to power down. This can be verified by watching for the instrument panel cluster (IPC) gage needles to drop slightly. 1. Allowing the ECM to power down will let DTC P0101 revert to a History DTC and the vehicle should return to full power if the issue has been eliminated. 2. Advise the customer to take the vehicle to the dealer as soon as possible to verify the condition has been eliminated. Ambient (Outside) Air Temperature Sensor Relocation For vehicles equipped with Automatic Temperature Control HVAC (RPO CJ2), the ambient (outside) air temperature sensor needs to be relocated using the following procedure: 1. Remove the radiator grille. Refer to the Radiator Grille Replacement procedure in SI. 2. Remove the ambient air sensor from its current location by carefully lifting the sensor from the radiator support cross bar. 3. Remove the harness clip nearest to the sensor. 4. Reinstall the ambient air sensor to the new location using the existing hole (1) in the lower section of the radiator support. 5. Reinstall the harness clip to the existing hole (2) in the radiator support. 6. Reinstall the radiator grille. Parts Information Warranty Information Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 08-06-04-054B > Jan > 11 > Diesel Engine - Low Power/MIL ON/DTC P0101 > Page 5601 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 08-06-04-054A > Jan > 10 > Engine - Reduced Power/MIL ON/DTC P0101 Air Filter Element: All Technical Service Bulletins Engine - Reduced Power/MIL ON/DTC P0101 TECHNICAL Bulletin No.: 08-06-04-054A Date: January 07, 2010 Subject: Snow or Ice Ingestion into Air Cleaner Element, Malfunction Indicator Lamp (MIL) Illuminated, Engine Power is Reduced Message Displayed, DTC P0101 Set (Perform Repair as Outlined) Models: 2007-2010 Chevrolet Silverado 2500/3500 Series 2007-2010 GMC Sierra 2500/3500 Series Equipped with Duramax(TM) Diesel Engine (RPO LMM) Please Refer to GMVIS Supercede: This bulletin is being revised to remove the graphic, update the Parts and Correction information and add information to advise a customer. Please discard Corporate Bulletin 08-06-04-054 (Section 06 - Engine / Propulsion System). Condition Some customers may comment on the malfunction indicator lamp (MIL) being illuminated and an Engine Power is Reduced message being displayed. The technician may observe DTC P0101 set as current or in history. Cause This condition may be caused by snow being ingested into the air cleaner housing and accumulating in the air cleaner element, resulting in restricted airflow into the engine. Correction 1. Verify the condition by questioning the customer as to when the condition occurs (such as during or right after a snow storm). ‹› If the condition occurs as described above, proceed to Step 2. ‹› If the condition does not occur as described above, refer to Diagnostic Trouble Code (DTC) List Vehicle in SI. 2. Remove the air cleaner element. Refer to Air Cleaner Element Replacement in SI. 3. Inspect the air cleaner element for the following conditions: 1. Packed snow 2. Frozen ice 3. A soaking wet condition that would indicate previous snow ingestion 4. Excessive debris and contamination as a result of the ingestion ‹› If any of the above conditions are observed, replace the air cleaner element. Remove any snow or ice that may have accumulated in the air intake duct. Note Winter covers for trucks that are equipped with the Duramax(TM) Diesel Engine are included with vehicle orders that ship to the following areas: All of Canada, and the following states: Alaska, Colorado, Idaho, Maine, Michigan, Minnesota, Montana, New Hampshire, New York, North Dakota, South Dakota, Vermont, Wisconsin, Wyoming. These vehicles should not need a new cover. 4. Install the grille opening section ONLY (if using the 2 piece cover) of the winter front cover following the usage guidelines provided in the Owners Manual for the appropriate type winter cover. ‹› If the customer does not have a cover, obtain and install the grille opening section ONLY, GM P/N 25822811 (GMC) or GM P/N 25822812 (Chevrolet). 5. The grille opening cover MUST BE installed to ensure a complete repair, BEFORE ENCOUNTERING SNOW. This repair allows warm air to be circulated into the air cleaner. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 08-06-04-054A > Jan > 10 > Engine - Reduced Power/MIL ON/DTC P0101 > Page 5606 Additional Information to Advise Customer Important If the vehicle is driven in a snow storm before installing the winter cover and the customer chooses to resolve the issue, they must follow this procedure using the following steps: 1. Remove ANY ice or snow that may have accumulated in the air intake duct, BEFORE REPLACING the air cleaner element. 2. INSTALL the winter cover BEFORE continuing to drive the truck. 3. Turn OFF the ignition, and all electrical accessories and components. 4. Remove the key from the vehicle, THEN open and close the door. 5. WAIT for 2 minutes to allow the engine control module (ECM) to power down. This can be verified by watching for the instrument panel cluster (IPC) gage needles to drop slightly. 1. Allowing the ECM to power down will let DTC P0101 revert to a History DTC and the vehicle should return to full power if the issue has been eliminated. 2. Advise the customer to take the vehicle to the dealer as soon as possible to verify the condition has been eliminated. Parts Information Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 5607 Air Filter Element: Service and Repair Air Cleaner Element Replacement Removal Procedure 1. Loosen the screw holding the air cleaner housing door in place. 2. Remove the air cleaner housing door. 3. Remove the air filter element. Installation Procedure 1. Stand facing the front fender on the passenger side of the vehicle. Insert the element into the housing. Place the palm of your hand on the inboard end of the element, and press the element into position. 2. Press both downward and inboard until the outboard end of the element clicks into place inboard of the locating tab. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 5608 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the air cleaner housing door and tighten the screw. Tighten the screw to 4 Nm (35 lb in). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations Air Flow Meter/Sensor: Locations Harness Routing Views Engine Harness Routing - Top (4.3L) 1 - Mega Fuse Ring Terminal 2 - X175 (M30) 3 - J128 4 - J105 5 - J106 6 - J130 (M30 with NQG/NQH) 7 - Engine Control Module (ECM) X1 8 - Engine Control Module (ECM) X2 9 - G103 10 - X112 11 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Connector Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 5612 Air Flow Meter/Sensor: Diagrams Component Connector End Views Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (Diesel) Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (Gas) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 5613 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 5614 Air Flow Meter/Sensor: Service and Repair Mass Airflow Sensor with Intake Air Temperature Sensor Replacement Removal Procedure 1. Disconnect the engine wiring harness electrical connector (1) from the mass air flow (MAF)/intake air temperature (IAT) sensor. 2. Remove the MAF/IAT sensor TORX(R) screws. 3. Remove the MAF/IAT sensor. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 5615 1. Install the MAF/IAT sensor. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the MAF/IAT sensor TORX(R) screws. Tighten the screws to 8 Nm (70 lb in). 3. Connect the engine wiring harness electrical connector (1) to the MAF/IAT sensor. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) Fuel: Technical Service Bulletins Fuel System - TOP TIER Detergent Gasoline (Canada) INFORMATION Bulletin No.: 05-06-04-022G Date: October 27, 2010 Subject: TOP TIER Detergent Gasoline Information and Available Brands (Deposits, Fuel Economy, No Start, Power, Performance, Stall Concerns) - Canada ONLY Models: 2011 and Prior GM Passenger Cars and Trucks (Canada Only) Supercede: This bulletin is being revised to update the model years and include an additional gasoline brand as a TOP TIER source. Please discard Corporate Bulletin Number 05-06-04-022F (Section 06 - Engine/Propulsion System). In the U.S., refer to the latest version of Corporate Bulletin Number 04-06-04-047I. A new class of fuel called TOP TIER Detergent Gasoline is appearing at retail stations of some fuel marketers. This gasoline meets detergency standards developed by six automotive companies. All vehicles will benefit from using TOP TIER Detergent Gasoline over gasoline containing the "Lowest Additive Concentration" recommended by the Canadian General Standards Board (CGSB). Those vehicles that have experienced deposit related concerns may especially benefit from use of TOP TIER Detergent Gasoline. Intake valve: 16,093 km (10,000 mi) with TOP TIER Detergent Gasoline Intake valve: 16,093 km (10,000 mi) with Minimum Additive recommended by the CGSB Top Tier Fuel Availability Chevron was the first to offer TOP TIER Detergent Gasoline in Canada. Shell became the first national gasoline retailer to offer TOP TIER Detergent Gasoline across Canada. Petro-Canada began offering TOP TIER Detergent Gasoline nationally as of October 1, 2006. Sunoco began offering TOP TIER Detergent Gasoline in March of 2007. Esso began offering TOP TIER Detergent Gasoline in May of 2010. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) > Page 5620 Gasoline Brands That Currently Meet TOP TIER Detergent Gasoline Standards The following gasoline brands meet the TOP TIER Detergent Gasoline Standards in all octane grades : Chevron Canada (markets in British Columbia and western Alberta) - Shell Canada (nationally) - Petro-Canada (nationally) - Sunoco-Canada (Ontario) - Esso-Canada (nationally) What is TOP TIER Detergent Gasoline? TOP TIER Detergent Gasoline is a new class of gasoline with enhanced detergency and no metallic additives. It meets new, voluntary deposit control standards developed by six automotive companies that exceed the detergent recommendations of Canadian standards and does not contain metallic additives, which can damage vehicle emission control components. Where Can TOP TIER Detergent Gasoline Be Purchased? The TOP TIER program began in the U.S. and Canada on May 3, 2004. Some fuel marketers have already joined and introduced TOP TIER Detergent Gasoline. This is a voluntary program and not all fuel marketers will offer this product. Once fuel marketers make public announcements, they will appear on a list of brands that meet the TOP TIER standards. Who developed TOP TIER Detergent Gasoline standards? TOP TIER Detergent Gasoline standards were developed by six automotive companies: BMW, General Motors, Honda, Toyota, Volkswagen and Audi. Why was TOP TIER Detergent Gasoline developed? TOP TIER Detergent Gasoline was developed to increase the level of detergent additive in gasoline. In the U.S., government regulations require that all gasoline sold in the U.S. contain a detergent additive. However, the requirement is minimal and in many cases, is not sufficient to keep engines clean. In Canada, gasoline standards recommend adherence to U.S. detergency requirements but do not require it. In fact, many brands of gasoline in Canada do not contain any detergent additive. In order to meet TOP TIER Detergent Gasoline standards, a higher level of detergent is needed than what is required or recommended, and no metallic additives are allowed. Also, TOP TIER was developed to give fuel marketers the opportunity to differentiate their product. Why did the six automotive companies join together to develop TOP TIER? All six corporations recognized the benefits to both the vehicle and the consumer. Also, joining together emphasized that low detergency and the intentional addition of metallic additives is an issue of concern to several automotive companies. What are the benefits of TOP TIER Detergent Gasoline? TOP TIER Detergent Gasoline will help keep engines cleaner than gasoline containing the "Lowest Additive Concentration" recommended by Canadian standards. Clean engines help provide optimal fuel economy and engine performance, and also provide reduced emissions. Also, the use of TOP TIER Detergent Gasoline will help reduce deposit related concerns. Who should use TOP TIER Detergent Gasoline? All vehicles will benefit from using TOP TIER Detergent Gasoline over gasoline containing the "Lowest Additive Concentration" recommended by Canadian standards. Those vehicles that have experienced deposit related concerns may especially benefit from use of TOP TIER Detergent Gasoline. More information on TOP TIER Detergent Gasoline can be found at this website, http://www.toptiergas.com/. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) > Page 5621 Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Page 5622 Fuel: Service Precautions Gasoline/Gasoline Vapors Warning Warning Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Page 5623 Fuel: Testing and Inspection Contaminants-in-Fuel Diagnosis Fungi and other microorganisms can survive and multiply in diesel fuel if water is present. The fungi can be present in any part of the fuel handling system. These fungi grow into long strings and will form into large globules. The growths appear slimy and are usually black, green, or brown. The fungi may grow anywhere in the fuel but are most plentiful where diesel fuel and water meet. Service station tanks may contain fungi that could be pumped into a vehicle during refueling. Fungi use the fuel as their main energy supply and need only trace amounts of water and minerals. As they grow and multiply, they change fuel into water, sludge, acids, and products of metabolism. The most common symptom is fuel filter plugging, however various metal fuel system components including fuel sender assembly, pipes, fuel injectors, and fuel injection pump can corrode. Warning Avoid physical contact with the biocides in order to avoid personal injury. If fungi have caused fuel system contamination, use a diesel fuel biocide to sterilize the fuel system. Do not exceed the dosage recommended on the label. Discontinue the use of a biocide when towing a trailer due to possible engine power loss. It is permissible to have biocide in the fuel when starting to tow, but do not add any biocide while towing. Water in fuel will also create drivability concerns and loss of engine power. If water is present in the fuel system , the fuel cannot cool and lubricate the components, causing overheating , rust and corrosion. This can result in component failure. Water can enter the fuel system in several ways, either through a contaminated refueling source, or through long term condensation the vehicle fuel tanks. Like fungi and water, gasoline contamination will cause drivability concerns and a possible hard starting or a no start condition if the overall content is large enough. Gasoline raises the API rating and reduces cooling and lubrication, resulting in possible component failure. Water in fuel will also create drivability concerns and loss of engine power. If water is present in the fuel system , the fuel cannot cool and lubricate the components, causing overheating , rust and corrosion. This can result in component failure. Water can enter the fuel system in several ways, either through a contaminated refueling source, or through long term condensation the vehicle fuel tanks. Like fungi and water, gasoline contamination will cause drivability concerns and a possible hard starting or a no start condition if the overall content is large enough. Gasoline raises the API rating and reduces cooling and lubrication, resulting in possible component failure. It is acceptable to use diesel fuel containing up to 5 percent bio-diesel. Bio-diesel is produced from vegetable oils or animal fat that have been chemically modified to reduce the possibility of damage to the fuel system and engine components. Concentrations greater than B5 fuels or the use of unmodified bio-oils blended into diesel fuel at any concentration is not recommended and may cause drivability concerns or component failure. Inspecting for Fuel Contaminants 1. Test the fuel specific gravity and record the results. Refer to Fuel System Specifications (See: Specifications). 2. Remove the fuel filter and inspect the inside area of the fuel filter for dirt, water deposits, or other debris. 3. Drain the fuel filter into an approved clear container and allow the contents to settle. Observe the container for contaminant separation. 4. Remove the water-in-fuel sensor from the bottom of the fuel filter and inspect inside the filter for rust deposits, dirt, or other debris. Note: The presence of water or gasoline in diesel fuel may also cause damage to other fuel system components. 5. If contaminants are present in the fuel or in any of the inspected areas, remove the fuel lines to the injectors and inspect the fuel injector return outlets and feed inlets for rust or corrosion. Replace the fuel injectors if rust or corrosion is present. Refer to Fuel Injector Replacement (Right) (See: Fuel Injector/Service and Repair/Removal and Replacement/Fuel Injector Replacement (Right))Fuel Injector Replacement (Left) (See: Fuel Injector/Service and Repair/Removal and Replacement/Fuel Injector Replacement (Left)) and Fuel System Cleaning (See: Service and Repair/Fuel System Cleaning). If rust or corrosion was not present in the injectors, but contaminated fuel was present, refer to Fuel System Cleaning (See: Service and Repair/Fuel System Cleaning) and attempt to start and run the engine after procedure is completed. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Cooler > Component Information > Service and Repair > Fuel Cooler Replacement (Pickup) Fuel Cooler: Service and Repair Fuel Cooler Replacement (Pickup) Fuel Cooler Replacement (Pickup) Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the fuel lines at the cooler (1). Refer to Metal Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Metal Collar Quick Connect Fitting Service). 3. Remove the fuel cooler bolts (4, 6). 4. Remove the fuel cooler (1). 5. Remove the fuel cooler support bracket bolt (2, 5), and bracket (3) from the fuel cooler (1), if necessary. Installation Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the fuel cooler support bracket (3), and bolts (2, 5) to the fuel cooler (1), if necessary. Tighten the bolts to 18 Nm (13 lb ft). 2. Install the fuel cooler (1) to the chassis and crossover. 3. Install the fuel cooler bolts (4, 6). Tighten the bolts to 18 Nm (13 lb ft). 4. Connect the fuel lines at the fuel cooler (1). Refer to Metal Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Metal Collar Quick Connect Fitting Service). 5. Lower the vehicle. 6. Prime the fuel system. Refer to Fuel System Priming (See: Service and Repair/Fuel System Priming). 7. Start the engine. If the engine stalls, repeat the above step. 8. Once the engine starts, inspect for fuel leaks. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Cooler > Component Information > Service and Repair > Fuel Cooler Replacement (Pickup) > Page 5628 Fuel Cooler: Service and Repair Fuel Cooler Replacement (Cab/Chassis) Fuel Cooler Replacement (Cab/Chassis) Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the fuel lines at the fuel cooler (1). Refer to Metal Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Metal Collar Quick Connect Fitting Service). 3. Remove the fuel cooler nuts (2). 4. Remove the fuel cooler (1). Installation Procedure 1. Install the fuel cooler (1). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the fuel cooler nuts (2). Tighten the nuts to 40 Nm (30 lb ft). 3. Connect the fuel lines at the fuel cooler (1). Refer to Metal Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Metal Collar Quick Connect Fitting Service). 4. Lower the vehicle. 5. Prime the fuel system. Refer to Fuel System Priming (See: Service and Repair/Fuel System Priming). 6. Start the engine. If the engine stalls, repeat the above step. 7. Once the engine starts, inspect for fuel leaks. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair Fuel Pressure Relief Valve Replacement Removal Procedure 1. Remove the glow plug module and bracket. Refer to Glow Plug Control Module Replacement (See: Glow Plug System/Glow Plug Control Module/Service and Repair). 2. Remove the fuel pressure relief valve from the left fuel rail. Installation Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the fuel pressure relief valve to the left fuel rail. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Page 5633 Tighten the valve to 100 Nm (74 lb ft). 2. Install the glow plug module and bracket. Refer to Glow Plug Control Module Replacement (See: Glow Plug System/Glow Plug Control Module/Service and Repair). 3. Prime the fuel system. Refer to Fuel System Priming (See: Service and Repair/Fuel System Priming). 4. Start the engine. If the engine stalls, repeat the above step. 5. Once the engine starts, inspect for fuel leaks. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Heater > Component Information > Diagrams Fuel Heater: Diagrams Component Connector End Views Fuel Heater (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Heater > Component Information > Diagrams > Page 5637 Fuel Heater: Service and Repair Fuel Heater Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Fuel System - Fuel Injector Service Information Fuel Injector: Technical Service Bulletins Fuel System - Fuel Injector Service Information INFORMATION Bulletin No.: 03-06-04-036B Date: November 10, 2009 Subject: Information on Servicing Duramax(TM) Fuel Injectors to Avoid and Remove Contamination Models: 2001-2010 Chevrolet Silverado 2003-2009 Chevrolet Kodiak C4500/C5500 Series 2006-2010 Chevrolet Express Vans 2001-2010 GMC Sierra 2003-2009 GMC TopKick C4500/C5500 Series 2006-2010 GMC Savana Vans Equipped with 6.6L Duramax(TM) Diesel Engine RPOs LB7, LLY, LMM, LBZ Please Refer to GMVIS Supercede: This bulletin is being revised to add model years and update the Parts Information. Please discard Corporate Bulletin Number 03-06-04-036A (Section 06 - Engine/Propulsion System). Fuel injectors may become contaminated during engine servicing. Debris between the injector line and the injector line nut may fall into the injector fuel inlet upon removal. Refer to the following SI procedures for the appropriate model year, vehicle and engine RPO when performing the following bulletin procedures for servicing the fuel injectors and lines. - Fuel Injection Fuel Rail Assembly Replacement - Bank 1 - Fuel Injection Fuel Rail Assembly Replacement - Bank 2 - Fuel Injector Replacement (Right) - Fuel Injector Replacement (Left) Removal of Fuel Injector Lines 1. Before removing the fuel injector line, use regulated compressed air to blow any debris from between the fuel injector line and the fittings (1, 2). Wipe the fittings (1, 2) clean of debris. 2. Spray Super Lube(R), P/N 12346241 (in Canada, P/N 10953474), or a lithium grease equivalent, between the fuel injector line and fittings (1, 2) to assist in containing any debris during removal. 3. Remove the fuel injector line. 4. Remove the upper valve cover. 5. Remove the lower valve cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Fuel System - Fuel Injector Service Information > Page 5642 Notice After the fuel line is removed and the fuel injector inlet is exposed, DO NOT use compressed air to clean debris. Using compressed air can allow debris to enter the fuel injector inlet and damage the fuel injector. 6. Immediately after removal of the lower valve cover, use a vacuum source to remove any contamination in the fuel injector inlet (1). Fuel Injector Cleaning and Inspection Notice The fuel injector must be cleaned with the proper cleaning equipment. DO NOT use abrasive cleaning methods such as a metallic brush to remove deposits. Cleaning an injector with improper tools may damage the fuel injector. 1. Use a soft bristle non-metallic brush and fuel injector cleaner, P/N 88861802 (in Canada, P/N 88861804), or equivalent, to remove any deposits from the nozzle tip (1) and the copper washer sealing area (2) before reinstallation. 2. Inspect the fuel injector nozzle tip (1) for cracks, dents, or other damage. 3. Inspect the nozzle tip (1) for any signs of discoloration (dark yellow, tan, or blue) due to excessive heat. Note For information on injector bore cleaning, refer to Corporate Bulletin Number 05-06-04-067 Information on New Essential Tool EN-47909 Injector Bore Cleaning Kit for 6.6L Duramax(TM) Diesel Engine. ‹› If any damage is found replace the fuel injector. Clean the fuel injector bore BEFORE installing the new fuel injector. 4. Clean the fuel injector high-pressure lines by performing the following steps: Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Fuel System - Fuel Injector Service Information > Page 5643 5. Inspect the fuel injector high-pressure line for excessive corrosion, scale or rust to the sealing surface as shown. Notice Medium size media glass beads have a cleaning and peening action and do not remove metal. They do not have the quick abrasive action of sharp edged media. Glass beads clean rust, scale and corrosion from metal parts without any damage. 6. Use an Abrasive Blasting Cabinet, P/N 624-AST-SBC1, (to order, call GM Dealer Equipment), or equivalent, with a medium size media glass beads to clean the high pressure lines and fittings. Important Black plastic electrical tape or equivalent will protect the fittings outside coating from being removed with the media. This must be done to ALL sixteen high pressure fittings. 7. Install black plastic electrical tape or equivalent on both of the fittings (1) as shown. 8. When using an Abrasive Blasting Cabinet or equivalent, make sure you only clean the inside of the fittings (2) and as much of the fitting threads as possible as shown. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Fuel System - Fuel Injector Service Information > Page 5644 9. Use pipe cleaners (1) to block the ends of the high pressure lines so the abrasive blasting glass beads will not contaminate the inside of the pipes. Before removing the pipe cleaners, clean them by using regulated compressed air to blow any debris and/or media glass beads from the pipe cleaners. 10. There may be some area of the fitting or line that the glass beads did not clean very well. Disregard any surface that did not clean up as long as the area of the fitting is clean at the bite edge or sealing surface. Refer to the above illustration (1). Replace any suspect high pressure line if the glass beads cannot remove corrosion, scale or rust from the sealing surfaces and/or pitting or any other damage that is found. 11. After cleaning all of the fuel injector high-pressure line fittings with the glass beads, clean by using compressed air to blow any debris and/or media glass beads from inside and outside of all the fittings and lines. Afterwards, wash thoroughly with All Purpose Parts Cleaner, P/N 88862650 (in Canada, P/N 88901247, Brake Parts Cleaner) or equivalent. Repeat this process until all of the debris and/or media glass beads have been removed from the fittings and lines. Fuel Injector Installation Install the fuel injectors and lines using published service procedures in SI. Notice Ensure proper torquing of the fuel injector line fittings (1, 2). An under-torqued fuel injector line will not seal properly and an over-torqued fuel injector line may damage the fuel injector fitting. An improperly sealed or damaged fuel injector line or fuel injector fitting may cause a fuel leak. Inspection For Fuel Leaks Into the Engine After Repair 1. Run the engine at idle for 10 minutes. Inspect for external fuel leaks while the engine is running. 2. Stop the engine and wait 10 minutes, then check the engine oil level. This will be the initial oil level. 3. Run the engine at idle for 5 minutes while commanding the fuel pressure to 160 MPa using a scan tool. 4. Stop the engine and wait 10 minutes, then check the oil level. ‹› If the engine oil level is more than 4.7 mm (3/16 in) above the initial oil level, refer to Fuel Leak Diagnosis (Inside of Engine), and Fuel in Engine Oil procedures in the Engine Controls and Engine Mechanical sections respectively in SI. ‹› If the engine oil level is less than 4.7 mm (3/16 in) above the initial oil level, the repair is complete. Parts Information Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Fuel System - Fuel Injector Service Information > Page 5645 Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Page 5646 Fuel Injector: Specifications Pressure Drop Balance rates should be between +4 mm(3) and -6.9 mm(3) in Park or Neutral. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Page 5647 Fuel Injector: Diagrams Component Connector End Views Fuel Injector 1 (Diesel) Fuel Injector 2 (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Page 5648 Fuel Injector 3 (Diesel) Fuel Injector 4 (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Page 5649 Fuel Injector 5 (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Page 5650 Fuel Injector 6 (Diesel) Fuel Injector 7 (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Page 5651 Fuel Injector 8 (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Page 5652 Fuel Injector: Testing and Inspection Fuel Injector Balance Test with Tech 2 Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Circuit/System Description The fuel injector balance test is performed when a misfire, knock, excessive smoke, or rough running condition exists with no electrical DTCs. This test uses the Balance Rate and Cylinder Power Balance test to identify cylinders that are not producing the designed power output. The balance rate adjustments are utilized by the engine control module (ECM) only at idle. The balance rates are the fuel adjustments for each individual cylinder based on the variations in engine crankshaft speed. The balance rates will change depending on if the transmission is in Neutral or Drive. During the Cylinder Power Balance portion of the test, the ECM turns OFF individual injectors while the engine is running. The ECM adjusts for the drop in engine RPM during cancellation and may not change on the scan tool display. The lack of power at the cancelled cylinder will feel like a misfiring cylinder or vibration. If a fuel injector is turned OFF and there is a no difference felt when compared to the other cylinders, that cylinder is identified with the concern. If the customer concern occurs during idle or during off-idle tip in acceleration, the balance rates are used to identify the cylinder with a fault related to the fuel injector or engine compression. Diagnostic Aids * The Cylinder Power Balance Test may be performed at any engine speed or load from idle to wide open throttle (WOT). There is a 5-minute time limit for each test. * A high balance rate may be caused by a fuel injector or cylinder compression only if the ECM can control fuel pressure. Circuit/System Verification Important: If any DTCs other than DTC P0300-P0308 are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle). 1. Start and run the engine until the coolant temperature is more than 82°C (180°F). Turn OFF all accessories. 2. Perform the fuel pressure regulator test, refer to Fuel Pressure Regulator Diagnosis (See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Fuel Pressure Regulator Diagnosis). 3. With a scan tool, command the Balance Rate Monitor ON. Balance rates should be between +4 mm(3) and -6.9 mm(3) in Park or Neutral. Balance rates outside the range may indicate contaminated fuel. Refer to Contaminants-in-Fuel Diagnosis (See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Contaminants-in-Fuel Diagnosis). Important: * The Cylinder Power Balance Test must be performed under the conditions for which the customer concern occurred. * Do not operate the cruise control during this test. Cruise control may cause a brief surge of engine speed after the completion of the test. 4. Perform the Cylinder Power Balance Test with a scan tool. During cylinder cancellation a noticeable power difference will feel like a misfiring cylinder or vibration. Circuit/System Testing Important: * You must perform the Circuit/System Verification before proceeding with Circuit/System Testing. * A fuel injector leak into the combustion chamber may result in mechanical damage to the cylinder. If any fuel spray comes out of a glow plug hole during the compression test, replace the fuel injector of the affected cylinder. * If fuel vapor is emitted during the engine compression test, replace the affected fuel injector and inspect for fuel contamination. refer to Contaminants-in-Fuel Diagnosis (See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Contaminants-in-Fuel Diagnosis). Perform the engine compression test. Refer to Engine Compression Test (See: Tune-up and Engine Performance Checks/Compression Check/Testing Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Page 5653 and Inspection). If the compression indicated any of the cylinders had low compression, refer to Symptoms - Engine Mechanical (See: Engine, Cooling and Exhaust/Engine/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Engine Mechanical). Important: * Failure to correctly identify the cylinder positions may result in the replacement of the wrong injector. * During replacement of the injectors, inspect the inlet and outlet fittings for corrosion or contamination. Refer to Contaminants-in-Fuel Diagnosis (See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Contaminants-in-Fuel Diagnosis). If the engine did not have low compression on any of the cylinders, replace the fuel injectors on the cylinders that had low cylinder power contribution, high balance rates, or a noise/smoke change during cancellation. Repair Instructions Perform the Diagnostic Repair Verification (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. * Fuel Injector Replacement (Right) (See: Service and Repair/Removal and Replacement/Fuel Injector Replacement (Right))Fuel Injector Replacement (Left) (See: Service and Repair/Removal and Replacement/Fuel Injector Replacement (Left)) * Fuel Pressure Regulator Replacement (See: Fuel Pressure Regulator/Service and Repair) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Procedures Fuel Injector: Procedures Fuel Injector Flow Rate Programming Circuit/System Description The control functions for the fuel injection system are integrated in the engine control module (ECM). Each injector's flow rate information and cylinder position are stored in the memory of both the glow plug control module (GPCM) and the ECM. The fuel injector flow rate programming must be done when any of the following procedures are performed: * The ECM is replaced * The GPCM is replaced * Any fuel injectors are replaced If the ECM does not communicate, the flow rate information can be retrieved from the GPCM. If both control modules fail to communicate, the fuel injector flow rate information, or injection quantity adjustment (IQA) flow rate numbers, will need to be retrieved from each individual injector. Before Programming A Control Module Important: DO NOT program a control module unless you are directed by a service procedure or you are directed by a General Motors Corporation service bulletin. Programming a control module at any other time will not permanently correct a customers concern. Ensure the following conditions are met before programming a control module: * Vehicle system voltage - There is no charging system concern. All charging system concerns must be repaired before programming a control module. - Battery voltage is between 12-16 volts. The battery must be charged before programming the control module if the battery voltage is low. - A battery charger is NOT connected to the vehicle battery. Incorrect system voltage or voltage fluctuations from a battery charger may cause programming failure or control module damage. - Turn OFF or disable any of the following systems that may put a load on the vehicle battery: * Twilight sentinel * Interior lights * Daytime running lights (DRL)-Applying the parking brake, on most vehicles, disables the DRL system. Refer to the Owner's Manual. * HVAC systems * Engine cooling fans, etc. * The ignition switch is in the proper position-The scan tool prompts you to turn ON the ignition, with the engine OFF. DO NOT change the position of the ignition switch during the programming procedure, unless instructed to do so. * All of the following tool connections are secure: - The connection at the data link connector (DLC) - The voltage supply circuits * DO NOT disturb the tool harnesses while programming. If an interruption occurs during the programming procedure, programming failure or control module damage may occur. Circuit/System Verification Review the Display ECM & GPCM Inj. Flow Rates parameter with a scan tool. All cylinders should be programmed with a flow rate number. Both the GPCM and the ECM should be programmed with the same flow rate numbers for the corresponding cylinders. Circuit/System Testing Important: If the flow rate number is not available in either control module, the numbers will need to be retrieved from each individual injector. Fuel Injector Identification Numbers Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Procedures > Page 5656 1 - Manufacturing Plant 2 - IQA Number 3 - Manufacturing Date 4 - Injector Number 5 - Serial Number 1. With a scan tool installed, enter the vehicle information and select the following options: * Engine Control Module * Module Setup * Injector Flow Rate Programming * Display ECM & GPCM Inj. Flow Rates 2. Record all flow rate numbers with the corresponding cylinders from the control modules. Important: When installing a new fuel injector, ensure that the IQA data number from the yellow IQA Data Tag, shipped with the new injector, is programmed to the correct cylinder ‹› If any injectors are replaced, go to Reprogram Injector Flow Rates parameter and enter the flow rate number of the new injector to the corresponding cylinder. The flow rate numbers will automatically update both control modules. ‹› If the ECM was replaced, go to Copy GPCM Inj. Flow Rates to ECM parameter and reprogram the ECM. This will update the ECM with the GPCM flow rate numbers. ‹› If the GPCM was replaced or the flow rate numbers are not the same for both modules, go to Copy ECM Inj. Flow Rates to GPCM parameter and reprogram the GPCM. This will update the GPCM with the ECM flow rate numbers. ‹› If both control modules were replaced, go to Reprogram Injector Flow Rates parameter and enter the previously recorded flow rate numbers or the numbers retrieved from each individual injector, to the corresponding cylinders. Repair Instructions Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Procedures > Page 5657 Important: The ECM and the GPCM must be allowed to completely power down after programming is complete. 1. Install any components or connectors that have been removed or replaced during diagnosis. 2. Perform any adjustment, programming or setup procedures that are required when a component or module is removed or replaced. 3. Turn ON the ignition, with the engine OFF, and clear the DTCs. 4. Disconnect the scan tool and turn OFF the ignition for 2 minutes. 5. If the repair was related to a DTC, duplicate the Conditions for Running the DTC and use the Freeze Frame/Failure Records, if applicable, in order to verify the DTC does not reset. If the DTC resets or another DTC is present, refer to the Diagnostic Trouble Code (DTC) List - Vehicle (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle) and perform the appropriate diagnostic procedure. OR If the repair was symptom related, duplicate the conditions under which the customer concern occurred to verify the repair. If the customer concern reoccurs, return to Symptoms - Vehicle (See: Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Vehicle) and perform the appropriate symptom diagnostic. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Procedures > Page 5658 Fuel Injector: Removal and Replacement Fuel Injector Replacement (Left) Fuel Injector Replacement (Left) Special Tools * EN-47909 Injector Bore and Sleeve Cleaning Kit * J-46594 Fuel Injector Puller Removal Procedure 1. Remove the left fuel injection fuel feed pipes. Refer to Fuel Injection Fuel Feed Pipe Replacement - Left Side (See: Fuel Supply Line/Service and Repair/Fuel Injection Fuel Feed/Fuel Injection Fuel Feed Pipe Replacement - Left Side). 2. Remove the left fuel injection fuel return pipe. Refer to Fuel Injection Fuel Return Pipe Replacement - Left Side (See: Fuel Return Line/Service and Repair/Fuel Injection Fuel Return Pipe Replacement - Left Side). Caution: Label all the injector electrical connectors before the connectors are removed in order to prevent reconnecting to the wrong injector. Failure to properly connect the injectors in the correct sequence will cause severe engine damage. 3. Disconnect the engine wiring harness electrical connectors from the fuel injectors. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Procedures > Page 5659 4. Remove the fuel injector bracket bolts. 5. Install the J-46594 (1) into the bolt hole in the fuel injector bracket. 6. Install a flare nut wrench onto the J-46594 and pull back away from the fuel injector, until the injector releases from its seat. 7. Remove the J-46594 . Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Procedures > Page 5660 Note: The unique fuel injector flow rates are programmed into the ECM according to cylinder location. Mark the injectors for correct re-installation to the same cylinders. Failure to do so may result in a poor driveability condition. 8. Remove the fuel injectors with brackets. 9. If necessary, remove the fuel injector bracket pins. 10. Remove and discard the copper washer from the fuel injector bore. 11. Remove and discard the O-ring from the fuel injector. Fuel Injector Cleaning and Inspection Note: If reusing the old injectors perform the following: Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Procedures > Page 5661 1. Use a soft bristle non-metallic brush and Top Engine Cleaner, GM P/N 1052626 or equivalent, to remove any deposits from the nozzle tip (1) and the copper washer sealing area (2) before re-installation. 2. Inspect the fuel injector nozzle tip (1) for any signs of discoloration (dark yellow, tan or blue) due to excessive heat. 3. Replace the injector if any damage is found. 4. Clean the fuel injector high pressure line. 5. Inspect the fuel injector line for excessive corrosion or damage to the sealing surfaces (1, 2). Replace the line if any damage is found. Injector Bore Cleaning Note: The procedure below will aid in the cleaning of carbon deposits from the injector sleeve during an injector replacement 1. Install the EN-47909-2 Radial Brush (brass), to the EN-47909-1 Handle Assembly. 2. Insert the brush into the injector bore and rotate the handle in order to break loose any carbon deposits from the injector bore walls and the combustion deck hole. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Procedures > Page 5662 Warning Wear safety glasses in order to avoid eye damage. 3. Using compressed air, evacuate any debris from the injector bore. 4. Remove the radial brush from the handle assembly. 5. Install the EN-47909-3 Axial Brush (nylon), to the EN-47909-1. 6. Insert the axial brush into the injector bore and rotate the handle while also applying a slight downward pressure, in order to force the brush ends into the bottom corners of the injector bore. Warning Wear safety glasses in order to avoid eye damage. 7. Using compressed air, evacuate any debris from the injector bore. Caution: Do not allow excessive amounts of solvent to go into the cylinder during cleaning. Failure to do so may cause engine damage upon startup. 8. Lightly dampen EN-47909-20 Cotton Swab with Top Engine Cleaner, GM P/N 1052626 (Canadian P/N 993026) or equivalent, and wipe away any deposits from the injector bore. 9. Inspect the injector bore for any deposits and repeat brushing if necessary. Warning Keep hands and face clear of glow plug holes while cranking. Hot liquid or gases may be expelled during cranking. Warning Wear safety glasses in order to avoid eye damage. 10. If necessary, crank the engine in order to expel any solvent before starting the engine. 1. Remove the glow plugs. Refer to Glow Plug Replacement - Bank 1 (See: Glow Plug System/Glow Plug/Service and Repair/Glow Plug Replacement - Bank 1) and/or Glow Plug Replacement - Bank 2 (See: Glow Plug System/Glow Plug/Service and Repair/Glow Plug Replacement - Bank 2). 2. Disable the fuel system. 3. Disconnect the crankshaft position (CKP) sensor electrical connector. 4. Crank the engine in order to expel any excessive solvent. 5. Using the cotton swabs supplied with the kit, wipe the injector bore clean of any solvent and/or debris. 6. Connect the CKP sensor electrical connector. 7. Enable the fuel system. 8. Reinstall the glow plugs. Refer to Glow Plug Replacement - Bank 1 (See: Glow Plug System/Glow Plug/Service and Repair/Glow Plug Replacement - Bank 1) and/or Glow Plug Replacement - Bank 2 (See: Glow Plug System/Glow Plug/Service and Repair/Glow Plug Replacement - Bank 2). Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Procedures > Page 5663 1. Install a NEW copper washer to the fuel injector bore. 2. Install a NEW O-ring onto the fuel injector. 3. If necessary, install the fuel injector bracket pins. 4. Install the fuel injectors with brackets. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Procedures > Page 5664 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Install the fuel injector bracket bolts. Tighten the bolts to 30 Nm (22 lb ft). 6. Connect the engine wiring harness electrical connectors to the fuel injectors. 7. Install the left fuel injection fuel return pipe. Refer to Fuel Injection Fuel Return Pipe Replacement - Left Side (See: Fuel Return Line/Service and Repair/Fuel Injection Fuel Return Pipe Replacement - Left Side). 8. Install the left fuel injection fuel feed pipes. Refer to Fuel Injection Fuel Feed Pipe Replacement Left Side (See: Fuel Supply Line/Service and Repair/Fuel Injection Fuel Feed/Fuel Injection Fuel Feed Pipe Replacement - Left Side). 9. If the fuel injectors were replaced, refer to Fuel Injector Flow Rate Programming (See: Procedures). 10. Prime the fuel system. Refer to Fuel System Priming (See: Service and Repair/Fuel System Priming). 11. Start the engine. If the engine stalls, repeat the above step. 12. Once the engine starts, inspect for fuel leaks. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Procedures > Page 5665 Fuel Injector Replacement (Right) Fuel Injector Replacement (Right) Special Tools * EN-47909 Injector Bore and Sleeve Cleaning Kit * J-46594 Fuel Injector Puller Removal Procedure 1. Remove the right fuel injection fuel feed pipes. Refer to Fuel Injection Fuel Feed Pipe Replacement - Right Side (See: Fuel Supply Line/Service and Repair/Fuel Injection Fuel Feed/Fuel Injection Fuel Feed Pipe Replacement - Right Side). 2. Remove the right fuel injection fuel return pipe. Refer to Fuel Injection Fuel Return Pipe Replacement - Right Side (See: Fuel Return Line/Service and Repair/Fuel Injection Fuel Return Pipe Replacement - Right Side). Caution: Label all the injector electrical connectors before the connectors are removed in order to prevent reconnecting to the wrong injector. Failure to properly connect the injectors in the correct sequence will cause severe engine damage. 3. Disconnect the engine wiring harness electrical connectors from the fuel injectors. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Procedures > Page 5666 4. Remove the engine wiring harness clip (1) from the wiring harness bracket and remove the bracket (2). 5. Remove the engine wiring harness clips from the wiring harness bracket. 6. Remove the engine wiring harness bracket bolts (1) and bracket. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Procedures > Page 5667 7. Remove the engine wiring harness clip from the oil level indicator tube bracket (2). 8. Remove the oil level indicator tube bolt (3). 9. Remove the oil level indicator tube bracket bolts (1). 10. Remove the oil level indicator tube bracket (2). 11. Remove the fuel injector bracket bolts. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Procedures > Page 5668 12. Install the J-46594 (1) into the bolt hole in the fuel injector bracket. 13. Install a flare nut wrench onto the J-46594 and pull back away from the fuel injector, until the injector releases from its seat. 14. Remove the J-46594 . Note: The unique fuel injector flow rates are programmed into the ECM according to cylinder location. Mark the injectors for correct re-installation to the same cylinders. Failure to do so may result in a poor driveability condition. 15. Remove the fuel injectors with brackets. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Procedures > Page 5669 16. If necessary, remove the fuel injector bracket pins. 17. Remove and discard the copper washer from the fuel injector bore. 18. Remove and discard the O-ring from the fuel injector. Fuel Injector Cleaning and Inspection Note: If reusing the old injectors perform the following: 1. Use a soft bristle non-metallic brush and Top Engine Cleaner, GM P/N 1052626 or equivalent, to remove any deposits from the nozzle tip (1) and the copper washer sealing area (2) before re-installation. 2. Inspect the fuel injector nozzle tip (1) for any signs of discoloration (dark yellow, tan or blue) due to excessive heat. 3. Replace the injector if any damage is found. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Procedures > Page 5670 4. Clean the fuel injector high pressure line. 5. Inspect the fuel injector line for excessive corrosion or damage to the sealing surfaces (1, 2). Replace the line if any damage is found. Injector Bore Cleaning Note: The procedure below will aid in the cleaning of carbon deposits from the injector sleeve during an injector replacement 1. Install the EN-47909-2 Radial Brush (brass), to the EN-47909-1 Handle Assembly. 2. Insert the brush into the injector bore and rotate the handle in order to break loose any carbon deposits from the injector bore walls and the combustion deck hole. Warning Wear safety glasses in order to avoid eye damage. 3. Using compressed air, evacuate any debris from the injector bore. 4. Remove the radial brush from the handle assembly. 5. Install the EN-47909-3 Axial Brush (nylon), to the EN-47909-1. 6. Insert the axial brush into the injector bore and rotate the handle while also applying a slight downward pressure, in order to force the brush ends into the bottom corners of the injector bore. Warning Wear safety glasses in order to avoid eye damage. 7. Using compressed air, evacuate any debris from the injector bore. Caution: Do not allow excessive amounts of solvent to go into the cylinder during cleaning. Failure to do so may cause engine damage upon startup. 8. Lightly dampen EN-47909-20 Cotton Swab with Top Engine Cleaner, GM P/N 1052626 (Canadian P/N 993026) or equivalent, and wipe away any deposits from the injector bore. 9. Inspect the injector bore for any deposits and repeat brushing if necessary. Warning Keep hands and face clear of glow plug holes while cranking. Hot liquid or gases may be expelled during cranking. Warning Wear safety glasses in order to avoid eye damage. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Procedures > Page 5671 10. If necessary, crank the engine in order to expel any solvent before starting the engine. 1. Remove the glow plugs. Refer to Glow Plug Replacement - Bank 1 (See: Glow Plug System/Glow Plug/Service and Repair/Glow Plug Replacement - Bank 1) and/or Glow Plug Replacement - Bank 2 (See: Glow Plug System/Glow Plug/Service and Repair/Glow Plug Replacement - Bank 2). 2. Disable the fuel system. 3. Disconnect the crankshaft position (CKP) sensor electrical connector. 4. Crank the engine in order to expel any excessive solvent. 5. Using the cotton swabs supplied with the kit, wipe the injector bore clean of any solvent and/or debris. 6. Connect the CKP sensor electrical connector. 7. Enable the fuel system. 8. Reinstall the glow plugs. Refer to Glow Plug Replacement - Bank 1 (See: Glow Plug System/Glow Plug/Service and Repair/Glow Plug Replacement - Bank 1) and/or Glow Plug Replacement - Bank 2 (See: Glow Plug System/Glow Plug/Service and Repair/Glow Plug Replacement - Bank 2). Installation Procedure 1. Install a NEW copper washer to the fuel injector bore. 2. Install a NEW O-ring onto the fuel injector. 3. If necessary, install the fuel injector bracket pins. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Procedures > Page 5672 4. Install the fuel injectors with brackets. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Install the fuel injector bracket bolts. Tighten the bolts to 30 Nm (22 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Procedures > Page 5673 6. Position the oil level indicator tube bracket (2) to the generator bracket. 7. Install the oil level indicator tube bracket bolts (1). Tighten the bolts to 21 Nm (15 lb ft). 8. Install the oil level indicator tube bolt (3). Tighten the bolt to 21 Nm (15 lb ft). 9. Install the wiring harness clip to the oil level indicator tube bracket (2). 10. Position the engine wiring harness bracket onto the upper valve rocker arm cover and install the bolts (1). Tighten the bolts to 21 Nm (15 lb ft). 11. Install the engine wiring harness clips to the wiring harness bracket. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Procedures > Page 5674 12. Position the engine wiring harness bracket (2) onto the upper valve rocker arm cover and install the engine wiring harness clip (1) to the wiring harness bracket. 13. Connect the engine wiring harness electrical connectors to the fuel injectors. 14. Install the right fuel injection fuel return pipe. Refer to Fuel Injection Fuel Return Pipe Replacement - Right Side (See: Fuel Return Line/Service and Repair/Fuel Injection Fuel Return Pipe Replacement - Right Side). 15. Install the right fuel injection fuel feed pipes. Refer to Fuel Injection Fuel Feed Pipe Replacement - Right Side (See: Fuel Supply Line/Service and Repair/Fuel Injection Fuel Feed/Fuel Injection Fuel Feed Pipe Replacement - Right Side). 16. If the fuel injectors were replaced, refer to Fuel Injector Flow Rate Programming (See: Procedures). 17. Prime the fuel system. Refer to Fuel System Priming (See: Service and Repair/Fuel System Priming). 18. Start the engine. If the engine stalls, repeat the above step. 19. Once the engine starts, inspect for fuel leaks. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Metal Collar Quick Connect Fitting Service Fuel Line Coupler: Service and Repair Metal Collar Quick Connect Fitting Service Metal Collar Quick Connect Fitting Service Special Tools * J 44581 Fuel Line Disconnect Tool * J 43178 Fuel Line Disconnect Tool * J 41769 Fuel Disconnect Tool Removal Procedure 1. Remove the retainers from the fuel feed and return pipe quick connect fittings. Warning Wear safety glasses when using compressed air, as flying dirt particles may cause eye injury. 2. Using compressed air, blow any dirt or debris from around the fitting. 3. Using the correct end of J 44581 for the size of the fitting. Insert J 44581 into the female connector, then push inward in order to release the locking tabs. 4. If the vehicle is a cab/chassis, it may be necessary to use J 43178 in order to release the quick connect fittings at the sending unit. 5. If disconnecting the fuel return line, it may be necessary to use J 41769 in order to release the quick connect fitting. 6. Pull the connection apart. 7. Use a clean shop towel in order to wipe off the male end. Caution: If necessary, remove rust or burrs from the fuel pipes with an emery cloth. Use a radial motion with the fuel pipe end in order to prevent damage to the O-ring sealing surface. Use a clean shop towel in order to wipe off the male tube ends. Inspect all the connections for dirt and burrs. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Metal Collar Quick Connect Fitting Service > Page 5679 Clean or replace the components and assemblies as required. 8. Inspect both ends of the fitting for dirt and burrs. Clean or replace the components as required. Installation Procedure Warning In order to reduce the risk of fire and personal injury, before connecting fuel pipe fittings, always apply a few drops of clean engine oil to the male pipe ends. This will ensure proper reconnection and prevent a possible fuel leak. During normal operation, the O-rings located in the female connector will swell and may prevent proper reconnection if not lubricated. 1. Apply a few drops of clean engine oil to the male connection end. 2. Push both sides of the fittings together in order to snap the retaining tabs into place. 3. Once installed, pull on both sides of the connections in order to make sure the connection is secure. 4. Install the retainers to the fuel feed/return pipes. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Metal Collar Quick Connect Fitting Service > Page 5680 Fuel Line Coupler: Service and Repair Plastic Collar Quick Connect Fitting Service Plastic Collar Quick Connect Fitting Service Disconnect Procedure Note: There are several types of Plastic Collar Fuel and Evaporative Emission Quick Connect Fittings used on this vehicle. * Bartholomew (1) * Q Release (2) * Squeeze to Release (3) * Sliding Retainer (4) * Push Down TI (5) The following instructions apply to all of these types of Plastic Collar Quick Connect Fittings except where indicated. 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). Warning: Refer to Fuel and Evaporative Emission Hose/Pipe Connection Cleaning Caution (See: Emission Control Systems/Evaporative Emissions System/Service Precautions/Vehicle Damage Warnings). 2. Using compressed air, blow any dirt or debris from around the connection. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Metal Collar Quick Connect Fitting Service > Page 5681 3. This step applies to Bartholomew style connector ONLY. Squeeze the plastic quick connect fitting release tabs. 4. This step applies to Release Tab style connector ONLY. Release the fitting by pushing the tab toward the other side of the slot in the fitting. 5. This step applies to the Squeeze to Release style connector ONLY. Squeeze where indicated by the arrows shown above on both sides of the plastic ring surrounding the quick connect fitting. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Metal Collar Quick Connect Fitting Service > Page 5682 6. This step applies to the Sliding Retainer style connector ONLY. Release the fitting by pressing on one side of the release tab causing it to push in slightly. If the tab does not move try pressing the tab in from the opposite side. The tab will only move in one direction. 7. This step applies to the Push Down TI style connector ONLY. Release the fitting by pressing on the tab indicated by the arrow. Quick Connect Fittings 8. Pull the connection apart. Connect Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Metal Collar Quick Connect Fitting Service > Page 5683 Warning: Refer to Fuel Pipe Fitting Warning (See: Service Precautions/Fuel Pipe Fitting Warning). 1. Apply a few drops of clean engine oil to the male connection end. 2. Push both sides of the quick-connect fitting together in order to cause the retaining feature to snap into place. 3. Once installed, pull on both sides of the connection in order to make sure the connection is secure. 4. Install the fuel fill cap. 5. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Control Module > Component Information > Diagrams Fuel Pressure Control Module: Diagrams Component Connector End Views Fuel Pump Flow Control Module (Gas except JL1 and except LU3, LY6 or LY6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Control Module > Component Information > Diagrams > Page 5687 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Diagrams Fuel Pressure Regulator: Diagrams Component Connector End Views Fuel Pressure Regulator (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Diagrams > Page 5691 Fuel Pressure Regulator: Testing and Inspection Fuel Pressure Regulator Diagnosis The Fuel Pressure Regulator graphing procedure offers valuable information on regulator performance by comparing desired and actual fuel rail pressure. An almost perfect comparison between fuel rail pressure and desired fuel rail pressure is found on a fairly new, low mileage engine. A minor ripple is acceptable behavior for the fuel rail pressure regulator and is seen on high mileage engines. A "shark tooth" fluctuation in fuel rail pressure indicates a sticking fuel pressure regulator. 1. Set up the following Min/Max ranges for graphing the fuel rail pressure on the scan tool. * Engine Speed Min/Max range is 0-1,000 RPM. * Fuel Rail Pressure Min/Max range is 1-160 MPa. * Desired Fuel Rail Pressure Min/Max is 1-160 MPa. 2. Start and idle the engine. 3. Observe the live plot for sharp changes or shark tooth pattern in the Fuel Rail Pressure while performing the following actions: * Idling the engine * Shifting the transmission from Park to Drive and back to Park * Turning the steering from left stop position to right stop position * Turning the air conditioning ON and OFF 4. If there is a violent fluctuation in the Fuel Rail Pressure , as seen in the surging graph below, replace the fuel pressure regulator. Refer to Fuel Pressure Regulator Replacement (See: Service and Repair). Good Fuel Pressure Regulator Graph, 0 Miles 1 - Engine Speed 2 - Fuel Rail Pressure 3 - Desired Fuel Rail Pressure Good Fuel Pressure Regulator Graph, 26K Miles Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Diagrams > Page 5692 1 - Engine Speed 2 - Fuel Rail Pressure 3 - Desired Fuel Rail Pressure Fuel Pressure Regulator Graph, Surging Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Diagrams > Page 5693 1 - Engine Speed 2 - Fuel Rail Pressure 3 - Desired Fuel Rail Pressure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Diagrams > Page 5694 Fuel Pressure Regulator: Service and Repair Fuel Pressure Regulator Replacement Removal Procedure 1. Remove the generator. Refer to Generator Replacement (V6) (See: Starting and Charging/Charging System/Alternator/Service and Repair )Generator Replacement (V8) (See: Starting and Charging/Charging System/Alternator/Service and Repair)Generator Replacement (6.6L) (See: Starting and Charging/Charging System/Alternator/Service and Repair). 2. Remove the intake manifold tube. Refer to Intake Manifold Tube Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair/Intake Manifold Tube Replacement). 3. Remove the water outlet tube. Refer to Water Outlet Tube Replacement (LU3) (See: Engine, Cooling and Exhaust/Cooling System/Coolant Outlet/Service and Repair)Water Outlet Tube Replacement (LMM) (See: Engine, Cooling and Exhaust/Cooling System/Coolant Outlet/Service and Repair). 4. Unbolt and reposition the air conditioning (A/C) compressor (with the hoses attached) to the right side of the engine compartment. Refer to Air Conditioning Compressor Replacement (LLY/LMM) (See: Heating and Air Conditioning/Compressor HVAC/Service and Repair/Removal and Replacement)Air Conditioning Compressor Replacement (LU3) (See: Heating and Air Conditioning/Compressor HVAC/Service and Repair/Removal and Replacement)Air Conditioning Compressor Replacement (LY2, LY5, LH6, L76, L92 and LMG) (See: Heating and Air Conditioning/Compressor HVAC/Service and Repair/Removal and Replacement)Air Conditioning Compressor Replacement (HP2) (See: Heating and Air Conditioning/Compressor HVAC/Service and Repair/Removal and Replacement). 5. Disconnect the engine coolant temperature (ECT) sensor electrical connectors (1) and reposition the harness branches. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Diagrams > Page 5695 6. Disconnect the wiring harness extension electrical connector (1) from the fuel pressure regulator. 7. Reposition the fuel hose clamp (2) at the fuel injection fuel feed manifold. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Diagrams > Page 5696 8. Reposition the fuel hose clamp (3) at the fuel injection pump. 9. Remove the fuel hose (4) from the fuel injection fuel feed manifold and injection pump. 10. Clean the fuel pressure regulator and high pressure injection pump thoroughly with solvent, such as GM P/N 12377981 (Canadian P/N 10953463) or equivalent. 11. Using compressed air, thoroughly blow dry the regulator and pump. 12. Remove the 3 fuel pressure regulator screws (1) using a T25 TORX(R). 13. Remove the fuel pressure regulator (2). 14. If dirt or debris is found in the bore or seating surfaces of the fuel injection pump, perform the following: * Place a clean rag over the bore on order to collect the excess fuel. * Bump the engine over in order to flush any debris out of the regulator bore. Installation Procedure Note: If the pressure regulator is being re-used, check the O-rings for damage. If the O-rings are damaged, install NEW O-rings. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Diagrams > Page 5697 1. Lubricate and install NEW O-rings onto the regulator. Lubricate the O-rings with clean, NEW engine oil. Note: If the regulator is installed at an angle the O-rings may be damaged, resulting in possible fuel leakage. 2. Install the fuel pressure regulator (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the 3 fuel pressure regulator screws (1) using a T25 TORX(R). * Tighten the screws a first pass to 4 Nm (35 lb in). * Tighten the screws a final pass to 7 Nm (62 lb in). 4. Install the fuel hose (4) to the fuel injection fuel feed manifold and injection pump. 5. Position the fuel hose clamp (3) at the fuel injection pump. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Diagrams > Page 5698 6. Position the fuel hose clamp (2) at the fuel injection fuel feed manifold. 7. Connect the wiring harness extension electrical connector (1) to the fuel pressure regulator. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Diagrams > Page 5699 8. Position the engine wiring harness branches to the ECT sensors and connect the ECT sensor electrical connectors (1). 9. Position and install the A/C compressor. Refer to Air Conditioning Compressor Replacement (LLY/LMM) (See: Heating and Air Conditioning/Compressor HVAC/Service and Repair/Removal and Replacement)Air Conditioning Compressor Replacement (LU3) (See: Heating and Air Conditioning/Compressor HVAC/Service and Repair/Removal and Replacement)Air Conditioning Compressor Replacement (LY2, LY5, LH6, L76, L92 and LMG) (See: Heating and Air Conditioning/Compressor HVAC/Service and Repair/Removal and Replacement )Air Conditioning Compressor Replacement (HP2) (See: Heating and Air Conditioning/Compressor HVAC/Service and Repair/Removal and Replacement). 10. Install the water outlet tube. Refer to Water Outlet Tube Replacement (LU3) (See: Engine, Cooling and Exhaust/Cooling System/Coolant Outlet/Service and Repair)Water Outlet Tube Replacement (LMM) (See: Engine, Cooling and Exhaust/Cooling System/Coolant Outlet/Service and Repair). 11. Install the intake manifold tube. Refer to Intake Manifold Tube Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair/Intake Manifold Tube Replacement). 12. Install the generator. Refer to Generator Replacement (V6) (See: Starting and Charging/Charging System/Alternator/Service and Repair )Generator Replacement (V8) (See: Starting and Charging/Charging System/Alternator/Service and Repair)Generator Replacement (6.6L) (See: Starting and Charging/Charging System/Alternator/Service and Repair). 13. Prime the fuel system. Refer to Fuel System Priming (See: Service and Repair/Fuel System Priming). 14. Start the engine. If the engine stalls, repeat the above step. 15. Once the engine starts, inspect for fuel leaks. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Diagrams Fuel Pressure Sensor/Switch: Diagrams Component Connector End Views Fuel Rail Pressure (FRP) Sensor (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Diagrams > Page 5703 Fuel Pressure Sensor/Switch: Service and Repair Fuel Injection Fuel Rail Fuel Pressure Sensor Replacement Removal Procedure 1. Remove the exhaust gas recirculation (EGR) valve cooler. Refer to Exhaust Gas Recirculation Valve Cooler Replacement (See: Emission Control Systems/Exhaust Gas Recirculation/EGR Cooler/Service and Repair/Exhaust Gas Recirculation Valve Cooler Replacement). 2. Disconnect the engine wiring harness electrical connector (1) from the fuel rail fuel pressure sensor wiring harness extension electrical connector. 3. Remove the fuel rail fuel pressure sensor wiring harness extension clip (3) from the wiring harness bracket. 4. Remove the EGR valve cooler rear bracket bolts and bracket. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Diagrams > Page 5704 5. Disconnect the fuel rail fuel pressure sensor wiring harness extension (1) from the fuel rail fuel pressure sensor. 6. Prior to removal, clean the fuel rail fuel pressure sensor and surrounding area thoroughly with solvent, such as GM P/N 12377981 (Canadian P/N 10953463) or equivalent. 7. Using compressed air, thoroughly blow dry the sensor and surrounding area. 8. Remove the fuel rail fuel pressure sensor (2). Installation Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the fuel rail fuel pressure sensor (2). Tighten the sensor to 70 Nm (52 lb ft). 2. Connect the fuel rail fuel pressure sensor wiring harness extension (1) to the fuel rail fuel pressure sensor. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Diagrams > Page 5705 3. Position the EGR valve cooler rear bracket to the cylinder head and install the bolts. Tighten the bolts to 25 Nm (18 lb ft). 4. Connect the engine wiring harness electrical connector (1) to the fuel rail fuel pressure sensor wiring harness extension electrical connector. 5. Install the fuel rail fuel pressure sensor wiring harness extension clip (3) to the wiring harness bracket. 6. Install the EGR valve cooler. Refer to Exhaust Gas Recirculation Valve Cooler Replacement (See: Emission Control Systems/Exhaust Gas Recirculation/EGR Cooler/Service and Repair/Exhaust Gas Recirculation Valve Cooler Replacement). 7. Prime the fuel system. Refer to Fuel System Priming (See: Service and Repair/Fuel System Priming). 8. Start the engine. If the engine stalls, repeat the above step. 9. Once the engine starts, inspect for fuel leaks. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications During engine cranking, the pressure should be at least 10 MPa. With the engine running at idle the pressure should be close to the Desired Fuel Rail Pressure. As the engine speed increase, the Desired Fuel Rail Pressure and the Actual Fuel Rail Pressure should be within 2 MPa of each other. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications > Page 5710 Fuel Pressure: Service Precautions Relieving Fuel Pressure Warning Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis Fuel Pressure: Testing and Inspection Fuel System Diagnosis Fuel System Diagnosis Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Circuit/System Description Fuel is drawn by the fuel injection pump from the tank to the engine through the fuel supply lines. Fuel flows to the fuel filter/heater element housing , which combines a water separator, a prime pump, fuel heater element and a filter element. A mechanical fuel injection pump at the front of the engine valley includes the fuel supply pump and the high-pressure pump. The small section of the fuel pump assembly is the supply pump, which creates a vacuum to pull fuel from the fuel tank to the high-pressure pump. The vacuum varies with engine load and speed as indicated by the table below. The pump is engine-driven by the camshaft gear. From the high-pressure pump, the pressurized fuel flows to the left fuel rail. A balance pipe from the center of the left rail then feeds the right fuel rail. Each fuel rail supplies one bank of 4 fuel injectors. The fuel rail pressure sensor is mounted in the end of the right fuel rail. Fuel is used to cool and lubricate the fuel injectors and fuel injection pump. The fuel return system is designed to return this fuel to the fuel tank. If the high side fuel pressure becomes excessive, the fuel rail pressure relief valve releases the fuel into the fuel return system. The return fuel travels through the fuel cooler and then to the fuel tank. Diagnostic Aids An Engine Cranks but Will Not Run or Hard Start symptom may exist if air is being drawn into the fuel injection system due to the following conditions: * Fuel contamination-Refer to Contaminants-in-Fuel Diagnosis (See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Contaminants-in-Fuel Diagnosis). * Deformed or cut O-rings at the fuel supply line connections * Improperly seated fuel supply line fittings * Porous or weathered rubber fuel supply lines * Fuel filter vent screw not tighten or cross threaded * Fuel filter not tighten properly Reference Information Special Tools * J-23738-A MityVac * EN-47969 Fuel Supply Diagnostic Hose * CH-48027 Digital Pressure Gauge * J 44581 Fuel Line Disconnect Tool Circuit/System Verification Observe the Actual Fuel Rail Pressure parameter with a scan tool. During engine cranking, the pressure should be at least 10 MPa. With the engine running at idle the pressure should be close to the Desired Fuel Rail Pressure. As the engine speed increase, the Desired Fuel Rail Pressure and the Actual Fuel Rail Pressure should be within 2 MPa of each other. Circuit/System Testing Note: Ensure that a sufficient amount of fuel is in the fuel tank to run the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis > Page 5713 1. Install the CH-48027 to the fuel system service port on the right front side of the engine. 2. Prime the fuel system until 10 psi is indicated on the CH-48027 . Fuel pressure should not drop below 2 psi in less than one minute. ‹› If fuel pressure drops below 2 psi in less than one minute, go to step 4. Note: It may be necessary to remove engine components for the visual inspections. 3. Attempt to start and idle the engine. Observe the CH-48027 during idle. The vacuum should be between 1-3 in Hg. ‹› If more than 3 in Hg is observed at idle, visually inspect the following items: * Fuel filter element for a restriction * Hoses and lines that are flattening when the engine is running, or have kinks that would restrict the flow of fuel ‹› If engine did not start and no vacuum was observed, refer to Fuel Injection Pump Replacement (See: Service and Repair). 4. Disconnect the fuel supply line at the engine and install a J-23738-A using the J 44581 to the engine side of the fuel supply line. 5. Apply vacuum to the fuel supply pipe until 25 in Hg has been reached. Wait for at least one minute to allow the fuel system to stabilize. Vacuum should not drop below 8 in Hg within 10 minutes. ‹› If vacuum cannot be obtained or the vacuum drops below 8 in Hg within 10 minutes, repair the air leak at fuel filter/heater element housing connections or at the fuel hoses/pipes on the engine supply line. 6. Remove both hoses from the fuel filter/heater element housing assembly. Cap the suction side port of the fuel filter/heater element housing assembly. Apply 25 in Hg to the discharge port of the fuel filter/heater element housing assembly. Vacuum should not drop below 8 in Hg within 10 minutes. ‹› If vacuum drops below 8 in Hg within 10 minutes, replace the fuel filter/heater element housing assembly. Note: The engine may start and then stall after briefly running. 7. Remove the J-23738-A from the fuel filter/heater element housing assembly. Install the removed fuel filter/heater element housing assembly, and cap off the fuel supply pipe on the engine. Crank the engine in 15-second intervals while observing the CH-48027 . More than 5 in Hg vacuum should be observed during cranking. ‹› If less than 5 in Hg was observed on the vacuum gauge during cranking, replace the fuel injection pump. Note: The engine may start, and then stall after briefly running. 8. Install the fuel supply line at the engine, and disconnect the chassis fuel supply line at the fuel tank. Install a J-23738-A to the supply hose at the fuel tank using the J 44581 . 9. Apply vacuum to the supply hose at the fuel tank until 25 in Hg has been reached. Wait for a least one minute for the fuel system to stabilize. Vacuum should not drop below 8 in Hg within 10 minutes. ‹› If vacuum cannot be obtained, or the vacuum drops below 8 in Hg within 10 minutes, repair the air leak in the fuel supply line between the engine and fuel tank, or the connection of the supply line to the engine. 10. Install all components and lines that were previously removed or disconnected. 11. Install the EN-47969 on the fuel supply line at the engine. Create a vertical loop in the hose to observe the incoming fuel for air bubbles. 12. Open the bleed screw on top of the fuel filter/heater element housing. Prime the system until fuel appears at the bleed screw. Continue to prime the fuel system until the engine starts and runs. 13. Run the engine for at least 10 minutes to allow the fuel system to stabilize, and purge any air from the system. Note: Changes in engine speed can cause an increase of air bubbles that enter the EN-47969 . An air pocket at the top of the EN-47969 loop is considered a normal condition. 14. At a stabilized idle, observe the fuel entering the EN-47969 for air bubbles. ‹› If air bubbles were observed entering the transparent hose, test the fuel sender for leaks. Refer to Fuel Sender Assembly Replacement (See: Fuel Tank/Fuel Gauge Sender/Service and Repair). 15. Install the fuel sender, fuel tank, and all fuel system connections and components that were previously disconnected. Leave the EN-47969 connected to the fuel supply line. Prime the fuel system 30 times to remove the air from the fuel hoses. Continue to prime the fuel system until the engine starts and runs. Observe the fuel entering the transparent hose. ‹› If air bubbles are still present, refer to Diagnostic Aids. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis > Page 5714 ‹› If no air bubbles are present , remove the EN-47969 and run the engine to ensure no fuel leaks exist. Repair Instructions Perform the Diagnostic Repair Verification (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. * Fuel Injection Pump Replacement (See: Service and Repair) * Fuel Sender Assembly Replacement (See: Fuel Tank/Fuel Gauge Sender/Service and Repair) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis > Page 5715 Fuel Pressure: Testing and Inspection Fuel System Diagnosis - High Pressure Side Fuel System Diagnosis - High Pressure Side Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Circuit/System Description High Pressure System The fuel injection pump at the front of the engine valley includes a fuel supply pump and a high-pressure pump. Fuel is drawn by the fuel supply pump from the primary fuel tank and delivered to the high-pressure pump. The pump is engine-driven by the camshaft gear. High pressure fuel is regulated by the fuel pressure regulator mounted on the fuel injection pump. From the high-pressure pump, the fuel moves to the left and right fuel rails through high pressure metal lines. Each fuel rail distributes high pressure fuel to one bank of 4 fuel injectors. The fuel pressure relief valve is location on the left rail, and relieves excessive fuel pressure which returns to the fuel tank. Return System The fuel return system routes fuel from the fuel injectors, the pressure relief valve, and the fuel injection pump. The return fuel travels to the fuel cooler and then to the fuel tank. This fuel is used to cool and lubricate the injection pump and the injectors. Diagnostic Aids * The fuel return volumes vary based on the American Petroleum Institute (API) rating of the diesel fuel. * A fuel injector may have high fuel return flow only at higher engine temperatures. Reference Information Special Tools * J 45873 Fuel Return Volume Test Kit * J-45873-30 Injector Flow Test Adapter Circuit/System Verification With the engine running at idle the Actual Fuel Pressure should be close to the Desired Fuel Rail Pressure. During engine cranking the Actual Fuel Pressure should be at least 10 MPa. Inspect the fuel return hoses and lines for external leaks or damage. Circuit/System Testing Important: If you were not referred to this test from another diagnostic, do not perform this procedure. Only perform this test when the fuel is more than 18°C (65°F). Important: Before replacing the fuel pressure relief valve, ensure that the break-away torque is within specifications. Refer to Fastener Tightening Specifications (See: Specifications). 1. Remove the fuel pressure relief valve return hose and plug the hose to prevent fuel leakage. 2. Install a section of rubber fuel hose on the fuel pressure relief valve connection and place loose end of hose into a clean fuel container. Important: Fuel that is contaminated with gasoline may cause permanent damage to the fuel pressure relief valve. Refer to Contaminants-in-Fuel Diagnosis (See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Contaminants-in-Fuel Diagnosis). * If the engine cranks but does not start, crank engine for 15 seconds. Observe for fuel leaking from fuel pressure relief valve. ‹› If fuel leaks from the fuel pressure relief valve, replace the pressure relief valve. Refer to Fuel Pressure Relief Valve Replacement (See: Fuel Filter/Fuel Pressure Release/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis > Page 5716 * If the engine starts and runs, idle the engine while commanding the fuel rail pressure to 180 MPa with a scan tool. Observe for fuel leaking from fuel pressure relief valve. ‹› If fuel leaks from the fuel pressure relief valve, replace the pressure relief valve. Refer to Fuel Pressure Relief Valve Replacement (See: Fuel Filter/Fuel Pressure Release/Service and Repair). Important: Always replace the fuel return hose retaining clips on the fuel injectors with new clips after removing. 3. Remove the fuel return hose from the fuel injectors of the right cylinder bank. Refer to Fuel Injection Fuel Return Pipe Replacement - Right Side (See: Fuel Return Line/Service and Repair/Fuel Injection Fuel Return Pipe Replacement - Right Side). 4. Connect the yellow hoses from the J 45873 to the J-45873-30 . 5. Connect the J-45873-30 with yellow hoses to each fuel injector return port of the right cylinder bank, and install the retaining clips. 6. Install the 4 yellow hoses in the J 45873 graduated cylinders in numerical order. 7. Connect the fuel return hoses to the J-45873-30 to prevent leakage. ‹› If the engine starts and runs, idle the engine until fuel start dripping into all the graduated cylinders and yellow hoses are full of fuel. Important: The engine cranking speed must be more than 150 RPM during the cranking portion of this test. ‹› If the engine does not start, crank the engine in 15-second intervals, with 1 minute cooling time between intervals, until fuel starts to flow into all of the graduated cylinders. 8. Elevate the 4 yellow hoses to retain the fuel in the hoses, and empty the 4 graduated cylinders into a suitable container. 9. Install the 4 yellow hoses in the J 45873 graduated cylinders in numerical order. ‹› If the engine starts and runs, idle the engine for 15 seconds. ‹› If the engine does not start, crank the engine for 15 seconds. Important: During replacement of the injectors, inspect the inlet and outlet fittings for corrosion or contamination. Refer to Contaminants-in-Fuel Diagnosis (See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Contaminants-in-Fuel Diagnosis). 10. Measure the quantity of fuel in each of the graduated cylinders. Refer to Fuel System Specifications (See: Specifications) for the desired quantities. ‹› If high return flows were recorded, replace those fuel injectors that had high return flow and retest the fuel return flow, referring to Fuel System Specifications (See: Specifications). Replace any additional high return flow injectors and proceed to the next number step. 11. Install and connect all fuel system components that were previously removed or disconnected. 12. Remove the fuel return pipes from the fuel injectors of the left cylinder bank and repeat the fuel return flow test previously preformed on the right cylinder bank. ‹› If high return flows were recorded, replace those fuel injectors that had high return flow and retest the fuel return flow, referring to Fuel System Specifications (See: Specifications). Replace any additional high return flow injectors and proceed to the next number step. 13. Install and connect all fuel system components that were previously removed or disconnected. 14. Start and idle the engine. You may have to prime the fuel system before the engine will start. Command the fuel pressure control to 180 MPa with a scan tool. The actual fuel pressure should be the same as the commanded pressure. ‹› If the engine does not start or the fuel pressure is less than 145 MPa when commanded, replace the fuel injection pump. 15. Command the fuel pressure control to 180 MPa with a scan tool. The fuel pressure should be able to reach 145 MPa when commanded. ‹› If the fuel pressure is less than the specified value, refer to Fuel System Diagnosis (See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Fuel System Diagnosis). 16. Operate the vehicle in order to verify the repairs. Repair Instructions Perform the Diagnostic Repair Verification (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. * Fuel Injection Pump Replacement (See: Service and Repair) * Fuel Pressure Relief Valve Replacement (See: Fuel Filter/Fuel Pressure Release/Service and Repair) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel System Diagnosis > Page 5717 * Fuel Injector Replacement (Right) (See: Fuel Injector/Service and Repair/Removal and Replacement/Fuel Injector Replacement (Right))Fuel Injector Replacement (Left) (See: Fuel Injector/Service and Repair/Removal and Replacement/Fuel Injector Replacement (Left)) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Fuse Block - Underhood Fuel Pump Relay: Locations Fuse Block - Underhood Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Fuse Block - Underhood > Page 5722 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Fuse Block - Underhood > Page 5723 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Fuse Block - Underhood > Page 5724 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Fuse Block - Underhood > Page 5725 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Fuse Block - Underhood > Page 5726 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Fuse Block - Underhood > Page 5727 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Fuse Block - Underhood > Page 5728 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Fuse Block - Underhood > Page 5729 Fuel Pump Relay: Locations Harness Routing Views Harness Routing Views Chassis Harness - Front Engine Compartment (31 Series) 1 - X102 (JL1) 2 - Fuel Pump Relay - Secondary (LY6 without NQZ) 3 - Fuse Block - Underhood 4 X126 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 5730 Fuel Pump Relay: Diagrams Component Connector End Views Fuel Pump Relay - Secondary (LY6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Fuel System - Fuel Injector Service Information Fuel Rail: Technical Service Bulletins Fuel System - Fuel Injector Service Information INFORMATION Bulletin No.: 03-06-04-036B Date: November 10, 2009 Subject: Information on Servicing Duramax(TM) Fuel Injectors to Avoid and Remove Contamination Models: 2001-2010 Chevrolet Silverado 2003-2009 Chevrolet Kodiak C4500/C5500 Series 2006-2010 Chevrolet Express Vans 2001-2010 GMC Sierra 2003-2009 GMC TopKick C4500/C5500 Series 2006-2010 GMC Savana Vans Equipped with 6.6L Duramax(TM) Diesel Engine RPOs LB7, LLY, LMM, LBZ Please Refer to GMVIS Supercede: This bulletin is being revised to add model years and update the Parts Information. Please discard Corporate Bulletin Number 03-06-04-036A (Section 06 - Engine/Propulsion System). Fuel injectors may become contaminated during engine servicing. Debris between the injector line and the injector line nut may fall into the injector fuel inlet upon removal. Refer to the following SI procedures for the appropriate model year, vehicle and engine RPO when performing the following bulletin procedures for servicing the fuel injectors and lines. - Fuel Injection Fuel Rail Assembly Replacement - Bank 1 - Fuel Injection Fuel Rail Assembly Replacement - Bank 2 - Fuel Injector Replacement (Right) - Fuel Injector Replacement (Left) Removal of Fuel Injector Lines 1. Before removing the fuel injector line, use regulated compressed air to blow any debris from between the fuel injector line and the fittings (1, 2). Wipe the fittings (1, 2) clean of debris. 2. Spray Super Lube(R), P/N 12346241 (in Canada, P/N 10953474), or a lithium grease equivalent, between the fuel injector line and fittings (1, 2) to assist in containing any debris during removal. 3. Remove the fuel injector line. 4. Remove the upper valve cover. 5. Remove the lower valve cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Fuel System - Fuel Injector Service Information > Page 5735 Notice After the fuel line is removed and the fuel injector inlet is exposed, DO NOT use compressed air to clean debris. Using compressed air can allow debris to enter the fuel injector inlet and damage the fuel injector. 6. Immediately after removal of the lower valve cover, use a vacuum source to remove any contamination in the fuel injector inlet (1). Fuel Injector Cleaning and Inspection Notice The fuel injector must be cleaned with the proper cleaning equipment. DO NOT use abrasive cleaning methods such as a metallic brush to remove deposits. Cleaning an injector with improper tools may damage the fuel injector. 1. Use a soft bristle non-metallic brush and fuel injector cleaner, P/N 88861802 (in Canada, P/N 88861804), or equivalent, to remove any deposits from the nozzle tip (1) and the copper washer sealing area (2) before reinstallation. 2. Inspect the fuel injector nozzle tip (1) for cracks, dents, or other damage. 3. Inspect the nozzle tip (1) for any signs of discoloration (dark yellow, tan, or blue) due to excessive heat. Note For information on injector bore cleaning, refer to Corporate Bulletin Number 05-06-04-067 Information on New Essential Tool EN-47909 Injector Bore Cleaning Kit for 6.6L Duramax(TM) Diesel Engine. ‹› If any damage is found replace the fuel injector. Clean the fuel injector bore BEFORE installing the new fuel injector. 4. Clean the fuel injector high-pressure lines by performing the following steps: Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Fuel System - Fuel Injector Service Information > Page 5736 5. Inspect the fuel injector high-pressure line for excessive corrosion, scale or rust to the sealing surface as shown. Notice Medium size media glass beads have a cleaning and peening action and do not remove metal. They do not have the quick abrasive action of sharp edged media. Glass beads clean rust, scale and corrosion from metal parts without any damage. 6. Use an Abrasive Blasting Cabinet, P/N 624-AST-SBC1, (to order, call GM Dealer Equipment), or equivalent, with a medium size media glass beads to clean the high pressure lines and fittings. Important Black plastic electrical tape or equivalent will protect the fittings outside coating from being removed with the media. This must be done to ALL sixteen high pressure fittings. 7. Install black plastic electrical tape or equivalent on both of the fittings (1) as shown. 8. When using an Abrasive Blasting Cabinet or equivalent, make sure you only clean the inside of the fittings (2) and as much of the fitting threads as possible as shown. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Fuel System - Fuel Injector Service Information > Page 5737 9. Use pipe cleaners (1) to block the ends of the high pressure lines so the abrasive blasting glass beads will not contaminate the inside of the pipes. Before removing the pipe cleaners, clean them by using regulated compressed air to blow any debris and/or media glass beads from the pipe cleaners. 10. There may be some area of the fitting or line that the glass beads did not clean very well. Disregard any surface that did not clean up as long as the area of the fitting is clean at the bite edge or sealing surface. Refer to the above illustration (1). Replace any suspect high pressure line if the glass beads cannot remove corrosion, scale or rust from the sealing surfaces and/or pitting or any other damage that is found. 11. After cleaning all of the fuel injector high-pressure line fittings with the glass beads, clean by using compressed air to blow any debris and/or media glass beads from inside and outside of all the fittings and lines. Afterwards, wash thoroughly with All Purpose Parts Cleaner, P/N 88862650 (in Canada, P/N 88901247, Brake Parts Cleaner) or equivalent. Repeat this process until all of the debris and/or media glass beads have been removed from the fittings and lines. Fuel Injector Installation Install the fuel injectors and lines using published service procedures in SI. Notice Ensure proper torquing of the fuel injector line fittings (1, 2). An under-torqued fuel injector line will not seal properly and an over-torqued fuel injector line may damage the fuel injector fitting. An improperly sealed or damaged fuel injector line or fuel injector fitting may cause a fuel leak. Inspection For Fuel Leaks Into the Engine After Repair 1. Run the engine at idle for 10 minutes. Inspect for external fuel leaks while the engine is running. 2. Stop the engine and wait 10 minutes, then check the engine oil level. This will be the initial oil level. 3. Run the engine at idle for 5 minutes while commanding the fuel pressure to 160 MPa using a scan tool. 4. Stop the engine and wait 10 minutes, then check the oil level. ‹› If the engine oil level is more than 4.7 mm (3/16 in) above the initial oil level, refer to Fuel Leak Diagnosis (Inside of Engine), and Fuel in Engine Oil procedures in the Engine Controls and Engine Mechanical sections respectively in SI. ‹› If the engine oil level is less than 4.7 mm (3/16 in) above the initial oil level, the repair is complete. Parts Information Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Fuel System - Fuel Injector Service Information > Page 5738 Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Fuel Injection Fuel Rail Assembly Replacement - Bank 1 Fuel Rail: Service and Repair Fuel Injection Fuel Rail Assembly Replacement - Bank 1 Fuel Injection Fuel Rail Assembly Replacement - Bank 1 Removal Procedure 1. Remove the heater outlet pipe. Refer to Heater Outlet Hose Replacement (Non-HP2) (See: Engine, Cooling and Exhaust/Cooling System/Heater Hose/Service and Repair). 2. Remove the fuel filter assembly. Refer to Fuel Filter Assembly Replacement (See: Fuel Filter/Service and Repair/Fuel Filter Assembly Replacement). 3. Remove the turbocharger coolant outlet pipe. Refer to Turbocharger Coolant Hoses/Pipes Replacement (LMM Outlet Pipe) (See: Turbocharger/Turbocharger Coolant Line/Service and Repair). 4. Disconnect the engine wiring harness electrical connector (1) from the fuel injection fuel rail fuel pressure sensor wiring harness extension. 5. Remove the fuel injection fuel rail fuel pressure sensor wiring harness extension clip (3) from the wiring harness bracket. 6. Remove the wiring harness bracket bolts and bracket (2). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Fuel Injection Fuel Rail Assembly Replacement - Bank 1 > Page 5741 7. Prior to removing the fuel injection fuel feed pipes, use compressed air to blow any debris from between the injector line and fittings. Wipe the fittings clean of debris. 8. Spray lithium grease, GM P/N 12346293 or equivalent, between the fuel injector line and fittings to assist in containing any debris during removal. Caution: DO NOT use compressed air to clean debris from the fuel injector inlet after the fuel line is removed. Using compressed air can allow debris to enter the fuel injector inlet and damage the fuel injector. 9. Remove the fuel injection fuel feed pipes. 10. Loosen the right fuel rail fuel feed pipe fitting (4) at the fuel rail. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Fuel Injection Fuel Rail Assembly Replacement - Bank 1 > Page 5742 11. Remove the fuel injection fuel rail bolts. 12. Remove the fuel rail. Installation Procedure 1. Position the fuel injection fuel rail to the intake manifold. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the fuel injection fuel rail bolts. Tighten the bolts to 25 Nm (18 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Fuel Injection Fuel Rail Assembly Replacement - Bank 1 > Page 5743 3. Tighten the right fuel rail fuel feed pipe fitting (4) at the fuel rail. Tighten the fittings to 41 Nm (30 lb ft). Caution: Ensure proper torquing of the fuel injector line. An under-torqued fuel injector line will not seal properly and an over-torqued fuel injector line may damage the fuel injector fitting. An improperly sealed or damaged fuel injector line or fuel injector fitting will cause a fuel leak. 4. Install the fuel injector pipes. Tighten the fittings to 41 Nm (30 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Fuel Injection Fuel Rail Assembly Replacement - Bank 1 > Page 5744 5. Position the wiring harness bracket (2) and install the bolts. Tighten the bolts to 24 Nm (18 lb ft). 6. Connect the engine wiring harness electrical connector (1) to the fuel injection fuel rail fuel pressure sensor wiring harness extension. 7. Install the fuel injection fuel rail fuel pressure sensor wiring harness extension clip (3) to the wiring harness bracket. 8. Install the turbocharger coolant outlet pipe. Refer to Turbocharger Coolant Hoses/Pipes Replacement (LMM Outlet Pipe) (See: Turbocharger/Turbocharger Coolant Line/Service and Repair). 9. Install the fuel filter assembly. Refer to Fuel Filter Assembly Replacement (See: Fuel Filter/Service and Repair/Fuel Filter Assembly Replacement). 10. Install the heater outlet pipe. Refer to Heater Outlet Hose Replacement (Non-HP2) (See: Engine, Cooling and Exhaust/Cooling System/Heater Hose/Service and Repair). 11. Prime the fuel system. Refer to Fuel System Priming (See: Service and Repair/Fuel System Priming). 12. Start the engine. If the engine stalls, repeat the above step. 13. Once the engine starts, inspect for fuel leaks. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Fuel Injection Fuel Rail Assembly Replacement - Bank 1 > Page 5745 Fuel Rail: Service and Repair Fuel Injection Fuel Rail Assembly Replacement - Bank 2 Fuel Injection Fuel Rail Assembly Replacement - Bank 2 Removal Procedure 1. Remove the fuel line bracket nut. 2. Remove the fuel line bracket from the stud. 3. Remove the charge air cooler inlet pipe. Refer to Charge Air Cooler Inlet Pipe Replacement (See: Turbocharger/Intercooler/Intercooler Duct/Service and Repair/Charge Air Cooler Inlet Pipe Replacement). 4. Remove the positive crankcase ventilation (PCV) hose/pipe. Refer to Positive Crankcase Ventilation Hose/Pipe/Tube Replacement (See: Emission Control Systems/Positive Crankcase Ventilation/PCV Valve Hose/Service and Repair). 5. Remove the right fuel rail fuel feed pipe. Refer to Fuel Injection Fuel Feed Front Pipe Replacement - Right Side (See: Fuel Supply Line/Service and Repair/Fuel Injection Fuel Feed/Fuel Injection Fuel Feed Front Pipe Replacement - Right Side). 6. Remove the fuel return pipe. Refer to Fuel Return Pipe Replacement (See: Fuel Return Line/Service and Repair/Fuel Return Pipe Replacement). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Fuel Injection Fuel Rail Assembly Replacement - Bank 1 > Page 5746 7. Remove the fuel pipe bracket bolt (4) and bracket (3). 8. Loosen the left fuel rail fuel feed pipe fittings (1). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Fuel Injection Fuel Rail Assembly Replacement - Bank 1 > Page 5747 9. Remove the left fuel rail fuel feed pipe. 10. Prior to removing the fuel injector pipes, use compressed air to blow any debris from between the injector line and fittings. Wipe the fittings clean of debris. 11. Spray lithium grease, GM P/N 12346293 or equivalent, between the fuel injector line and fittings to assist in containing any debris during removal. Caution: DO NOT use compressed air to clean debris from the fuel injector inlet after the fuel line is removed. Using compressed air can allow debris to enter the fuel injector inlet and damage the fuel injector. 12. Remove the left fuel injection fuel feed pipes. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Fuel Injection Fuel Rail Assembly Replacement - Bank 1 > Page 5748 13. Remove the fuel injection fuel rail bolts. 14. Remove the fuel injection fuel rail and bracket. 15. Reposition the fuel hose clamp at the rail and remove the fuel hose, if required. Installation Procedure 1. Install the fuel hose to the fuel injection fuel rail and position the clamp, if required. 2. Position the fuel injection fuel rail and bracket to the left intake manifold. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the fuel injection fuel rail bolts. Tighten the bolts to 25 Nm (18 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Fuel Injection Fuel Rail Assembly Replacement - Bank 1 > Page 5749 Caution: Ensure proper torquing of the fuel injector line. An under-torqued fuel injector line will not seal properly and an over-torqued fuel injector line may damage the fuel injector fitting. An improperly sealed or damaged fuel injector line or fuel injector fitting will cause a fuel leak. 4. Position the fuel injection fuel feed pipes. 5. Tighten the left fuel rail fuel feed pipe fittings (1). Tighten the fittings to 41 Nm (30 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Fuel Injection Fuel Rail Assembly Replacement - Bank 1 > Page 5750 6. Position the fuel pipe bracket (3) and install the bolt (4). Tighten the bolt to 24 Nm (18 lb ft). 7. Install the fuel return pipe. Refer to Fuel Return Pipe Replacement (See: Fuel Return Line/Service and Repair/Fuel Return Pipe Replacement). 8. Install the right fuel rail fuel feed pipe. Refer to Fuel Injection Fuel Feed Front Pipe Replacement - Right Side (See: Fuel Supply Line/Service and Repair/Fuel Injection Fuel Feed/Fuel Injection Fuel Feed Front Pipe Replacement - Right Side). 9. Install the PCV hose/pipe. Refer to Positive Crankcase Ventilation Hose/Pipe/Tube Replacement (See: Emission Control Systems/Positive Crankcase Ventilation/PCV Valve Hose/Service and Repair). 10. Install the charge air cooler inlet pipe. Refer to Charge Air Cooler Inlet Pipe Replacement (See: Turbocharger/Intercooler/Intercooler Duct/Service and Repair/Charge Air Cooler Inlet Pipe Replacement). 11. Install the fuel line bracket to the stud. 12. Install the fuel line bracket nut. Tighten the nut to 16 Nm (12 lb ft). 13. Prime the fuel system. Refer to Fuel System Priming (See: Service and Repair/Fuel System Priming). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Fuel Injection Fuel Rail Assembly Replacement - Bank 1 > Page 5751 14. Start the engine. If the engine stalls, repeat the above step. 15. Once the engine starts, inspect for fuel leaks. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Return Pipe Replacement Fuel Return Line: Service and Repair Fuel Return Pipe Replacement Fuel Return Pipe Replacement Removal Procedure 1. Remove the water outlet. Refer to Water Outlet Tube Replacement (LU3) (See: Engine, Cooling and Exhaust/Cooling System/Coolant Outlet/Service and Repair)Water Outlet Tube Replacement (LMM) (See: Engine, Cooling and Exhaust/Cooling System/Coolant Outlet/Service and Repair). 2. Remove the intake manifold tube. Refer to Intake Manifold Tube Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair/Intake Manifold Tube Replacement). 3. Remove the glow plug control module and bracket. Refer to Glow Plug Control Module Replacement (See: Glow Plug System/Glow Plug Control Module/Service and Repair). 4. Remove the fuel temperature sensor. Refer to Fuel Temperature Sensor Replacement (See: Fuel Temperature Sensor/Service and Repair). 5. Reposition the fuel hose clamp (1) at the fuel return pipe. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Return Pipe Replacement > Page 5756 6. Remove the fuel hose (1) from the return pipe. Note: Engine wiring harness shown removed for clarity. 7. Reposition the fuel return hose clamp (2) at the fuel return pipe. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Return Pipe Replacement > Page 5757 8. Remove the fuel return pipe clip bolt (2) and clip. 9. Remove the fuel return pipe clamp bolt (1) and bracket. 10. Reposition the fuel return hose clamp (1) at the return pipe. 11. Remove the fuel return hose from the return pipe. 12. Remove the fuel return pipe clamp bolt (2) and clamp. 13. Disconnect the fuel injection fuel feed pipe (3) from the fuel return pipe. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Return Pipe Replacement > Page 5758 Note: Note the routing of the fuel return pipe prior to removal. 14. Remove the fuel return pipe from the fuel return hose and the vehicle. Installation Procedure Note: Ensure to route the fuel return pipe under the wiring harness and noted during removal. 1. Position and install the fuel return pipe to the vehicle and the fuel return hose. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Return Pipe Replacement > Page 5759 2. Connect the fuel injection fuel feed pipe (3) to the fuel return pipe. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Position and install the fuel return pipe clamp and bolt (2). Tighten the bolt to 24 Nm (18 lb ft). 4. Install the fuel return hose to the return pipe. 5. Position the fuel return hose clamp (1) at the return pipe. 6. Install the fuel return pipe bracket, clamp, and bolt (1). Tighten the bolt to 24 Nm (18 lb ft). 7. Install the fuel return pipe clip and bolt (2). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Return Pipe Replacement > Page 5760 Tighten the bolt to 24 Nm (18 lb ft). 8. Position the fuel return hose clamp (2) at the fuel return pipe. 9. Install the fuel hose (1) to the return pipe. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Return Pipe Replacement > Page 5761 10. Position the fuel hose clamp (1) at the fuel return pipe. 11. Install the fuel temperature sensor. Refer to Fuel Temperature Sensor Replacement (See: Fuel Temperature Sensor/Service and Repair). 12. Install the glow plug control module and bracket. Refer to Glow Plug Control Module Replacement (See: Glow Plug System/Glow Plug Control Module/Service and Repair). 13. Install the intake manifold tube. Refer to Intake Manifold Tube Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair/Intake Manifold Tube Replacement). 14. Install the water outlet. Refer to Water Outlet Tube Replacement (LU3) (See: Engine, Cooling and Exhaust/Cooling System/Coolant Outlet/Service and Repair)Water Outlet Tube Replacement (LMM) (See: Engine, Cooling and Exhaust/Cooling System/Coolant Outlet/Service and Repair). 15. Prime the fuel system. Refer to Fuel System Priming (See: Service and Repair/Fuel System Priming). 16. Start the engine. If the engine stalls, repeat the above step. 17. Once the engine starts, inspect for fuel leaks. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Return Pipe Replacement > Page 5762 Fuel Return Line: Service and Repair Fuel Return Hose Replacement - Fuel Return Pipe to Fuel Injection Pump Fuel Return Hose Replacement - Fuel Return Pipe to Fuel Injection Pump Removal Procedure 1. Remove the water outlet. Refer to Water Outlet Tube Replacement (LU3) (See: Engine, Cooling and Exhaust/Cooling System/Coolant Outlet/Service and Repair)Water Outlet Tube Replacement (LMM) (See: Engine, Cooling and Exhaust/Cooling System/Coolant Outlet/Service and Repair). 2. Remove the intake manifold tube. Refer to Intake Manifold Tube Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair/Intake Manifold Tube Replacement). 3. Reposition the fuel hose clamp (1) at the fuel return pipe. 4. Reposition the fuel hose clamp (2) at the fuel injection pump. 5. Remove the fuel hose (1) from the return pipe and injection pump. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Return Pipe Replacement > Page 5763 Installation Procedure 1. Install the fuel hose (1) to the return pipe and injection pump. 2. Position the fuel hose clamp (2) at the fuel injection pump. 3. Position the fuel hose clamp (1) at the fuel return pipe. 4. Install the intake manifold tube. Refer to Intake Manifold Tube Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair/Intake Manifold Tube Replacement). 5. Install the water outlet. Refer to Water Outlet Tube Replacement (LU3) (See: Engine, Cooling and Exhaust/Cooling System/Coolant Outlet/Service and Repair)Water Outlet Tube Replacement (LMM) (See: Engine, Cooling and Exhaust/Cooling System/Coolant Outlet/Service and Repair). 6. Prime the fuel system. Refer to Fuel System Priming (See: Service and Repair/Fuel System Priming). 7. Start the engine. If the engine stalls, repeat the above step. 8. Once the engine starts, inspect for fuel leaks. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Return Pipe Replacement > Page 5764 Fuel Return Line: Service and Repair Fuel Injection Fuel Return Pipe Replacement - Left Side Fuel Injection Fuel Return Pipe Replacement - Left Side Removal Procedure 1. Remove the glow plug control module. Refer to Glow Plug Control Module Replacement (See: Glow Plug System/Glow Plug Control Module/Service and Repair). 2. Remove the fuel injection fuel return pipe clips (1). 3. Disconnect the fuel injection fuel return pipe from the fuel injectors. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Return Pipe Replacement > Page 5765 4. Cut the tie strap (1) securing the fuel injection fuel return pipe to the engine wiring harness. 5. Disconnect the fuel injection fuel return pipe from the fuel return pipe. Important: Note the routing of the fuel injection fuel return pipe under the engine wiring harness. 6. Remove the fuel injection fuel return pipe from the engine. Installation Procedure 1. Position the fuel injection fuel return pipe to the engine. Ensure to route the fuel injection fuel return pipe under the engine wiring harness. 2. Connect the fuel injection fuel return pipe to the fuel return pipe. 3. Install a NEW tie strap (1) securing the fuel injection fuel return pipe to the engine wiring harness in the location shown. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Return Pipe Replacement > Page 5766 4. Connect the fuel injection fuel return pipe to the fuel injectors. 5. Install the fuel injection fuel return pipe clips (1). 6. Install the glow plug control module. Refer to Glow Plug Control Module Replacement (See: Glow Plug System/Glow Plug Control Module/Service and Repair). 7. Prime the fuel system. Refer to Fuel System Priming (See: Service and Repair/Fuel System Priming). 8. Start the engine. If the engine stalls, repeat the above step. 9. Once the engine starts, inspect for fuel leaks. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Return Pipe Replacement > Page 5767 Fuel Return Line: Service and Repair Fuel Injection Fuel Return Pipe Replacement - Right Side Fuel Injection Fuel Return Pipe Replacement - Right Side Removal Procedure 1. Remove the fuel filter and bracket. Refer to Fuel Filter Assembly Replacement (See: Fuel Filter/Service and Repair/Fuel Filter Assembly Replacement). 2. Remove the intake air heater. Refer to Intake Air Heater Replacement (See: Intake Air Heater/Service and Repair). 3. Remove the fuel injection fuel return pipe clips (1). 4. Disconnect the fuel injection fuel return pipe from the fuel injectors. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Return Pipe Replacement > Page 5768 5. Disconnect the fuel injection fuel return pipe from the fuel injection fuel feed manifold. Important: Note the routing of the fuel injection fuel return pipe under/behind the engine wiring harness. 6. Remove the fuel injection fuel return pipe from the engine. Installation Procedure 1. Position the fuel injection fuel return pipe to the engine. Ensure to route the fuel injection fuel return pipe under/behind the engine wiring harness. 2. Connect the fuel injection fuel return pipe to the fuel injection fuel feed manifold. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Fuel Return Pipe Replacement > Page 5769 3. Connect the fuel injection fuel return pipe to the fuel injectors. 4. Install the fuel injection fuel return pipe clips (1). 5. Install the intake air heater. Refer to Intake Air Heater Replacement (See: Intake Air Heater/Service and Repair). 6. Install the fuel filter and bracket. Refer to Fuel Filter Assembly Replacement (See: Fuel Filter/Service and Repair/Fuel Filter Assembly Replacement) 7. Prime the fuel system. Refer to Fuel System Priming (See: Service and Repair/Fuel System Priming). 8. Start the engine. If the engine stalls, repeat the above step. 9. Once the engine starts, inspect for fuel leaks. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Line Replacement Fuel Supply Line: Service and Repair Fuel Line Replacement Fuel Line Replacement - Chassis (Cab/Chassis W/Balance Pump) Fuel Line Replacement - Chassis (Cab/Chassis w/Balance Pump) Removal Procedure 1. Remove the front and auxiliary fuel tanks. Refer to Fuel Tank Replacement (Pickup) (See: Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (Cab/Chassis - Front) (See: Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (Cab/Chassis - Rear) (See: Fuel Tank/Service and Repair/Removal and Replacement). 2. Disconnect the pressure balance pump electrical connector. 3. Remove the fuel bundle nuts. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Line Replacement > Page 5774 4. Remove the fuel bundle. Installation Procedure 1. Install the fuel bundle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the fuel bundle nuts. Tighten the nuts to 16 Nm (12 lb ft). 3. Connect the pressure balance pump electrical connector. 4. Install the front and auxiliary fuel tanks. Refer to Fuel Tank Replacement (Pickup) (See: Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (Cab/Chassis - Front) (See: Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (Cab/Chassis - Rear) (See: Fuel Tank/Service and Repair/Removal and Replacement). Fuel Line Replacement - Chassis (Cab/Chassis) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Line Replacement > Page 5775 Fuel Line Replacement - Chassis (Cab/Chassis) Removal Procedure 1. Disconnect the fuel feed and return lines. Refer to Metal Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Metal Collar Quick Connect Fitting Service). 2. Remove the fuel line bracket nut. 3. Remove the fuel line bracket from the stud. 4. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 5. Remove the fuel bundle clips (2) from the transmission brackets (1). 6. Disconnect the chassis harness from the retaining clips. 7. Remove the fuel system cooler, if necessary. Refer to Fuel Cooler Replacement (Pickup) (See: Fuel Cooler/Service and Repair/Fuel Cooler Replacement (Pickup))Fuel Cooler Replacement (Cab/Chassis) (See: Fuel Cooler/Service and Repair/Fuel Cooler Replacement (Cab/Chassis)). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Line Replacement > Page 5776 8. Disconnect the fuel feed and return lines from the fuel tank lines. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). 9. Remove the fuel bundle nuts from the chassis. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Line Replacement > Page 5777 10. Loosen the electronic brake control module (EBCM) bracket bolts (4). 11. Allow the EBCM to remain loose in order to allow fuel pipe clearance. 12. Remove the fuel bundle using the following procedure: 1. Guide the fuel bundle pipes towards the rear of vehicle to clear the engine. 2. Lower the fuel bundle while moving it foreword and out. Installation Procedure 1. Install the fuel pipe bundle using the following procedure: 1. Install the fuel bundle to the chassis by guiding the pipes towards the rear of vehicle. 2. Lift the fuel pipes, while guiding the forward portion of the pipes up towards the engine connections. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the fuel bundle nuts to the chassis. Tighten the nuts to 16 Nm (12 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Line Replacement > Page 5778 3. Connect the fuel feed and return lines to the fuel tank lines. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). 4. Install the fuel system cooler, if necessary. Refer to Fuel Cooler Replacement (Pickup) (See: Fuel Cooler/Service and Repair/Fuel Cooler Replacement (Pickup))Fuel Cooler Replacement (Cab/Chassis) (See: Fuel Cooler/Service and Repair/Fuel Cooler Replacement (Cab/Chassis)). 5. Connect the fuel bundle clips (2) to the transmission brackets (1). 6. Tighten the EBCM bracket bolts (4). Tighten the bolts to 25 Nm (18 lb ft). 7. Lower the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Line Replacement > Page 5779 8. Install the fuel line bracket to the stud. 9. Install the fuel line bracket nut. Tighten the nut to 16 Nm (12 lb ft). 10. Connect the fuel feed and return lines. Refer to Metal Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Metal Collar Quick Connect Fitting Service). 11. Prime the fuel system. Refer to Fuel System Priming (See: Service and Repair/Fuel System Priming). 12. Start the engine. If the engine stalls, repeat the above step. 13. Once the engine starts, inspect for fuel leaks. Fuel Line Replacement - Chassis (Pickup) Fuel Line Replacement - Chassis (Pickup) Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Line Replacement > Page 5780 1. Disconnect the fuel feed and return lines. Refer to Metal Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Metal Collar Quick Connect Fitting Service). 2. Remove the fuel line bracket nut. 3. Remove the fuel line bracket from the stud. 4. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 5. Remove the fuel bundle clips (2) from the transmission brackets (1). 6. Disconnect the chassis harness from the retaining clips. 7. Remove the fuel system cooler, if necessary. Refer to Fuel Cooler Replacement (Pickup) (See: Fuel Cooler/Service and Repair/Fuel Cooler Replacement (Pickup))Fuel Cooler Replacement (Cab/Chassis) (See: Fuel Cooler/Service and Repair/Fuel Cooler Replacement (Cab/Chassis)). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Line Replacement > Page 5781 8. Disconnect the fuel feed and return lines from the fuel tank lines. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). 9. Remove the fuel bundle nuts from the chassis. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Line Replacement > Page 5782 10. Loosen the electronic brake control module (EBCM) bracket bolts (4). 11. Allow the EBCM to remain loose in order to allow fuel pipe clearance. 12. Remove the fuel bundle using the following procedure: 1. Guide the fuel bundle pipes towards the rear of the vehicle to clear the engine. 2. Lower the fuel bundle while moving it forward and out. Installation Procedure 1. Install the fuel pipe bundle using the following procedure: 1. Install the fuel bundle to the chassis by guiding the pipes towards the rear of vehicle. 2. Lift the fuel pipes, while guiding the forward portion of the pipes up towards the engine connections. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the fuel bundle nuts to the chassis. Tighten the nuts to 16 Nm (12 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Line Replacement > Page 5783 3. Connect the fuel feed and return lines to the fuel tank lines. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). 4. Install the fuel system cooler, if necessary. Refer to Fuel Cooler Replacement (Pickup) (See: Fuel Cooler/Service and Repair/Fuel Cooler Replacement (Pickup))Fuel Cooler Replacement (Cab/Chassis) (See: Fuel Cooler/Service and Repair/Fuel Cooler Replacement (Cab/Chassis)). 5. Connect the fuel bundle clips (2) to the transmission brackets (1). 6. Tighten the EBCM bracket bolts (4). Tighten the bolts to 25 Nm (18 lb ft). 7. Lower the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Line Replacement > Page 5784 8. Install the fuel line bracket to the stud. 9. Install the fuel line bracket nut. Tighten the nut to 16 Nm (12 lb ft). 10. Connect the fuel feed and return lines. Refer to Metal Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Metal Collar Quick Connect Fitting Service). 11. Prime the fuel system. Refer to Fuel System Priming (See: Service and Repair/Fuel System Priming). 12. Start the engine. If the engine stalls, repeat the above step. 13. Once the engine starts, inspect for fuel leaks. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Line Replacement > Page 5785 Fuel Supply Line: Service and Repair Fuel Injection Fuel Feed Fuel Feed Pipe Replacement Fuel Feed Pipe Replacement Removal Procedure 1. Remove the water outlet tube. Refer to Water Outlet Tube Replacement (LU3) (See: Engine, Cooling and Exhaust/Cooling System/Coolant Outlet/Service and Repair)Water Outlet Tube Replacement (LMM) (See: Engine, Cooling and Exhaust/Cooling System/Coolant Outlet/Service and Repair). 2. Remove the intake manifold tube. Refer to Intake Manifold Tube Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair/Intake Manifold Tube Replacement). 3. Remove the generator. Refer to Generator Replacement (V6) (See: Starting and Charging/Charging System/Alternator/Service and Repair )Generator Replacement (V8) (See: Starting and Charging/Charging System/Alternator/Service and Repair)Generator Replacement (6.6L) (See: Starting and Charging/Charging System/Alternator/Service and Repair). 4. Disconnect the chassis fuel feed pipe quick connect fitting from the fuel feed pipe. Refer to Metal Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Metal Collar Quick Connect Fitting Service). 5. Disconnect the engine wiring harness electrical connectors (1) from the engine coolant temperature (ECT) sensors, and reposition the wiring out of the way. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Line Replacement > Page 5786 6. Reposition the fuel filter hose clamp (2) at the fuel feed pipe. 7. Remove the fuel filter hose (2) from the fuel feed pipe. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Line Replacement > Page 5787 8. Reposition the fuel hose clamp (2) at the fuel injection pump. 9. Remove the fuel hose (1) from the injection pump and reposition the hose out of the way. 10. Remove the fuel feed pipe clip nuts (1 and 2) and bolt (3). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Line Replacement > Page 5788 11. Remove the fuel pipe bracket bolt (1) and fuel feed pipe clip (2). Note: Note the routing of the fuel feed pipe under the engine wiring harness. 12. Remove the fuel feed pipe. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Line Replacement > Page 5789 Note: Ensure to route the fuel feed pipe under the engine wiring harness as noted during removal. 1. Position and install the fuel feed pipe to the engine. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Position fuel feed pipe clip (2) behind the fuel pipe bracket and install the bolt (1). Tighten the bolt to 24 Nm (18 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Line Replacement > Page 5790 3. Install the fuel feed pipe clip nuts (1 and 2) and bolt (3). Tighten the bolt/nuts to 24 Nm (18 lb ft). 4. Position the fuel hose and install the hose (1) to the injection pump. 5. Position the fuel hose clamp (2) at the fuel injection pump. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Line Replacement > Page 5791 6. Install the fuel filter hose (2) to the fuel feed pipe. 7. Position the fuel filter hose clamp (2) at the fuel feed pipe. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Line Replacement > Page 5792 8. Position the engine wiring harness and connect the engine wiring harness electrical connectors (1) to the ECT sensors. 9. Connect the chassis fuel feed pipe quick connect fitting to the fuel feed pipe. Refer to Metal Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Metal Collar Quick Connect Fitting Service). 10. Install the generator. Refer to Generator Replacement (V6) (See: Starting and Charging/Charging System/Alternator/Service and Repair )Generator Replacement (V8) (See: Starting and Charging/Charging System/Alternator/Service and Repair)Generator Replacement (6.6L) (See: Starting and Charging/Charging System/Alternator/Service and Repair). 11. Install the intake manifold tube. Refer to Intake Manifold Tube Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair/Intake Manifold Tube Replacement). 12. Install the water outlet tube. Refer to Water Outlet Tube Replacement (LU3) (See: Engine, Cooling and Exhaust/Cooling System/Coolant Outlet/Service and Repair)Water Outlet Tube Replacement (LMM) (See: Engine, Cooling and Exhaust/Cooling System/Coolant Outlet/Service and Repair). 13. Prime the fuel system. Refer to Fuel System Priming (See: Service and Repair/Fuel System Priming). 14. Start the engine. If the engine stalls, repeat the above step. 15. Once the engine starts, inspect for fuel leaks. Fuel Injection Fuel Feed Front Pipe Replacement - Left Side Fuel Injection Fuel Feed Front Pipe Replacement - Left Side Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Line Replacement > Page 5793 1. Remove the fuel return pipe to fuel injection pump fuel hose. Refer to Fuel Return Hose Replacement - Fuel Return Pipe to Fuel Injection Pump ( See: Fuel Return Line/Service and Repair/Fuel Return Hose Replacement - Fuel Return Pipe to Fuel Injection Pump). 2. Loosen the left fuel rail fuel feed pipe fittings (1). Note: Note the routing of the left fuel rail fuel feed pipe under the fuel feed and return pipes. 3. Remove the left fuel rail fuel feed pipe. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Line Replacement > Page 5794 Note: Ensure that the routing of the left fuel rail fuel feed pipe is under the fuel feed and return pipes. 1. Position and install the left fuel rail fuel feed pipe. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Tighten the left fuel rail fuel feed pipe fittings (1). Tighten the fittings to 41 Nm (30 lb ft). 3. Install the fuel return pipe to fuel injection pump fuel hose. Refer to Fuel Return Hose Replacement - Fuel Return Pipe to Fuel Injection Pump ( See: Fuel Return Line/Service and Repair/Fuel Return Hose Replacement - Fuel Return Pipe to Fuel Injection Pump). 4. Prime the fuel system. Refer to Fuel System Priming (See: Service and Repair/Fuel System Priming). 5. Start the engine. If the engine stalls, repeat the above step. 6. Once the engine starts, inspect for fuel leaks. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Line Replacement > Page 5795 Fuel Injection Fuel Feed Front Pipe Replacement - Right Side Fuel Injection Fuel Feed Front Pipe Replacement - Right Side Removal Procedure 1. Remove the fuel feed pipe. Refer to Fuel Feed Pipe Replacement (). 2. Remove the exhaust gas recirculation (EGR) valve cooler. Refer to Exhaust Gas Recirculation Valve Cooler Replacement (See: Emission Control Systems/Exhaust Gas Recirculation/EGR Cooler/Service and Repair/Exhaust Gas Recirculation Valve Cooler Replacement). Note: Engine wiring harness shown removed for clarity. 3. Remove the fuel rail fuel feed pipe clamp bolts (2 and 3) and upper clamps. 4. Loosen the fuel rail fuel feed pipe fitting (1) at the left fuel rail. 5. Loosen the fuel rail fuel feed pipe fitting (4) at the right fuel rail. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Line Replacement > Page 5796 6. Remove the right fuel rail fuel feed pipe. Installation Procedure 1. Position and install the right fuel rail fuel feed pipe. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Line Replacement > Page 5797 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the fuel rail fuel feed pipe upper clamps and bolts (2 and 3). Tighten the bolts to 24 Nm (18 lb ft). 3. Tighten the fuel rail fuel feed pipe fitting (4) at the right fuel rail. Tighten the fitting to 41 Nm (30 lb ft). 4. Tighten the fuel rail fuel feed pipe fitting (1) at the left fuel rail. Tighten the fitting to 41 Nm (30 lb ft). 5. Install the EGR valve cooler. Refer to Exhaust Gas Recirculation Valve Cooler Replacement (See: Emission Control Systems/Exhaust Gas Recirculation/EGR Cooler/Service and Repair/Exhaust Gas Recirculation Valve Cooler Replacement). 6. Install the fuel feed pipe. Refer to Fuel Feed Pipe Replacement (). 7. Prime the fuel system. Refer to Fuel System Priming (See: Service and Repair/Fuel System Priming). 8. Start the engine. If the engine stalls, repeat the above step. 9. Once the engine starts, inspect for fuel leaks. Fuel Injection Fuel Feed Manifold Replacement Fuel Injection Fuel Feed Manifold Replacement Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Line Replacement > Page 5798 1. Remove the generator. Refer to Generator Replacement (V6) (See: Starting and Charging/Charging System/Alternator/Service and Repair )Generator Replacement (V8) (See: Starting and Charging/Charging System/Alternator/Service and Repair)Generator Replacement (6.6L) (See: Starting and Charging/Charging System/Alternator/Service and Repair). 2. Remove the fuel filter/heater element housing to fuel feed block fuel hose. Refer to Fuel Hose Replacement - Fuel Filter/Heater Element Housing to Fuel Feed Block (See: Fuel Hose Replacement - Fuel Filter/Heater Element Housing to Fuel Feed Block). 3. Remove the intake manifold tube. Refer to Intake Manifold Tube Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair/Intake Manifold Tube Replacement). 4. Remove the water outlet tube. Refer to Water Outlet Tube Replacement (LU3) (See: Engine, Cooling and Exhaust/Cooling System/Coolant Outlet/Service and Repair)Water Outlet Tube Replacement (LMM) (See: Engine, Cooling and Exhaust/Cooling System/Coolant Outlet/Service and Repair). 5. Reposition the fuel hose clamp (2) at the fuel injection fuel feed manifold. 6. Remove the fuel hose (4) from the fuel injection fuel feed manifold. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Line Replacement > Page 5799 7. Reposition the fuel return hose clamp (1) at the fuel injection fuel feed manifold. 8. Remove the fuel pipe clip bolt (1) and clip. 9. Disconnect the fuel injector fuel feed pipe (2) from the fuel injection fuel feed manifold. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Line Replacement > Page 5800 Note: Note the routing of the fuel injection fuel feed manifold pipes under the exhaust gas recirculation (EGR) bracket. 10. Remove the fuel injection fuel feed manifold from the fuel return hose and the vehicle. Installation Procedure Note: Ensure to route the fuel injection fuel feed manifold pipes under the EGR bracket. 1. Install the fuel injection fuel feed manifold to the vehicle and the fuel return hose. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Line Replacement > Page 5801 2. Connect the fuel injector fuel feed pipe (2) to the fuel injection fuel feed manifold. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the fuel pipe clip and bolt (1). Tighten the bolt to 24 Nm (18 lb ft). 4. Position the fuel return hose clamp (1) at the fuel injection fuel feed manifold. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Line Replacement > Page 5802 5. Install the fuel hose (4) to the fuel injection fuel feed manifold. 6. Position the fuel hose clamp (2) at the fuel injection fuel feed manifold. 7. Install the water outlet tube. Refer to Water Outlet Tube Replacement (LU3) (See: Engine, Cooling and Exhaust/Cooling System/Coolant Outlet/Service and Repair)Water Outlet Tube Replacement (LMM) (See: Engine, Cooling and Exhaust/Cooling System/Coolant Outlet/Service and Repair). 8. Install the intake manifold tube. Refer to Intake Manifold Tube Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair/Intake Manifold Tube Replacement). 9. Install the fuel filter/heater element housing to fuel feed block fuel hose. Refer to Fuel Hose Replacement - Fuel Filter/Heater Element Housing to Fuel Feed Block (See: Fuel Hose Replacement - Fuel Filter/Heater Element Housing to Fuel Feed Block). 10. Install the generator. Refer to Generator Replacement (V6) (See: Starting and Charging/Charging System/Alternator/Service and Repair )Generator Replacement (V8) (See: Starting and Charging/Charging System/Alternator/Service and Repair)Generator Replacement (6.6L) (See: Starting and Charging/Charging System/Alternator/Service and Repair). 11. Prime the fuel system. Refer to Fuel System Priming (See: Service and Repair/Fuel System Priming). 12. Start the engine. If the engine stalls, repeat the above step. 13. Once the engine starts, inspect for fuel leaks. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Line Replacement > Page 5803 Fuel Injection Fuel Feed Pipe Replacement - Left Side Fuel Injection Fuel Feed Pipe Replacement - Left Side Removal Procedure 1. Remove the charge air cooler inlet pipe. Refer to Charge Air Cooler Inlet Pipe Replacement (See: Turbocharger/Intercooler/Intercooler Duct/Service and Repair/Charge Air Cooler Inlet Pipe Replacement). 2. Remove the water outlet. Refer to Water Outlet Tube Replacement (LU3) (See: Engine, Cooling and Exhaust/Cooling System/Coolant Outlet/Service and Repair)Water Outlet Tube Replacement (LMM) (See: Engine, Cooling and Exhaust/Cooling System/Coolant Outlet/Service and Repair). 3. Remove the glow plug control module and bracket. Refer to Glow Plug Control Module Replacement (See: Glow Plug System/Glow Plug Control Module/Service and Repair). 4. Disconnect the chassis fuel feed and return line quick connect fittings from the engine fuel feed and return pipes. Refer to Metal Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Metal Collar Quick Connect Fitting Service). 5. Remove the fuel line bracket nut. 6. Remove the fuel line bracket from the stud. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Line Replacement > Page 5804 7. Remove the engine wiring harness clip from the fuel line bracket. 8. Remove the fuel line bracket bolts (1 and 4), clamp (2), and bracket (3). 9. Prior to removing the fuel injector pipes, use compressed air to blow any debris from between the injector line and fittings. Wipe the fittings clean of debris. 10. Spray lithium grease, GM P/N 12346293 or equivalent, between the fuel injector line and fittings to assist in containing any debris during removal. Caution: DO NOT use compressed air to clean debris from the fuel injector inlet after the fuel line is removed. Using compressed air can allow debris to enter the fuel injector inlet and damage the fuel injector. 11. Remove the left fuel injector pipes. Installation Procedure Caution: Ensure proper torquing of the fuel injector line. An under-torqued fuel injector line will not seal properly and an over-torqued fuel injector line may damage the fuel injector fitting. An improperly sealed or damaged fuel injector line or fuel injector fitting will cause a fuel leak. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Line Replacement > Page 5805 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the fuel injector pipes. Tighten the fittings to 41 Nm (30 lb ft). 2. Position the fuel line bracket (3) to the valve rocker arm cover, and install the clamp (2) and bolts (1 and 4). Tighten the bolts to 24 Nm (18 lb ft). 3. Install the engine wiring harness clip to the fuel line bracket. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Line Replacement > Page 5806 4. Install the fuel line bracket to the stud. 5. Install the fuel line bracket nut. Tighten the nut to 21 Nm (15 lb ft). 6. Connect the chassis fuel feed and return line quick connect fittings to the engine fuel feed and return pipes. Refer to Metal Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Metal Collar Quick Connect Fitting Service). 7. Install the glow plug control module and bracket. Refer to Glow Plug Control Module Replacement (See: Glow Plug System/Glow Plug Control Module/Service and Repair). 8. Install the water outlet. Refer to Water Outlet Tube Replacement (LU3) (See: Engine, Cooling and Exhaust/Cooling System/Coolant Outlet/Service and Repair)Water Outlet Tube Replacement (LMM) (See: Engine, Cooling and Exhaust/Cooling System/Coolant Outlet/Service and Repair). 9. Install the charge air cooler inlet pipe. Refer to Charge Air Cooler Inlet Pipe Replacement (See: Turbocharger/Intercooler/Intercooler Duct/Service and Repair/Charge Air Cooler Inlet Pipe Replacement). 10. Prime the fuel system. Refer to Fuel System Priming (See: Service and Repair/Fuel System Priming). 11. Start the engine. If the engine stalls, repeat the above step. 12. Once the engine starts, inspect for fuel leaks. Fuel Injection Fuel Feed Pipe Replacement - Right Side Fuel Injection Fuel Feed Pipe Replacement - Right Side Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Line Replacement > Page 5807 1. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (See: Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair/Air Cleaner Outlet Duct Replacement). 2. Remove the charge air cooler outlet pipe. Refer to Charge Air Cooler Outlet Pipe Replacement (See: Turbocharger/Intercooler/Intercooler Duct/Service and Repair/Charge Air Cooler Outlet Pipe Replacement). 3. Remove the fuel filter assembly. Refer to Fuel Filter Assembly Replacement (See: Fuel Filter/Service and Repair/Fuel Filter Assembly Replacement). 4. Remove the fuel filter/heater element housing to fuel feed block fuel hoses. Refer to Fuel Hose Replacement - Fuel Filter/Heater Element Housing to Fuel Feed Block (See: Fuel Hose Replacement - Fuel Filter/Heater Element Housing to Fuel Feed Block). 5. Disconnect the engine wiring harness electrical connector (1) from the exhaust gas recirculation (EGR) valve. 6. Disconnect the engine wiring harness electrical connector (1) from the fuel injection fuel rail pressure sensor wiring harness extension electrical connector. 7. Remove the fuel injection fuel rail pressure sensor wiring harness extension retainer (3) from the bracket. 8. Remove the engine wiring harness bracket bolts and remove the bracket (2). 9. Reposition the engine wiring harness slightly in order to access the front fuel injection fuel feed pipe. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Line Replacement > Page 5808 10. Prior to removing the fuel injector pipes, use compressed air to blow any debris from between the injector line and fittings. Wipe the fittings clean of debris. 11. Spray lithium grease, GM P/N 12346293 or equivalent, between the fuel injector line and fittings to assist in containing any debris during removal. Caution: DO NOT use compressed air to clean debris from the fuel injector inlet after the fuel line is removed. Using compressed air can allow debris to enter the fuel injector inlet and damage the fuel injector. 12. Remove the fuel injector pipes. Installation Procedure Caution: Ensure proper torquing of the fuel injector line. An under-torqued fuel injector line will not seal properly and an over-torqued fuel injector line may damage the fuel injector fitting. An improperly sealed or damaged fuel injector line or fuel injector fitting will cause a fuel leak. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Line Replacement > Page 5809 1. Install the fuel injector pipes. Tighten the fittings to 41 Nm (30 lb ft). 2. Reposition the engine wiring harness as necessary. 3. Position the engine wiring harness bracket (2) to the valve rocker arm cover and install the bracket bolts. Tighten the bolts to 24 Nm (18 lb ft). 4. Connect the engine wiring harness electrical connector (1) to the fuel injection fuel rail pressure sensor wiring harness extension electrical connector. 5. Install the fuel injection fuel rail pressure sensor wiring harness extension retainer (3) to the bracket. 6. Connect the engine wiring harness electrical connector (1) to the EGR valve. 7. Install the fuel filter/heater element housing to fuel feed block fuel hoses. Refer to Fuel Hose Replacement - Fuel Filter/Heater Element Housing to Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Line Replacement > Page 5810 Fuel Feed Block (See: Fuel Hose Replacement - Fuel Filter/Heater Element Housing to Fuel Feed Block). 8. Install the fuel filter assembly. Refer to Fuel Filter Assembly Replacement (See: Fuel Filter/Service and Repair/Fuel Filter Assembly Replacement). 9. Install the charge air cooler outlet pipe. Refer to Charge Air Cooler Outlet Pipe Replacement (See: Turbocharger/Intercooler/Intercooler Duct/Service and Repair/Charge Air Cooler Outlet Pipe Replacement). 10. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (See: Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair/Air Cleaner Outlet Duct Replacement). 11. Prime the fuel system. Refer to Fuel System Priming (See: Service and Repair/Fuel System Priming). 12. Start the engine. If the engine stalls, repeat the above step. 13. Once the engine starts, inspect for fuel leaks. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Line Replacement > Page 5811 Fuel Supply Line: Service and Repair Fuel Feed and Return Pipe Purging Fuel Feed and Return Pipe Purging 1. Pump the primer (1) located on top of the fuel filter 30 times or until stiff. 2. Attempt to start and run the engine. If the engine does not start, repeat step 1. 3. Allow to run for 5 minutes at idle. 4. Check for fuel leaks. 5. Clear all engine diagnostic trouble codes (DTCs). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Line Replacement > Page 5812 Fuel Supply Line: Service and Repair Fuel Hose Replacement - Fuel Filter/Heater Element Housing to Fuel Feed Block Fuel Hose Replacement - Fuel Filter/Heater Element Housing to Fuel Feed Block Removal Procedure 1. Reposition the fuel filter hose clamp(s) (1 or 2) at the fuel filter adapter. 2. Reposition the fuel filter hose clamp(s) (1 or 2) at the fuel injection fuel feed manifold and/or the fuel feed pipe. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Line Replacement > Page 5813 3. Remove the fuel hose retainer (3) from the appropriate fuel filter hose. 4. Remove the fuel filter hose (1) from the fuel filter adapter and the fuel injection fuel feed manifold, if required. 5. Remove the fuel filter hose (2) from the fuel filter adapter and the fuel feed pipe, if required. Installation Procedure 1. Install the fuel filter hose (1) to the fuel filter adapter and the fuel injection fuel feed manifold, if required. 2. Install the fuel filter hose (2) from the fuel filter adapter and the fuel feed pipe, if required. 3. Install the fuel hose retainer (3) to the fuel filter hose(s). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Line Replacement > Page 5814 4. Position the fuel filter hose clamp(s) (1 or 2) at the fuel injection fuel feed manifold and/or the fuel feed pipe. 5. Position the fuel filter hose clamp(s) (1 or 2) at the fuel filter adapter. 6. Prime the fuel system. Refer to Fuel System Priming (See: Service and Repair/Fuel System Priming). 7. Start the engine. If the engine stalls, repeat the above step. 8. Once the engine starts, inspect for fuel leaks. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Line Replacement > Page 5815 Fuel Supply Line: Service and Repair Fuel Hose Replacement - Fuel Injection Pump to Fuel Feed Block Fuel Hose Replacement - Fuel Injection Pump to Fuel Feed Block Removal Procedure 1. Remove the water outlet. Refer to Water Outlet Tube Replacement (LU3) (See: Engine, Cooling and Exhaust/Cooling System/Coolant Outlet/Service and Repair)Water Outlet Tube Replacement (LMM) (See: Engine, Cooling and Exhaust/Cooling System/Coolant Outlet/Service and Repair). 2. Remove the intake manifold tube. Refer to Intake Manifold Tube Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair/Intake Manifold Tube Replacement). 3. Reposition the fuel hose clamp (2) at the fuel injection fuel feed manifold. 4. Reposition the fuel hose clamp (3) at the fuel injection pump. 5. Remove the fuel hose (4) from the fuel injection fuel feed manifold and injection pump. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Line Replacement > Page 5816 Installation Procedure 1. Install the fuel hose (4) to the fuel injection fuel feed manifold and injection pump. 2. Position the fuel hose clamp (3) at the fuel injection pump. 3. Position the fuel hose clamp (2) at the fuel injection fuel feed manifold. 4. Install the intake manifold tube. Refer to Intake Manifold Tube Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair/Intake Manifold Tube Replacement). 5. Install the water outlet. Refer to Water Outlet Tube Replacement (LU3) (See: Engine, Cooling and Exhaust/Cooling System/Coolant Outlet/Service and Repair)Water Outlet Tube Replacement (LMM) (See: Engine, Cooling and Exhaust/Cooling System/Coolant Outlet/Service and Repair). 6. Prime the fuel system. Refer to Fuel System Priming (See: Service and Repair/Fuel System Priming). 7. Start the engine. If the engine stalls, repeat the above step. 8. Once the engine starts, inspect for fuel leaks. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Fuel Tank Filler Hose Replacement (Cab/Chassis) Fuel Filler Hose: Service and Repair Fuel Tank Filler Hose Replacement (Cab/Chassis) Fuel Tank Filler Hose Replacement (Cab/Chassis) Removal Procedure 1. Relieve the fuel system pressure. 2. Disconnect the fuel feed and pressure balance rear lines. Refer to Metal Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Metal Collar Quick Connect Fitting Service). 3. Loosen the fuel fill and vent hose clamps (1, 2) at the tank. 4. Remove the fuel fill and vent hoses from the tank. 5. Cap the fuel and vent holes in the fuel tank in order to prevent possible fuel system contamination. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Fuel Tank Filler Hose Replacement (Cab/Chassis) > Page 5822 1. Remove the caps from the fuel and vent holes in the fuel tank. 2. Install the fuel fill and vent hoses to the tank. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Tighten the fuel fill and vent hose clamps (1, 2) at the tank. Tighten the clamp to 2.5 Nm (22 lb in). 4. Connect the fuel feed and pressure balance rear lines. Refer to Metal Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Metal Collar Quick Connect Fitting Service). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Fuel Tank Filler Hose Replacement (Cab/Chassis) > Page 5823 Fuel Filler Hose: Service and Repair Fuel Tank Filler Hose Replacement (Pickup) Fuel Tank Filler Hose Replacement (Pickup) Removal Procedure 1. Remove the fuel tank filler housing to body screws (1) and retainer (2). 2. Remove the fuel tank filler pipe housing to fuel tank fill pipe screws. 3. Remove the fuel tank filler housing. 4. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 5. Remove the fuel tank ground strap bolt (1). 6. Remove the chassis harness ground strap (2) and fuel tank ground strap (3). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Fuel Tank Filler Hose Replacement (Cab/Chassis) > Page 5824 7. Remove the rear axle vent hose from the clip on the fuel fill pipe bracket. 8. Loosen the fuel tank vent hose and fill hose clamps (1, 2). 9. Remove the vent hose from the tank. 10. Remove the fill hose from the tank and the vehicle. 11. Cap the opening on the fuel tank in order to prevent possible fuel system contamination. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Fuel Tank Filler Hose Replacement (Cab/Chassis) > Page 5825 1. Remove the cap from the opening on the fuel tank. 2. Install the fill hose to the vehicle and tank. 3. Install the vent hose to the tank. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Tighten the fuel tank vent hose and fill hose clamps (1, 2). Tighten the clamp to 2.5 Nm (22 lb in). 5. Install the rear axle vent hose to the clip on the fuel fill pipe bracket. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Service and Repair > Fuel Tank Filler Hose Replacement (Cab/Chassis) > Page 5826 6. Position the chassis harness ground strap (2) and fuel tank ground strap (3). 7. Install the ground strap anti-rotation tab into the frame hole. 8. Install the fuel tank ground strap bolt (1). Tighten the bolt to 9 Nm (80 lb in). 9. Lower the vehicle. 10. Install the fuel tank filler housing. 11. Install the fuel tank filler housing to fuel tank fill pipe screws. Tighten the screws to 2.3 Nm (20 lb in). 12. Install the fuel tank filler housing to body screws (1) and retainer (2). Tighten the screws to 2.3 Nm (20 lb in). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Service and Repair Fuel Filler Neck: Service and Repair Fuel Tank Filler Pipe Housing Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Service and Repair Fuel Gauge Sender: Service and Repair Fuel Sender Assembly Replacement Special Tools J 45722 Fuel Sender Lock Ring Wrench Removal Procedure 1. Remove the fuel tank. Refer to Fuel Tank Replacement (Pickup) (See: Service and Repair/Removal and Replacement)Fuel Tank Replacement (Cab/Chassis - Front) (See: Service and Repair/Removal and Replacement)Fuel Tank Replacement (Cab/Chassis - Rear) (See: Service and Repair/Removal and Replacement). 2. Disconnect the fuel lines from the sending unit. Refer to Metal Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Metal Collar Quick Connect Fitting Service) or Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). Caution: Avoid damaging the lock ring. Use only J-45722 to prevent damage to the lock ring. Caution: Do Not handle the fuel sender assembly by the fuel pipes. The amount of leverage generated by handling the fuel pipes could damage the joints. Note: Do NOT use impact tools. Significant force will be required to release the lock ring. The use of a hammer and screwdriver is not recommended. Secure the fuel tank in order to prevent fuel tank rotation. 3. Use the J 45722 and a long breaker-bar in order to unlock the fuel sender lock ring. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Service and Repair > Page 5833 4. Remove the sending unit and seal. Discard the seal. 5. Clean the sending unit sealing surfaces. Note: Some lock rings were manufactured with "DO NOT REUSE" stamped into them. These lock rings may be reused if they are not damaged or warped. Note: Inspect the lock ring for damage due to improper removal or installation procedures. If damage is found, install a NEW lock ring. Note: Check the lock ring for flatness. 6. Place the lock ring on a flat surface. Measure the clearance between the lock ring and the flat surface using a feeler gauge at 7 points. 7. If warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement. 8. If warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Service and Repair > Page 5834 1. Install the sending unit and a NEW seal. Note: Always replace the fuel sender seal when installing the fuel sender assembly. Replace the lock ring if necessary. DO NOT apply any type of lubrication in the seal groove. Ensure the lock ring is installed with the correct side facing upward. A correctly installed lock ring will only turn in a clockwise direction. 2. Use the J 45722 in order to install the fuel sender lock ring. Turn the fuel sender lock ring in a clockwise direction. 3. Connect the fuel lines to the sending unit. Refer to Metal Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Metal Collar Quick Connect Fitting Service) or Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). 4. Install the fuel tank. Refer to Fuel Tank Replacement (Pickup) (See: Service and Repair/Removal and Replacement)Fuel Tank Replacement (Cab/Chassis - Front) (See: Service and Repair/Removal and Replacement)Fuel Tank Replacement (Cab/Chassis - Rear) (See: Service and Repair/Removal and Replacement). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Service and Repair Fuel Tank Unit: Service and Repair Fuel Sender Assembly Replacement Special Tools J 45722 Fuel Sender Lock Ring Wrench Removal Procedure 1. Remove the fuel tank. Refer to Fuel Tank Replacement (Pickup) (See: Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (Cab/Chassis - Front) (See: Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (Cab/Chassis - Rear) (See: Fuel Tank/Service and Repair/Removal and Replacement). 2. Disconnect the fuel lines from the sending unit. Refer to Metal Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Metal Collar Quick Connect Fitting Service) or Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). Caution: Avoid damaging the lock ring. Use only J-45722 to prevent damage to the lock ring. Caution: Do Not handle the fuel sender assembly by the fuel pipes. The amount of leverage generated by handling the fuel pipes could damage the joints. Note: Do NOT use impact tools. Significant force will be required to release the lock ring. The use of a hammer and screwdriver is not recommended. Secure the fuel tank in order to prevent fuel tank rotation. 3. Use the J 45722 and a long breaker-bar in order to unlock the fuel sender lock ring. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Service and Repair > Page 5838 4. Remove the sending unit and seal. Discard the seal. 5. Clean the sending unit sealing surfaces. Note: Some lock rings were manufactured with "DO NOT REUSE" stamped into them. These lock rings may be reused if they are not damaged or warped. Note: Inspect the lock ring for damage due to improper removal or installation procedures. If damage is found, install a NEW lock ring. Note: Check the lock ring for flatness. 6. Place the lock ring on a flat surface. Measure the clearance between the lock ring and the flat surface using a feeler gauge at 7 points. 7. If warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement. 8. If warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Service and Repair > Page 5839 1. Install the sending unit and a NEW seal. Note: Always replace the fuel sender seal when installing the fuel sender assembly. Replace the lock ring if necessary. DO NOT apply any type of lubrication in the seal groove. Ensure the lock ring is installed with the correct side facing upward. A correctly installed lock ring will only turn in a clockwise direction. 2. Use the J 45722 in order to install the fuel sender lock ring. Turn the fuel sender lock ring in a clockwise direction. 3. Connect the fuel lines to the sending unit. Refer to Metal Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Metal Collar Quick Connect Fitting Service) or Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). 4. Install the fuel tank. Refer to Fuel Tank Replacement (Pickup) (See: Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (Cab/Chassis - Front) (See: Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (Cab/Chassis - Rear) (See: Fuel Tank/Service and Repair/Removal and Replacement). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Diagrams Fuel Temperature Sensor: Diagrams Component Connector End Views Fuel Temperature Sensor (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Diagrams > Page 5843 Fuel Temperature Sensor: Service and Repair Fuel Temperature Sensor Replacement Removal Procedure 1. Remove the charge air cooler inlet pipe. Refer to Charge Air Cooler Inlet Pipe Replacement (See: Turbocharger/Intercooler/Intercooler Duct/Service and Repair/Charge Air Cooler Inlet Pipe Replacement). 2. Disconnect the engine wiring harness electrical connector from the fuel temperature sensor. 3. Remove the fuel temperature sensor (1) from the fuel return pipe. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Diagrams > Page 5844 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the fuel temperature sensor (1) to the fuel return pipe. Tighten the sensor to 22 Nm (16 lb ft). 2. Connect the engine wiring harness electrical connector to the fuel temperature sensor. 3. Prime the fuel system. Refer to Fuel System Priming (See: Service and Repair/Fuel System Priming). 4. Start the engine. If the engine stalls, repeat the above step. 5. Once the engine starts, inspect for fuel leaks. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel/Water Separator > Component Information > Service and Repair > Procedures Fuel/Water Separator: Procedures Water-in-Fuel Draining 1. Attach a small piece of hose to the drain onto the water in fuel sensor. 2. Place the other end of the piece of hose into an approved fuel-resistant container. 3. Open the drain 3 or 4 turns or until the water contaminated fuel seeps from the drain. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel/Water Separator > Component Information > Service and Repair > Procedures > Page 5849 4. Operate the priming pump (1) until only diesel fuel is visible. Allow the pump to fully return upward between pushes. 5. Tighten the drain. 6. Remove the container and hose. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel/Water Separator > Component Information > Service and Repair > Procedures > Page 5850 Fuel/Water Separator: Removal and Replacement Water in Fuel Indicator Sensor Replacement Removal Procedure 1. Drain the fuel from the fuel filter. Refer to Water-in-Fuel Draining (See: Procedures). 2. Remove the right front wheelhouse liner rear bolts/retainers as required to reposition the rear half of the wheelhouse liner (1) in order to access the water in fuel sensor. 3. Disconnect the water in fuel sensor wiring pigtail (2) from the engine wiring harness electrical connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel/Water Separator > Component Information > Service and Repair > Procedures > Page 5851 4. Remove the water in fuel sensor (1) from the fuel filter. Installation Procedure 1. Install the water in fuel sensor (1) to the fuel filter, and tighten 1/2 turn after the seal contacts the filter. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel/Water Separator > Component Information > Service and Repair > Procedures > Page 5852 2. Connect the water in fuel sensor wiring pigtail (2) to the engine wiring harness electrical connector. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Position the rear half of the wheelhouse liner (1) and install the rear bolts/retainers as required. Tighten the bolts, if required to 2.5 Nm (22 lb in). 4. Prime the fuel system. Refer to Fuel System Priming (See: Service and Repair/Fuel System Priming). 5. Start the engine. If the engine stalls, repeat the above step. 6. Once the engine starts, inspect for fuel leaks. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > High Idle Switch > Component Information > Testing and Inspection High Idle Switch: Testing and Inspection High Idle Switch Diagnosis Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions )provide an overview of each diagnostic category. Diagnostic Fault Information Reference Information Schematic Reference Engine Controls Schematics (See: Diagrams/Electrical Diagrams) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning)for scan tool information Circuit/System Verification Ignition ON, observe the scan tool High Idle switch parameter while exercising the switch. The reading should change between ON/OFF. Circuit/System Testing 1. Ignition OFF, disconnect the harness connector at the high idle switch. 2. Test for less than 5 ohms between the ground circuit terminal A and ground. ‹› If greater than 5 ohms, test the ground circuit for an open/high resistance. 3. Ignition ON, verify the scan tool High Idle switch parameter is OFF. ‹› If not OFF, test the signal circuit for a short to ground. If the circuit tests normal, replace the ECM. 4. Install a 3A fused jumper wire between the signal circuit terminal C and ground. Verify the scan tool High Idle switch parameter is ON. ‹› If not ON, test the signal circuit for a short to voltage or an open/high resistance. If the circuit tests normal, replace the ECM. 5. If all circuits test normal, test or replace the high idle switch. Component Testing Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > High Idle Switch > Component Information > Testing and Inspection > Page 5856 1. Ignition OFF, disconnect the harness connector at the high idle switch. 2. Test for infinite resistance between the signal terminal C and the ground circuit terminal A with the switch in the open position. ‹› If less than infinite resistance, replace the high idle switch. 3. Test for less than 1 ohm between the signal terminal C and the ground terminal A with the switch in the closed position. ‹› If greater than 1 ohm, replace the high idle switch. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Duct > Component Information > Service and Repair Intake Air Duct: Service and Repair Intake Air Valve Replacement Removal Procedure 1. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (See: Air Cleaner Housing/Service and Repair). 2. Remove the charge air cooler outlet pipe. Refer to Charge Air Cooler Outlet Pipe Replacement (See: Turbocharger/Intercooler/Intercooler Duct/Service and Repair/Charge Air Cooler Outlet Pipe Replacement). 3. Disconnect the engine wiring harness electrical connector (2) from the intake air valve. 4. Remove the upper intake manifold brace bolts and brace. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Duct > Component Information > Service and Repair > Page 5860 5. Remove the intake air valve bolts (1), nuts (2) and valve. Installation Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Position the intake air valve to the intake pipe and install the intake air valve bolts (1) and nuts (2). Tighten the bolts to 20 Nm (15 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Duct > Component Information > Service and Repair > Page 5861 2. Install the upper intake manifold brace and bolts. Tighten the bolts to 24 Nm (18 lb ft). 3. Connect the engine wiring harness electrical connector (2) to the intake air valve. 4. Install the charge air cooler outlet pipe. Refer to Charge Air Cooler Outlet Pipe Replacement (See: Turbocharger/Intercooler/Intercooler Duct/Service and Repair/Charge Air Cooler Outlet Pipe Replacement). 5. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (See: Air Cleaner Housing/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Heater > Component Information > Diagrams Intake Air Heater: Diagrams Component Connector End Views Intake Air Heater (IAH) X1 (Diesel) Intake Air Heater X2 (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Heater > Component Information > Diagrams > Page 5865 Intake Air Heater: Service and Repair Intake Air Heater Replacement Removal Procedure 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 2. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (See: Air Cleaner Housing/Service and Repair). 3. Remove the exhaust gas recirculation (EGR) valve motor. Refer to Exhaust Gas Recirculation Valve Motor Replacement (See: Emission Control Systems/Exhaust Gas Recirculation/EGR Valve Actuator/Service and Repair). 4. Remove the upper intake manifold brace bolts and brace. 5. Remove the engine wiring harness clip (1) from the intake manifold tube. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Heater > Component Information > Diagrams > Page 5866 6. Remove the engine wiring harness clip bolt (2) from the intake manifold tube. 7. Disconnect the engine wiring harness electrical connector (1) from the intake air heater (IAH). 8. Disconnect the engine wiring harness electrical connector (2) from the manifold absolute pressure (MAP) sensor. 9. Reposition the engine wiring harness branches out of the way. 10. Open the IAH harness lead cover (2). 11. Remove the engine wiring harness lead nut (1) from the IAH stud. 12. Remove the engine wiring harness lead (3) from the IAH stud. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Heater > Component Information > Diagrams > Page 5867 13. Remove the IAH bolts (1) and nuts (2). 14. Remove the intake manifold front tube and IAH from the intake manifold rear tube. 15. Remove the IAH (3) from the intake manifold front tube studs. 16. Remove and discard the IAH gasket. Installation Procedure 1. Install a NEW IAH gasket. 2. Install the IAH (3) to the intake manifold front tube studs. 3. Install the intake manifold front tube and IAH to the intake manifold rear tube. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the IAH bolts (1) and nuts (2). Tighten the bolts/nuts to 20 Nm (15 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Heater > Component Information > Diagrams > Page 5868 5. Install the engine wiring harness lead (3) to the IAH stud. 6. Install the engine wiring harness lead nut (1) to the IAH stud. Tighten the nut to 10 Nm (89 lb in). 7. Close the IAH harness lead cover (2). 8. Position the engine wiring harness branches. 9. Connect the engine wiring harness electrical connector (2) to the MAP sensor. 10. Connect the engine wiring harness electrical connector (1) to the IAH. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Heater > Component Information > Diagrams > Page 5869 11. Install the engine wiring harness clip (1) to the intake manifold tube. 12. Install the engine wiring harness clip bolt (2) to the intake manifold tube. Tighten the bolt to 4 Nm (35 lb in). 13. Install the upper intake manifold brace and bolts. Tighten the bolts to 24 Nm (18 lb ft). 14. Install the EGR valve motor. Refer to Exhaust Gas Recirculation Valve Motor Replacement (See: Emission Control Systems/Exhaust Gas Recirculation/EGR Valve Actuator/Service and Repair). 15. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (See: Air Cleaner Housing/Service and Repair). 16. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 5873 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 5874 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 5875 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 5876 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 5877 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 5878 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 5879 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pressure Control Module > Component Information > Diagrams Fuel Pressure Control Module: Diagrams Component Connector End Views Fuel Pump Flow Control Module (Gas except JL1 and except LU3, LY6 or LY6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pressure Control Module > Component Information > Diagrams > Page 5884 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Fuse Block - Underhood Fuel Pump Relay: Locations Fuse Block - Underhood Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Fuse Block - Underhood > Page 5889 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Fuse Block - Underhood > Page 5890 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Fuse Block - Underhood > Page 5891 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Fuse Block - Underhood > Page 5892 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Fuse Block - Underhood > Page 5893 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Fuse Block - Underhood > Page 5894 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Fuse Block - Underhood > Page 5895 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Fuse Block - Underhood > Page 5896 Fuel Pump Relay: Locations Harness Routing Views Harness Routing Views Chassis Harness - Front Engine Compartment (31 Series) 1 - X102 (JL1) 2 - Fuel Pump Relay - Secondary (LY6 without NQZ) 3 - Fuse Block - Underhood 4 X126 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 5897 Fuel Pump Relay: Diagrams Component Connector End Views Fuel Pump Relay - Secondary (LY6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 5901 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 5902 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 5903 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 5904 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 5905 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 5906 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 5907 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations Accelerator Pedal Position Sensor: Locations Harness Routing Views Brake Clutch Harness Routing 1 - Driver Door Frame 2 - X205 3 - X102 (JL1) 4 - Accelerator Pedal Position (APP) Sensor Connector 5 - Junction Block - Left I/P (except MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 5912 Accelerator Pedal Position Sensor: Diagrams Component Connector End Views Accelerator Pedal Position (APP) Sensor Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 5913 Accelerator Pedal Position Sensor: Description and Operation Accelerator Pedal Position System Description The accelerator pedal position (APP) sensor is mounted inside the accelerator pedal control assembly. The sensor is made up of the two individual sensors within a single housing. Each sensor has a unique functionality to determine pedal position. The accelerator pedal position (APP) system along with the engine control module (ECM) is used to calculate and control the amount of acceleration and deceleration through fuel injector control. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 5914 Accelerator Pedal Position Sensor: Service and Repair Accelerator Pedal Position Sensor Replacement Removal Procedure Caution: Handle the electronic throttle control components carefully. Use cleanliness in order to prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the electronic throttle control components. Do not immerse the electronic throttle control components in cleaning solvents of any type. 1. Remove the connector position assurance (CPA) retainer. 2. Disconnect the accelerator pedal position (APP) sensor electrical connector (1). 3. Remove the accelerator pedal bolts. 4. Remove the accelerator pedal. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 5915 Installation Procedure 1. Position the accelerator pedal to the accelerator pedal bracket. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the accelerator pedal bolts and tighten to 9 Nm (80 lb in).. 3. Connect the APP sensor electrical connector (1). 4. Install the CPA retainer. 5. Connect a scan tool to the diagnostic port in order to test for proper throttle-opening and throttle-closing range. 6. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle, and a wide open throttle (WOT). 7. Verify that the vehicle meets the following conditions: * The vehicle is not in a reduced engine power mode. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 5916 * The ignition is ON. * The engine is OFF. 8. Inspect the carpet fit under the accelerator pedal. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations Air Flow Meter/Sensor: Locations Harness Routing Views Engine Harness Routing - Top (4.3L) 1 - Mega Fuse Ring Terminal 2 - X175 (M30) 3 - J128 4 - J105 5 - J106 6 - J130 (M30 with NQG/NQH) 7 - Engine Control Module (ECM) X1 8 - Engine Control Module (ECM) X2 9 - G103 10 - X112 11 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Connector Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 5920 Air Flow Meter/Sensor: Diagrams Component Connector End Views Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (Diesel) Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (Gas) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 5921 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 5922 Air Flow Meter/Sensor: Service and Repair Mass Airflow Sensor with Intake Air Temperature Sensor Replacement Removal Procedure 1. Disconnect the engine wiring harness electrical connector (1) from the mass air flow (MAF)/intake air temperature (IAT) sensor. 2. Remove the MAF/IAT sensor TORX(R) screws. 3. Remove the MAF/IAT sensor. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Locations > Page 5923 1. Install the MAF/IAT sensor. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the MAF/IAT sensor TORX(R) screws. Tighten the screws to 8 Nm (70 lb in). 3. Connect the engine wiring harness electrical connector (1) to the MAF/IAT sensor. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Diagrams Fuel Pressure Sensor/Switch: Diagrams Component Connector End Views Fuel Rail Pressure (FRP) Sensor (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Diagrams > Page 5927 Fuel Pressure Sensor/Switch: Service and Repair Fuel Injection Fuel Rail Fuel Pressure Sensor Replacement Removal Procedure 1. Remove the exhaust gas recirculation (EGR) valve cooler. Refer to Exhaust Gas Recirculation Valve Cooler Replacement (See: Emission Control Systems/Exhaust Gas Recirculation/EGR Cooler/Service and Repair/Exhaust Gas Recirculation Valve Cooler Replacement). 2. Disconnect the engine wiring harness electrical connector (1) from the fuel rail fuel pressure sensor wiring harness extension electrical connector. 3. Remove the fuel rail fuel pressure sensor wiring harness extension clip (3) from the wiring harness bracket. 4. Remove the EGR valve cooler rear bracket bolts and bracket. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Diagrams > Page 5928 5. Disconnect the fuel rail fuel pressure sensor wiring harness extension (1) from the fuel rail fuel pressure sensor. 6. Prior to removal, clean the fuel rail fuel pressure sensor and surrounding area thoroughly with solvent, such as GM P/N 12377981 (Canadian P/N 10953463) or equivalent. 7. Using compressed air, thoroughly blow dry the sensor and surrounding area. 8. Remove the fuel rail fuel pressure sensor (2). Installation Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the fuel rail fuel pressure sensor (2). Tighten the sensor to 70 Nm (52 lb ft). 2. Connect the fuel rail fuel pressure sensor wiring harness extension (1) to the fuel rail fuel pressure sensor. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Diagrams > Page 5929 3. Position the EGR valve cooler rear bracket to the cylinder head and install the bolts. Tighten the bolts to 25 Nm (18 lb ft). 4. Connect the engine wiring harness electrical connector (1) to the fuel rail fuel pressure sensor wiring harness extension electrical connector. 5. Install the fuel rail fuel pressure sensor wiring harness extension clip (3) to the wiring harness bracket. 6. Install the EGR valve cooler. Refer to Exhaust Gas Recirculation Valve Cooler Replacement (See: Emission Control Systems/Exhaust Gas Recirculation/EGR Cooler/Service and Repair/Exhaust Gas Recirculation Valve Cooler Replacement). 7. Prime the fuel system. Refer to Fuel System Priming (See: Service and Repair/Fuel System Priming). 8. Start the engine. If the engine stalls, repeat the above step. 9. Once the engine starts, inspect for fuel leaks. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Diagrams Fuel Temperature Sensor: Diagrams Component Connector End Views Fuel Temperature Sensor (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Diagrams > Page 5933 Fuel Temperature Sensor: Service and Repair Fuel Temperature Sensor Replacement Removal Procedure 1. Remove the charge air cooler inlet pipe. Refer to Charge Air Cooler Inlet Pipe Replacement (See: Turbocharger/Intercooler/Intercooler Duct/Service and Repair/Charge Air Cooler Inlet Pipe Replacement). 2. Disconnect the engine wiring harness electrical connector from the fuel temperature sensor. 3. Remove the fuel temperature sensor (1) from the fuel return pipe. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Diagrams > Page 5934 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the fuel temperature sensor (1) to the fuel return pipe. Tighten the sensor to 22 Nm (16 lb ft). 2. Connect the engine wiring harness electrical connector to the fuel temperature sensor. 3. Prime the fuel system. Refer to Fuel System Priming (See: Service and Repair/Fuel System Priming). 4. Start the engine. If the engine stalls, repeat the above step. 5. Once the engine starts, inspect for fuel leaks. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > High Idle Switch > Component Information > Testing and Inspection High Idle Switch: Testing and Inspection High Idle Switch Diagnosis Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions )provide an overview of each diagnostic category. Diagnostic Fault Information Reference Information Schematic Reference Engine Controls Schematics (See: Diagrams/Electrical Diagrams) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning)for scan tool information Circuit/System Verification Ignition ON, observe the scan tool High Idle switch parameter while exercising the switch. The reading should change between ON/OFF. Circuit/System Testing 1. Ignition OFF, disconnect the harness connector at the high idle switch. 2. Test for less than 5 ohms between the ground circuit terminal A and ground. ‹› If greater than 5 ohms, test the ground circuit for an open/high resistance. 3. Ignition ON, verify the scan tool High Idle switch parameter is OFF. ‹› If not OFF, test the signal circuit for a short to ground. If the circuit tests normal, replace the ECM. 4. Install a 3A fused jumper wire between the signal circuit terminal C and ground. Verify the scan tool High Idle switch parameter is ON. ‹› If not ON, test the signal circuit for a short to voltage or an open/high resistance. If the circuit tests normal, replace the ECM. 5. If all circuits test normal, test or replace the high idle switch. Component Testing Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > High Idle Switch > Component Information > Testing and Inspection > Page 5938 1. Ignition OFF, disconnect the harness connector at the high idle switch. 2. Test for infinite resistance between the signal terminal C and the ground circuit terminal A with the switch in the open position. ‹› If less than infinite resistance, replace the high idle switch. 3. Test for less than 1 ohm between the signal terminal C and the ground terminal A with the switch in the closed position. ‹› If greater than 1 ohm, replace the high idle switch. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Turbocharger Vane Position Sensor > Component Information > Technical Service Bulletins > Engine - Info on Duramax Turbo Vane Position Sensor Turbocharger Vane Position Sensor: Technical Service Bulletins Engine - Info on Duramax Turbo Vane Position Sensor INFORMATION Bulletin No.: 10-06-04-014 Date: November 03, 2010 Subject: Information on Duramax Turbo Vane Position Sensor Models: 2010-2011 Chevrolet Express Vans, Silverado 2010-2011 GMC Savana Vans, Sierra Equipped with Duramax(TM) Diesel Engine (RPOs LGH, LML) An improvement has been implemented to the turbocharger vane position sensor. Some turbochargers existing in inventory have the old style vane position sensor. If turbochargers, GM P/N 12635325 or 12635167 are being replaced, the original turbo vane sensor should be removed and replaced with the new style sensor, GM P/N 12643471. Turbochargers that are supersessions to these part numbers will have the new style vane position sensor and no action is necessary. Parts Information Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Turbocharger Vane Position Sensor > Component Information > Technical Service Bulletins > Page 5943 Turbocharger Vane Position Sensor: Diagrams Component Connector End Views Turbocharger Vane Position Sensor (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Diagrams Throttle Body: Diagrams Component Connector End Views Intake Air Valve (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Intercooler > Intercooler Duct > Component Information > Technical Service Bulletins > Customer Interest for Intercooler Duct: > 09-06-93-001A > Feb > 10 > Engine - Oil Leaks from Charge Air Cooler/Turbocharger Intercooler Duct: Customer Interest Engine - Oil Leaks from Charge Air Cooler/Turbocharger TECHNICAL Bulletin No.: 09-06-93-001A Date: February 12, 2010 Subject: Engine Oil Leaks from Charge Air Cooler and Turbocharger Air Inlet Adapter (Replace Clamp and/or Turbo Inlet Duct/Pipe) Models: 2007-2009 Chevrolet Kodiak 2007-2010 Chevrolet and GMC Light and Medium Duty Trucks Equipped with Diesel Engines 2007-2010 Chevrolet Silverado Equipped with Engine RPO LLY, LBZ or LMM Diesel 2007-2009 GMC TopKick Equipped with Engine RPO LLY, LBZ or LMM Diesel 2007-2010 GMC Sierra Please Refer to GMVIS Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 09-06-93-001 (Section 06 - Engine/Propulsion System). Condition Some customers may comment on an engine oil leak from the rear of the engine near the flywheel housing. Upon further investigation, a technician may find oil in the charge air cooler or turbocharger air inlet adapter. Cause Note Oil found in this system is very rarely an indication of a turbocharger failure. This condition may be caused by a loose clamp at the inlet duct/pipe located on the turbocharger. Oil may carry over from the PCV system and leak out the turbo inlet duct/pipe. Correction Note Do not replace the turbocharger if oil is found in the charge air cooler pipes. Important When replacing the clamp, tighten the clamp to 5 Nm (41 lb in), then loosen and re-tighten to 5 Nm (41 lb in). OIL LEAK FOUND AT CHARGE AIR COOLER OUTLET (HOT SIDE) Clean the rubber duct hose with soapy water and allow to dry. Apply a thin bead of high temperature RTV silicone sealant to the turbocharger compressor outlet port and CAC duct connections. Tighten Tighten the clamps to 8 Nm (70 lb in). OIL LEAK FOUND (Full-Size Pickup Trucks - Silverado and Sierra) Replace the turbo inlet duct/pipe and clamp with P/N 98011738. OIL LEAK FOUND (Vans and Medium Duty Trucks) Replace the air intake clamp with P/N 97376379. Refer to Air Intake Pipe Replacement in SI. Parts Information Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Intercooler > Intercooler Duct > Component Information > Technical Service Bulletins > Customer Interest for Intercooler Duct: > 09-06-93-001A > Feb > 10 > Engine - Oil Leaks from Charge Air Cooler/Turbocharger > Page 5957 Note Do not replace the inlet adapter/duct on vans and medium duty trucks - only replace the clamp. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Intercooler > Intercooler Duct > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intercooler Duct: > 09-06-93-001A > Feb > 10 > Engine - Oil Leaks from Charge Air Cooler/Turbocharger Intercooler Duct: All Technical Service Bulletins Engine - Oil Leaks from Charge Air Cooler/Turbocharger TECHNICAL Bulletin No.: 09-06-93-001A Date: February 12, 2010 Subject: Engine Oil Leaks from Charge Air Cooler and Turbocharger Air Inlet Adapter (Replace Clamp and/or Turbo Inlet Duct/Pipe) Models: 2007-2009 Chevrolet Kodiak 2007-2010 Chevrolet and GMC Light and Medium Duty Trucks Equipped with Diesel Engines 2007-2010 Chevrolet Silverado Equipped with Engine RPO LLY, LBZ or LMM Diesel 2007-2009 GMC TopKick Equipped with Engine RPO LLY, LBZ or LMM Diesel 2007-2010 GMC Sierra Please Refer to GMVIS Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 09-06-93-001 (Section 06 - Engine/Propulsion System). Condition Some customers may comment on an engine oil leak from the rear of the engine near the flywheel housing. Upon further investigation, a technician may find oil in the charge air cooler or turbocharger air inlet adapter. Cause Note Oil found in this system is very rarely an indication of a turbocharger failure. This condition may be caused by a loose clamp at the inlet duct/pipe located on the turbocharger. Oil may carry over from the PCV system and leak out the turbo inlet duct/pipe. Correction Note Do not replace the turbocharger if oil is found in the charge air cooler pipes. Important When replacing the clamp, tighten the clamp to 5 Nm (41 lb in), then loosen and re-tighten to 5 Nm (41 lb in). OIL LEAK FOUND AT CHARGE AIR COOLER OUTLET (HOT SIDE) Clean the rubber duct hose with soapy water and allow to dry. Apply a thin bead of high temperature RTV silicone sealant to the turbocharger compressor outlet port and CAC duct connections. Tighten Tighten the clamps to 8 Nm (70 lb in). OIL LEAK FOUND (Full-Size Pickup Trucks - Silverado and Sierra) Replace the turbo inlet duct/pipe and clamp with P/N 98011738. OIL LEAK FOUND (Vans and Medium Duty Trucks) Replace the air intake clamp with P/N 97376379. Refer to Air Intake Pipe Replacement in SI. Parts Information Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Intercooler > Intercooler Duct > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intercooler Duct: > 09-06-93-001A > Feb > 10 > Engine - Oil Leaks from Charge Air Cooler/Turbocharger > Page 5963 Note Do not replace the inlet adapter/duct on vans and medium duty trucks - only replace the clamp. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Intercooler > Intercooler Duct > Component Information > Service and Repair > Charge Air Cooler Inlet Pipe Replacement Intercooler Duct: Service and Repair Charge Air Cooler Inlet Pipe Replacement Charge Air Cooler Inlet Pipe Replacement Removal Procedure 1. Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair/Intake Manifold Cover Replacement). 2. Loosen the charge air cooler inlet pipe connector clamp (1) at the turbocharger. Note: Do not use a screwdriver or other tool to pry the connector loose. The connector can be torn or damaged. Loosen the connector by twisting. 3. Remove the charge air cooler inlet pipe connector (2) from the turbocharger. 4. Cover the turbocharger opening with tape in order to prevent possible entry of foreign objects. 5. Remove the wheelhouse panel. Refer to Front Wheelhouse Liner Replacement - Left Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Left Side)Front Wheelhouse Liner Replacement - Left Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Left Side). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Intercooler > Intercooler Duct > Component Information > Service and Repair > Charge Air Cooler Inlet Pipe Replacement > Page 5966 6. Working through the wheelhouse, loosen the charge air cooler inlet pipe connector clamp (1) at the charge air cooler. Note: Do not use a screwdriver or other tool to pry the connector loose. The connector can be torn or damaged. Loosen the connector by twisting. 7. Remove the charge air cooler inlet pipe connector (2) from the charge air cooler. 8. Lower the vehicle. 9. Remove the charge air cooler inlet pipe from the vehicle. Installation Procedure 1. Install the charge air cooler inlet pipe to the vehicle. 2. Remove the turbocharger opening cover. Note: Do not over tighten the charge air cooler connector clamp. If the clamp is overtightened, the connector may become distorted allowing separation of the connector from the pipe. Make sure the charge air cooler pipe is properly orientated. 3. Install the charge air cooler inlet pipe connector (2) onto the turbocharger. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Intercooler > Intercooler Duct > Component Information > Service and Repair > Charge Air Cooler Inlet Pipe Replacement > Page 5967 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Tighten the charge air cooler inlet pipe to turbocharger connector clamp (1). Tighten the clamp to 8 Nm (70 lb in). 5. Raise and support the vehicle half way. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). Note: Do not over tighten the charged air cooler pipe connector clamp. If the clamp is overtightened, the connector may become distorted allowing separation of the connector from the pipe. Make sure the charge air cooler pipe is properly orientated. 6. Working through the wheelhouse, install the charge air cooler inlet pipe connector onto the charge air cooler. 7. Tighten the charge air cooler inlet pipe to charge air cooler connector clamp (1). Tighten the clamp to 8 Nm (70 lb in). 8. Install the wheelhouse panel. Refer to Front Wheelhouse Liner Replacement - Left Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Left Side)Front Wheelhouse Liner Replacement - Left Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Left Side). 9. Install the intake manifold cover. Refer to Intake Manifold Cover Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair/Intake Manifold Cover Replacement). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Intercooler > Intercooler Duct > Component Information > Service and Repair > Charge Air Cooler Inlet Pipe Replacement > Page 5968 Intercooler Duct: Service and Repair Charge Air Cooler Outlet Pipe Replacement Charge Air Cooler Outlet Pipe Replacement Removal Procedure 1. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (See: Air Cleaner Housing/Service and Repair). 2. Using a pick or a small flat-bladed screwdriver, remove and discard the quick connect fitting clip (1) from the charge air cooler outlet pipe. 3. Remove the charge air cooler outlet pipe (2) from the intake air heater. 4. Remove the wheelhouse panel. Refer to Front Wheelhouse Liner Replacement - Right Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side)Front Wheelhouse Liner Replacement - Right Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side). 5. Working through the wheelhouse, Using the pick or a small flat-bladed screwdriver, remove and discard the quick connect fitting clip (1) from the Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Intercooler > Intercooler Duct > Component Information > Service and Repair > Charge Air Cooler Inlet Pipe Replacement > Page 5969 charge air cooler outlet pipe. 6. Remove the charge air cooler outlet pipe (2) from the charge air cooler and the vehicle. Installation Procedure 1. Install NEW quick connect fitting clips to both ends of the charge air cooler outlet pipe. 2. Working through the wheelhouse, install the charge air cooler outlet pipe onto the charge air cooler. 3. Install the wheelhouse panel. Refer to Front Wheelhouse Liner Replacement - Right Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side)Front Wheelhouse Liner Replacement - Right Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Intercooler > Intercooler Duct > Component Information > Service and Repair > Charge Air Cooler Inlet Pipe Replacement > Page 5970 4. Install the charge air cooler outlet pipe onto the intake air valve. 5. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (See: Air Cleaner Housing/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Turbocharger Coolant Line > Component Information > Service and Repair Turbocharger Coolant Line: Service and Repair Turbocharger Coolant Hoses/Pipes Replacement (LMM Outlet Pipe) Removal Procedure 1. Remove the turbocharger coolant inlet pipe. Refer to Turbocharger Coolant Hoses/Pipes Replacement (LMM Outlet Pipe) . 2. Remove the generator mounting bracket. Refer to Generator Bracket Replacement (V6) (See: Starting and Charging/Charging System/Alternator/Service and Repair)Generator Bracket Replacement (6.6L) (See: Starting and Charging/Charging System/Alternator/Service and Repair)Generator Bracket Replacement (V8) (See: Starting and Charging/Charging System/Alternator/Service and Repair). 3. Remove the exhaust gas recirculation (EGR) cooler assembly. Refer to Exhaust Gas Recirculation Valve Cooler Replacement (See: Emission Control Systems/Exhaust Gas Recirculation/EGR Cooler/Service and Repair/Exhaust Gas Recirculation Valve Cooler Replacement). 4. Remove the cooling fan clutch. Refer to Fan Clutch Replacement (Diesel) (See: Engine, Cooling and Exhaust/Cooling System/Radiator Cooling Fan/Fan Clutch/Service and Repair). 5. Reposition the hose clamp at the bypass pipe. 6. Remove the turbocharger coolant outlet hose from the bypass pipe. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Turbocharger Coolant Line > Component Information > Service and Repair > Page 5974 7. Reposition the turbocharger coolant outlet hose clamp. 8. Remove the turbocharger coolant outlet hose from the pipe on the turbocharger. 9. Remove the turbocharger coolant outlet pipe bolt and nut. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Turbocharger Coolant Line > Component Information > Service and Repair > Page 5975 10. If necessary, remove the turbocharger. Refer to Turbocharger Replacement (See: Service and Repair/Turbocharger Replacement). 11. If necessary, remove the coolant outlet pipe clip bolt (3) from the turbocharger. 12. If necessary, remove the coolant outlet pipe. Installation Procedure 1. If necessary, install the coolant outlet pipe. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. If necessary, install the coolant outlet pipe clip bolt (3) to the turbocharger. Tighten the bolt to 9 Nm (80 lb in). 3. If necessary, install the turbocharger. Refer to Turbocharger Replacement (See: Service and Repair/Turbocharger Replacement). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Turbocharger Coolant Line > Component Information > Service and Repair > Page 5976 4. Install the turbocharger coolant outlet pipe bolt and nut. Tighten the bolt/nut to 9 Nm (80 lb in). 5. Install the turbocharger coolant outlet hose to the pipe on the turbocharger. 6. Position the turbocharger coolant outlet hose clamp. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Turbocharger Coolant Line > Component Information > Service and Repair > Page 5977 7. Install the turbocharger coolant outlet hose to the bypass pipe. 8. Position the hose clamp at the bypass pipe. 9. Install the cooling fan clutch. Refer to Fan Clutch Replacement (Diesel) (See: Engine, Cooling and Exhaust/Cooling System/Radiator Cooling Fan/Fan Clutch/Service and Repair). 10. Install the EGR cooler assembly. Refer to Exhaust Gas Recirculation Valve Cooler Replacement (See: Emission Control Systems/Exhaust Gas Recirculation/EGR Cooler/Service and Repair/Exhaust Gas Recirculation Valve Cooler Replacement). 11. Install the generator mounting bracket. Refer to Generator Bracket Replacement (V6) (See: Starting and Charging/Charging System/Alternator/Service and Repair)Generator Bracket Replacement (6.6L) (See: Starting and Charging/Charging System/Alternator/Service and Repair)Generator Bracket Replacement (V8) (See: Starting and Charging/Charging System/Alternator/Service and Repair). 12. Install the turbocharger coolant inlet pipe. Refer to Turbocharger Coolant Hoses/Pipes Replacement (LMM Outlet Pipe) . Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Oil Line, Turbocharger > Component Information > Service and Repair Oil Line: Service and Repair Turbocharger Oil Feed Pipe Replacement Removal Procedure 1. Remove the turbocharger. Refer to Turbocharger Replacement (See: Service and Repair/Turbocharger Replacement). 2. Remove the turbocharger oil feed pipe bolt. 3. Remove the oil feed pipe and washer. Installation Procedure Caution: Do not twist the turbocharger oil feed pipe. Twisting of the feed pipe will result in the collapse and deformation of the plastic pipe, restricting oil flow and causing turbocharger damage. During turbocharger replacement, gently push the oil feed pipe towards the front of the engine to clear the turbocharger. Assistance may be required to keep the pipes clear of the turbocharger during removal or installation. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Oil Line, Turbocharger > Component Information > Service and Repair > Page 5981 Note: Lubricate the NEW washer with diesel fuel before installing. 1. Position the oil feed pipe and a NEW washer into place. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the oil feed pipe bolt. Tighten the bolt to 34 Nm (25 lb ft). 3. Install the turbocharger. Refer to Turbocharger Replacement (See: Service and Repair/Turbocharger Replacement). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Turbocharger Vane Position Sensor > Component Information > Technical Service Bulletins > Engine - Info on Duramax Turbo Vane Position Sensor Turbocharger Vane Position Sensor: Technical Service Bulletins Engine - Info on Duramax Turbo Vane Position Sensor INFORMATION Bulletin No.: 10-06-04-014 Date: November 03, 2010 Subject: Information on Duramax Turbo Vane Position Sensor Models: 2010-2011 Chevrolet Express Vans, Silverado 2010-2011 GMC Savana Vans, Sierra Equipped with Duramax(TM) Diesel Engine (RPOs LGH, LML) An improvement has been implemented to the turbocharger vane position sensor. Some turbochargers existing in inventory have the old style vane position sensor. If turbochargers, GM P/N 12635325 or 12635167 are being replaced, the original turbo vane sensor should be removed and replaced with the new style sensor, GM P/N 12643471. Turbochargers that are supersessions to these part numbers will have the new style vane position sensor and no action is necessary. Parts Information Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Turbocharger Vane Position Sensor > Component Information > Technical Service Bulletins > Page 5986 Turbocharger Vane Position Sensor: Diagrams Component Connector End Views Turbocharger Vane Position Sensor (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Variable Boost Control Solenoid, Turbocharger > Component Information > Diagrams Variable Boost Control Solenoid: Diagrams Component Connector End Views Turbocharger Vane Position Control Solenoid Valve (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Harness Routing Views Camshaft Position Sensor Jumper Harness Routing (4.8L/5.3L/6.0L/6.2L) 1 - X112 2 - Camshaft Position Sensor Jumper Harness Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 5994 Camshaft Position Sensor: Diagrams Component Connector End Views Camshaft Position (CMP) Actuator Solenoid Valve (LZ1, LY6, L96 or L9H) Camshaft Position (CMP) Sensor (LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 5995 Camshaft Position (CMP) Sensor (Gas except LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 5996 Camshaft Position (CMP) Sensor (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 5997 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 5998 Camshaft Position Sensor: Service Precautions Camshaft Position Actuator Removal and Installation Warning Warning Do not push or pull on the reluctor wheel of the camshaft position (CMP) actuator during removal or installation. The reluctor wheel is retained to the front of the CMP actuator by 3 roll pins. Pushing or pulling on the wheel may dislodge the wheel from the front of the actuator. The actuator return spring is under tension and may rotate the dislodged reluctor wheel, causing personal injury. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 5999 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor Replacement Removal Procedure 1. Remove the cooling fan pulley. Refer to Fan Pulley Replacement (See: Engine, Cooling and Exhaust/Cooling System/Radiator Cooling Fan/Service and Repair). 2. Remove the camshaft position (CMP) sensor bolt. 3. Remove the CMP sensor. Installation Procedure 1. Lubricate the CMP sensor O-ring with clean engine oil. 2. Install the CMP sensor. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 6000 3. Install the CMP sensor bolt. Tighten the bolt to 10 Nm (89 lb in). 4. Install the cooling fan pulley. Refer to Fan Pulley Replacement (See: Engine, Cooling and Exhaust/Cooling System/Radiator Cooling Fan/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams Crankshaft Position Sensor: Diagrams Component Connector End Views Crankshaft Position (CKP) Sensor (LU3) Crankshaft Position (CKP) Sensor (Gas except LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 6004 Crankshaft Position (CKP) Sensor (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 6005 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement Crankshaft Position Sensor Replacement Removal Procedure 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 2. Remove the right wheelhouse panel. Refer to Front Wheelhouse Liner Replacement - Right Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side)Front Wheelhouse Liner Replacement - Right Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side). 3. Disconnect the crankshaft position (CKP) sensor electrical connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 6008 4. Remove the CKP sensor bolt. 5. Remove the CKP sensor. 6. If necessary, remove the CKP sensor spacer bolts. 7. If necessary, remove the CKP sensor spacer. Installation Procedure 1. If necessary, lubricate a NEW CKP spacer O-ring with clean engine oil. 2. If necessary, install the NEW O-ring to the CKP sensor spacer. Note: The crankshaft position sensor spacers are machined with different timing positions. However, if the crankshaft position sensor spacer requires replacement, replace with a grade "C" spacer. 3. If necessary, install the CKP sensor spacer. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. If necessary, install the CKP sensor spacer bolts. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 6009 Tighten the bolts to 10 Nm (89 lb in). 5. Lubricate a NEW CKP sensor O-ring with clean engine oil. 6. Install the NEW O-ring to the CKP sensor. 7. Install the CKP sensor. 8. Install the CKP sensor bolt. Tighten the bolt to 10 Nm (89 lb in). 9. Connect the CKP sensor electrical connector. 10. Install the right wheelhouse panel. Refer to Front Wheelhouse Liner Replacement - Right Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side)Front Wheelhouse Liner Replacement - Right Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side). 11. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 6010 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Exciter Ring and Oil Pump Drive Gear Replacement Crankshaft Position Sensor Exciter Ring and Oil Pump Drive Gear Replacement Removal Procedure 1. Remove the engine front cover. Refer to Engine Front Cover Replacement (See: Engine, Cooling and Exhaust/Engine/Timing Components/Timing Cover/Service and Repair). 2. Remove the upper oil pan. Refer to Upper Oil Pan Replacement (See: Engine, Cooling and Exhaust/Engine/Engine Lubrication/Oil Pan/Service and Repair/Upper Oil Pan Replacement). Caution: Do not use an impact driver to remove or install the oil pump driven gear nut. Use of an impact driver may shear the oil pump drive gear pin in the crankshaft. 3. While holding the secondary oil pump shaft with a hex driver, remove the oil pump driven gear nut. 4. Remove the oil pump driven gear. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 6011 5. Remove the oil pump drive gear and crankshaft sensor reluctor. Do not damage the crankshaft reluctor teeth. Note: Do not remove the reluctor from the oil pump drive gear unless replacing the reluctor or the oil pump drive gear. The reluctor is timed to the gear and once removed the correct timing will be lost. 6. Remove the crankshaft reluctor to oil pump drive gear bolts. 7. Inspect the crankshaft reluctor for the damage, bent teeth, being bent or warped. 8. Inspect the oil pump drive gear for damaged or worn teeth. 9. Inspect the oil pump drive gear crankshaft pin for wear. 10. Inspect the groove of the crankshaft pin in the oil pump drive gear for wear. 11. Replace any parts that are damaged or worn. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 6012 Note: The crankshaft reluctor and the oil pump drive gear are timed at the factory. In order to re-establish proper timing, install knock pins in the oil pump drive gear if the crankshaft reluctor was removed from the oil pump drive gear. The knock pins are available through the parts department. 1. Install the knock pins in the oil pump drive gear to a height of 4.5-5.5 mm (0.177-0.217 in) 2. Install the crankshaft reluctor on the oil pump drive gear. Ensure the reluctor is aligned on the knock pins. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the crankshaft reluctor bolts and tighten to 8 Nm (71 lb in). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 6013 Note: Do not damage the teeth on the crankshaft reluctor. 4. Install the oil pump drive gear and reluctor to the crankshaft. 5. Install the oil pump driven gear. Caution: Do not use an impact driver to remove or install the oil pump driven gear nut. Use of an impact driver may shear the oil pump drive gear pin in the crankshaft. 6. While holding the secondary oil pump shaft with a hex driver, install the oil pump driven gear nut and tighten to 100 Nm (74 lb ft). 7. Install the upper oil pan. Refer to Upper Oil Pan Replacement (See: Engine, Cooling and Exhaust/Engine/Engine Lubrication/Oil Pan/Service and Repair/Upper Oil Pan Replacement). 8. Install the engine front cover. Refer to Engine Front Cover Replacement (See: Engine, Cooling and Exhaust/Engine/Timing Components/Timing Cover/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams Knock Sensor: Diagrams Component Connector End Views Knock Sensor (KS) 1 (Gas) Knock Sensor (KS) 2 (Gas) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Page 6017 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Harness Routing Views Camshaft Position Sensor Jumper Harness Routing (4.8L/5.3L/6.0L/6.2L) 1 - X112 2 - Camshaft Position Sensor Jumper Harness Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 6022 Camshaft Position Sensor: Diagrams Component Connector End Views Camshaft Position (CMP) Actuator Solenoid Valve (LZ1, LY6, L96 or L9H) Camshaft Position (CMP) Sensor (LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 6023 Camshaft Position (CMP) Sensor (Gas except LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 6024 Camshaft Position (CMP) Sensor (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 6025 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 6026 Camshaft Position Sensor: Service Precautions Camshaft Position Actuator Removal and Installation Warning Warning Do not push or pull on the reluctor wheel of the camshaft position (CMP) actuator during removal or installation. The reluctor wheel is retained to the front of the CMP actuator by 3 roll pins. Pushing or pulling on the wheel may dislodge the wheel from the front of the actuator. The actuator return spring is under tension and may rotate the dislodged reluctor wheel, causing personal injury. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 6027 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor Replacement Removal Procedure 1. Remove the cooling fan pulley. Refer to Fan Pulley Replacement (See: Engine, Cooling and Exhaust/Cooling System/Radiator Cooling Fan/Service and Repair). 2. Remove the camshaft position (CMP) sensor bolt. 3. Remove the CMP sensor. Installation Procedure 1. Lubricate the CMP sensor O-ring with clean engine oil. 2. Install the CMP sensor. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 6028 3. Install the CMP sensor bolt. Tighten the bolt to 10 Nm (89 lb in). 4. Install the cooling fan pulley. Refer to Fan Pulley Replacement (See: Engine, Cooling and Exhaust/Cooling System/Radiator Cooling Fan/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams Crankshaft Position Sensor: Diagrams Component Connector End Views Crankshaft Position (CKP) Sensor (LU3) Crankshaft Position (CKP) Sensor (Gas except LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 6032 Crankshaft Position (CKP) Sensor (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 6033 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement Crankshaft Position Sensor Replacement Removal Procedure 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 2. Remove the right wheelhouse panel. Refer to Front Wheelhouse Liner Replacement - Right Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side)Front Wheelhouse Liner Replacement - Right Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side). 3. Disconnect the crankshaft position (CKP) sensor electrical connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 6036 4. Remove the CKP sensor bolt. 5. Remove the CKP sensor. 6. If necessary, remove the CKP sensor spacer bolts. 7. If necessary, remove the CKP sensor spacer. Installation Procedure 1. If necessary, lubricate a NEW CKP spacer O-ring with clean engine oil. 2. If necessary, install the NEW O-ring to the CKP sensor spacer. Note: The crankshaft position sensor spacers are machined with different timing positions. However, if the crankshaft position sensor spacer requires replacement, replace with a grade "C" spacer. 3. If necessary, install the CKP sensor spacer. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. If necessary, install the CKP sensor spacer bolts. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 6037 Tighten the bolts to 10 Nm (89 lb in). 5. Lubricate a NEW CKP sensor O-ring with clean engine oil. 6. Install the NEW O-ring to the CKP sensor. 7. Install the CKP sensor. 8. Install the CKP sensor bolt. Tighten the bolt to 10 Nm (89 lb in). 9. Connect the CKP sensor electrical connector. 10. Install the right wheelhouse panel. Refer to Front Wheelhouse Liner Replacement - Right Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side)Front Wheelhouse Liner Replacement - Right Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side). 11. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 6038 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Exciter Ring and Oil Pump Drive Gear Replacement Crankshaft Position Sensor Exciter Ring and Oil Pump Drive Gear Replacement Removal Procedure 1. Remove the engine front cover. Refer to Engine Front Cover Replacement (See: Engine, Cooling and Exhaust/Engine/Timing Components/Timing Cover/Service and Repair). 2. Remove the upper oil pan. Refer to Upper Oil Pan Replacement (See: Engine, Cooling and Exhaust/Engine/Engine Lubrication/Oil Pan/Service and Repair/Upper Oil Pan Replacement). Caution: Do not use an impact driver to remove or install the oil pump driven gear nut. Use of an impact driver may shear the oil pump drive gear pin in the crankshaft. 3. While holding the secondary oil pump shaft with a hex driver, remove the oil pump driven gear nut. 4. Remove the oil pump driven gear. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 6039 5. Remove the oil pump drive gear and crankshaft sensor reluctor. Do not damage the crankshaft reluctor teeth. Note: Do not remove the reluctor from the oil pump drive gear unless replacing the reluctor or the oil pump drive gear. The reluctor is timed to the gear and once removed the correct timing will be lost. 6. Remove the crankshaft reluctor to oil pump drive gear bolts. 7. Inspect the crankshaft reluctor for the damage, bent teeth, being bent or warped. 8. Inspect the oil pump drive gear for damaged or worn teeth. 9. Inspect the oil pump drive gear crankshaft pin for wear. 10. Inspect the groove of the crankshaft pin in the oil pump drive gear for wear. 11. Replace any parts that are damaged or worn. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 6040 Note: The crankshaft reluctor and the oil pump drive gear are timed at the factory. In order to re-establish proper timing, install knock pins in the oil pump drive gear if the crankshaft reluctor was removed from the oil pump drive gear. The knock pins are available through the parts department. 1. Install the knock pins in the oil pump drive gear to a height of 4.5-5.5 mm (0.177-0.217 in) 2. Install the crankshaft reluctor on the oil pump drive gear. Ensure the reluctor is aligned on the knock pins. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the crankshaft reluctor bolts and tighten to 8 Nm (71 lb in). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor Replacement > Page 6041 Note: Do not damage the teeth on the crankshaft reluctor. 4. Install the oil pump drive gear and reluctor to the crankshaft. 5. Install the oil pump driven gear. Caution: Do not use an impact driver to remove or install the oil pump driven gear nut. Use of an impact driver may shear the oil pump drive gear pin in the crankshaft. 6. While holding the secondary oil pump shaft with a hex driver, install the oil pump driven gear nut and tighten to 100 Nm (74 lb ft). 7. Install the upper oil pan. Refer to Upper Oil Pan Replacement (See: Engine, Cooling and Exhaust/Engine/Engine Lubrication/Oil Pan/Service and Repair/Upper Oil Pan Replacement). 8. Install the engine front cover. Refer to Engine Front Cover Replacement (See: Engine, Cooling and Exhaust/Engine/Timing Components/Timing Cover/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder Case Replacement Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder Case Replacement Ignition Lock Cylinder Case Replacement Removal Procedure Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). 1. Remove the inflatable restraint steering wheel module coil. Refer to Steering Wheel Inflatable Restraint Module Coil Replacement (See: Restraint Systems/Air Bag Systems/Clockspring Assembly / Spiral Cable/Service and Repair/Removal and Replacement). 2. Remove the ignition/start switch. Refer to Ignition and Start Switch Replacement (See: Service and Repair). 3. Disconnect the park lock cable from the ignition lock cylinder case. 4. Disconnect the passlock and key buzzer from the ignition lock cylinder case. 5. Remove the 3 ignition lock cylinder case screws (2). 6. Remove the ignition lock cylinder case (1) from the vehicle. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder Case Replacement > Page 6047 1. Install the ignition lock cylinder case (1) to the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the 3 ignition lock cylinder case screws (2). Tighten the screws to 7 Nm (62 lb in). 3. Install the park lock cable into the lock cylinder housing. 4. Connect the passlock and key buzzer to the ignition lock cylinder case. 5. Install the ignition/start switch. Refer to Ignition and Start Switch Replacement (See: Service and Repair). 6. Install the inflatable restraint steering wheel module coil. Refer to Steering Wheel Inflatable Restraint Module Coil Replacement (See: Restraint Systems/Air Bag Systems/Clockspring Assembly / Spiral Cable/Service and Repair/Removal and Replacement). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder Case Replacement > Page 6048 Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder Replacement Ignition Lock Cylinder Replacement Removal Procedure Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). 1. Disable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair). 2. Remove the steering column shroud. Refer to Steering Column Shroud Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Column Shroud Replacement). 3. With the key installed hold it in the START position. 4. Install an allen wrench into the hole on top of the ignition lock cylinder case. Push down on the allen wrench to release the tab on the ignition lock cylinder inside the ignition lock cylinder case. 5. Slide the ignition lock cylinder out of the ignition lock cylinder case. Installation Procedure Note: The gears between the ignition/start switch and the ignition lock cylinder case must be in the correct position. Failure to do so will cause a misalignment of the gears in the ignition/start switch and the ignition lock cylinder case, which may result in a NO START or BATTERY DRAIN. 1. Use a screwdriver to rotate the ignition lock cylinder case gear clockwise to the start position allowing it to spring return into the RUN position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder Case Replacement > Page 6049 2. Install the key into the ignition lock cylinder. 3. Align the ignition lock cylinder and install it into the ignition lock cylinder case. 4. Install the steering column shroud. Refer to Steering Column Shroud Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Column Shroud Replacement). 5. Enable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams Knock Sensor: Diagrams Component Connector End Views Knock Sensor (KS) 1 (Gas) Knock Sensor (KS) 2 (Gas) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Page 6053 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Glow Plug System > Glow Plug > Component Information > Service and Repair > Glow Plug Replacement - Bank 1 Glow Plug: Service and Repair Glow Plug Replacement - Bank 1 Glow Plug Replacement - Bank 1 Removal Procedure 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 2. Remove the right wheelhouse panel. Refer to Front Wheelhouse Liner Replacement - Right Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side)Front Wheelhouse Liner Replacement - Right Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side). 3. Remove the engine wiring harness nut(s) from the glow plug(s). 4. Remove the engine wiring harness lead(s) from the glow plug(s). Note: If a glow plug is replaced and the tip is missing or burned off, the cylinder head must be removed and all debris must be cleaned out of the cylinder. 5. Remove the glow plug(s) from the cylinder head. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Glow Plug System > Glow Plug > Component Information > Service and Repair > Glow Plug Replacement - Bank 1 > Page 6059 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the glow plug(s) to the cylinder head and tighten to 18 Nm (13 lb ft). 2. Install the engine wiring harness lead(s) to the glow plug(s). 3. Install the engine wiring harness nut(s) to the glow plug(s) and tighten to 1.7 Nm (15 lb in). 4. Install the right wheelhouse panel. Refer to Front Wheelhouse Liner Replacement - Right Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side)Front Wheelhouse Liner Replacement - Right Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side). 5. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Glow Plug System > Glow Plug > Component Information > Service and Repair > Glow Plug Replacement - Bank 1 > Page 6060 Glow Plug: Service and Repair Glow Plug Replacement - Bank 2 Glow Plug Replacement - Bank 2 Removal Procedure 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 2. Remove the left wheelhouse panel. Refer to Front Wheelhouse Liner Replacement - Left Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Left Side)Front Wheelhouse Liner Replacement - Left Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Left Side). 3. Remove the engine wiring harness nut(s) from the glow plug(s). 4. Remove the engine wiring harness lead(s) from the glow plug(s). Note: If a glow plug is replaced and the tip is missing or burned off, the cylinder head must be removed and all debris must be cleaned out of the cylinder. 5. Remove the glow plug(s) from the cylinder head. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Glow Plug System > Glow Plug > Component Information > Service and Repair > Glow Plug Replacement - Bank 1 > Page 6061 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the glow plug(s) to the cylinder head and tighten to 18 Nm (13 lb ft). 2. Install the engine wiring harness lead(s) to the glow plug(s). 3. Install the engine wiring harness nut(s) to the glow plug(s) and tighten to 1.7 Nm (15 lb in). 4. Install the left wheelhouse panel. Refer to Front Wheelhouse Liner Replacement - Left Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Left Side)Front Wheelhouse Liner Replacement - Left Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Left Side). 5. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Glow Plug System > Glow Plug Control Module > Component Information > Diagrams Glow Plug Control Module: Diagrams Component Connector End Views Glow Plug Control Module (GPCM) X1 (Diesel) Glow Plug Control Module (GPCM) X2 (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Glow Plug System > Glow Plug Control Module > Component Information > Diagrams > Page 6065 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Glow Plug System > Glow Plug Control Module > Component Information > Diagrams > Page 6066 Glow Plug Control Module: Service and Repair Glow Plug Control Module Replacement Removal Procedure 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 2. Disconnect the positive battery cable (1) from the glow plug control module. 3. Disconnect the engine wiring harness electrical connector (2) from the glow plug control module. 4. Remove the glow plug control module bolts and module. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Glow Plug System > Glow Plug Control Module > Component Information > Diagrams > Page 6067 5. Remove the fuel return pipe clamp bolt (1). 6. Remove the glow plug control module protector bolts and protector (1), if required. 7. Remove the glow plug control module bracket and bolts (2), if required. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Glow Plug System > Glow Plug Control Module > Component Information > Diagrams > Page 6068 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Position the glow plug control module bracket (2) to the lower valve rocker arm cover and install the bolts, if required. Tighten the bolts to 10 Nm (89 lb in). 2. Position the glow plug control module protector (1) and install the bolts, if required. Tighten the bolts to 10 Nm (89 lb in). 3. Install the fuel return pipe clamp bolt (1). Tighten the bolt to 24 Nm (18 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Glow Plug System > Glow Plug Control Module > Component Information > Diagrams > Page 6069 4. Position the glow plug control module onto the bracket and install the bolts. Tighten the bolts to 10 Nm (89 lb in). 5. Connect the engine wiring harness electrical connector (2) to the glow plug control module. 6. Connect the positive battery cable (1) to the glow plug control module. 7. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 8. If a NEW glow plug control module was installed, program the module. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Glow Plug System > Relays and Modules - Glow Plug System > Glow Plug Control Module > Component Information > Diagrams Glow Plug Control Module: Diagrams Component Connector End Views Glow Plug Control Module (GPCM) X1 (Diesel) Glow Plug Control Module (GPCM) X2 (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Glow Plug System > Relays and Modules - Glow Plug System > Glow Plug Control Module > Component Information > Diagrams > Page 6074 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Glow Plug System > Relays and Modules - Glow Plug System > Glow Plug Control Module > Component Information > Diagrams > Page 6075 Glow Plug Control Module: Service and Repair Glow Plug Control Module Replacement Removal Procedure 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 2. Disconnect the positive battery cable (1) from the glow plug control module. 3. Disconnect the engine wiring harness electrical connector (2) from the glow plug control module. 4. Remove the glow plug control module bolts and module. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Glow Plug System > Relays and Modules - Glow Plug System > Glow Plug Control Module > Component Information > Diagrams > Page 6076 5. Remove the fuel return pipe clamp bolt (1). 6. Remove the glow plug control module protector bolts and protector (1), if required. 7. Remove the glow plug control module bracket and bolts (2), if required. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Glow Plug System > Relays and Modules - Glow Plug System > Glow Plug Control Module > Component Information > Diagrams > Page 6077 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Position the glow plug control module bracket (2) to the lower valve rocker arm cover and install the bolts, if required. Tighten the bolts to 10 Nm (89 lb in). 2. Position the glow plug control module protector (1) and install the bolts, if required. Tighten the bolts to 10 Nm (89 lb in). 3. Install the fuel return pipe clamp bolt (1). Tighten the bolt to 24 Nm (18 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Glow Plug System > Relays and Modules - Glow Plug System > Glow Plug Control Module > Component Information > Diagrams > Page 6078 4. Position the glow plug control module onto the bracket and install the bolts. Tighten the bolts to 10 Nm (89 lb in). 5. Connect the engine wiring harness electrical connector (2) to the glow plug control module. 6. Connect the positive battery cable (1) to the glow plug control module. 7. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 8. If a NEW glow plug control module was installed, program the module. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams Pressure Regulating Solenoid: Diagrams Component Connector End Views Pressure Control (PC) Solenoid Valve (M30) Pressure Control (PC) Solenoid Valve 1 (MW7) Pressure Control (PC) Solenoid Valve 2 (MW7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 6085 Modulated Main Pressure Control (PC) Solenoid Valve (MW7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Service and Repair Shift Interlock Solenoid: Service and Repair Automatic Transmission Shift Lock Control Actuator Replacement Removal Procedure 1. Disable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair). 2. Remove the knee bolster. Refer to Knee Bolster Replacement (With SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (With SLT))Knee Bolster Replacement (Without SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (Without SLT)). 3. Put the shift lever clevis into the neutral position. 4. Disconnect the electrical connector. 5. Using a small screwdriver, pry the automatic transmission shift lock control actuator away from the steering column jacket and the cable shift cam. 6. Remove the shift lock control actuator. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Service and Repair > Page 6089 1. Firmly install the shift lock control actuator onto the steering column jacket and the cable shift cam. 2. Connect the electrical connector. 3. Adjust the shift lock control actuator (with the shift lever clevis in the neutral position) in the following way: 1. Pull out the tab (1) on the adjuster block side (2) of the shift lock control actuator. 2. Press on the adjuster block (2) to compress the internal adjuster spring which disengages the adjuster teeth. Slide the adjuster block (2) as far away from the actuator as possible. 3. Lock the adjuster block (2) in place by pushing in on the tab (1). 4. Inspect the shift lock control actuator for the following items: 1. The shift lock control actuator must lock the shift lever clevis when the shift lever clevis is put into the park position. 2. Depress the brake pedal to move the shift lever out of the park position. 3. The actuator will be energized. 4. Readjust the shift lock control actuator if needed. 5. Install the knee bolster. Refer to Knee Bolster Replacement (With SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (With SLT))Knee Bolster Replacement (Without SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (Without SLT)). 6. Enable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations Shift Solenoid: Locations Disassembled Views Main Valve Body Assembly 1 - Main Valve Body Assembly 2 - Retaining Clip 3 - Exhaust Pressure Regulator Valve Spring 4 Exhaust Pressure Regulator Valve 5 - Retaining Clip 6 - Control Relief Spring 7 - Control Relief Valve 8 - Main Valve Body 9 - Locating Pin (4) 10 - Locating Pin 11 - Pressure Control Solenoid 1 (PCS1) Spring 12 - PCS1 Valve 13 - PCS1 Spring 14 - Trim Gain Valve 15 - PCS1 16 - PCS1 O-Ring 17 - PCS2 Spring 18 - PCS2 Valve 19 - Trim Gain Valve 20 - PCS2 21 - PCS2 O-Ring 22 Shift Solenoid (SS) 3 23 - SS3 O-Ring 24 - SS3 O-Ring 25 - SS2 26 - SS2 O-Ring 27 - SS2 O-Ring Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Page 6093 28 - Torque Converter Clutch Pressure Control Solenoid (TCC PCS) Spring 29 - TCC PCS Valve 31 - TCC PCS 32 - TCC PCS O-Ring 33 - TCC PCS O-Ring 34 - TCC PCS Retaining Bracket 35 - SS2 and SS3 Retainers (2) 36 - Accumulator Plug (2) 37 - Accumulator Spring (2) 38 - PCS1 and PCS2 Retaining Bracket Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Shift Solenoid: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Schematic Symbols Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6096 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6097 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6098 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6099 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6100 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6101 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6102 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6103 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6104 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6105 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6106 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6107 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6108 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6109 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6110 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6111 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6112 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6113 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6114 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6115 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6116 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6117 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6118 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6119 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6120 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6121 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6122 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6123 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6124 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6125 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6126 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6127 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6128 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6129 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6130 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6131 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6132 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6133 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6134 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6135 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6136 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6137 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6138 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6139 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6140 Shift Solenoid: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed with Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6141 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6142 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Connector Test Adapters) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6143 Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Test Lamp) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Fused Jumper Wires) * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage Drop) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Frequency) * Testing Ground and Low Reference Circuits (See: Testing and Inspection/Component Tests and General Diagnostics/Testing Ground and Low Reference Circuits) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fuses) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Circuit Breakers) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fusible Links) Troubleshooting with a Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Testing for a Short to Voltage Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6144 Testing for a Short to Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure tests for a short to voltage in a circuit. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the Digital Multimeter (DMM) to the V (DC) position. 4. Connect the positive lead of the DMM to one end of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. Turn ON the ignition and operate all accessories. 7. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Special Tools J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure). Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents). Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6145 The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the frequency of a signal. Note: Connecting the Digital Multimeter (DMM) to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Set to Hz on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6146 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the Digital Multimeter (DMM). 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the difference in voltage potential between 2 points. 1. Set the Digital Multimeter (DMM) to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6147 Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Backprobe Note: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6148 (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for Continuity Testing for Continuity Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures verify good continuity in a circuit. With a Digital Multimeter (DMM) 1. Set the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Select the MIN MAX function on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6149 Testing for Electrical Intermittents Testing for Electrical Intermittents Special Tools J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. Note: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions). 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6150 visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing for Terminal Fretting Some intermittent conditions can be caused by wire terminal fretting corrosion. Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can pile up enough at the electrical contact spots that the electrical resistance across the connection increases. Movement between the contacting surfaces as small as 10 to 100 microns can cause fretting. To put this in perspective, a sheet of paper is about 100 microns thick, so fretting motion is small and hard to see. Vibration and thermal expansion/contraction are the main sources that create fretting motion. Since vehicles vibrate and can experience large temperature swings, they are a good source for fretting motion. Tin, copper, nickel, and iron surfaces are all susceptible to fretting corrosion. Fretting corrosion can be difficult to see but it looks like small, dark smudges on the terminals contact surface. To correct a fretting condition disconnect the suspect connector and add Nyogel lubricant 760G (dielectric grease) to both sides of the connector terminals. Then reconnect the connector and wipe away any excess lubricant. This will correct the additional terminal contact resistance due to the terminal fretting corrosion. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6151 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics). * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Ground Distribution Schematics). Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Checking Aftermarket Accessories). * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6152 Note: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures test for a short to ground in a circuit. With a Digital Multimeter (DMM) 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohms position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Danger: High voltage circuits should only be tested using a digital multimeter (DMM) and test leads with at least a CAT III rating, such as the J 39200-A Digital Multimeter. Failure to follow the procedures exactly as written may result in serious injury or death. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Digital Multimeter (DMM) Basic Requirements Service information is validated using digital multimeters that meet or exceed the following requirements. Using a multimeter that does not meet these basic requirements may give inaccurate readings which could lead to an incorrect diagnosis. Display and Settings 1. Four digits displayed 2. Voltage, amperage, resistance, frequency, diode test settings, and min-max function 3. Display positive and negative values Voltage 1. Have at least 10 M ohm input impedance Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6153 2. Test a DC voltage range of 0.1-1000 V. 3. Test an AC voltage range of 0.1-1000 V. Amperage 1. Test a DC amperage range of 0.1µA-10 A. 2. Test an AC amperage range of 0.1µA-10 A. Resistance Test a resistance range of 0.1 ohm-40 Mohm and displays infinite for a value greater than 40 M ohm (O.L. (Over-load)) Frequency Test for a frequency range of 0.5 HZ-199 K HZ Diode Test 1. Apply at least 1 mA when performing the diode bias test 2. Display the break over voltage drop (0-3 V) of a forward biased diode 3. Display infinite (O.L. (Over-load)) when a diode is reverse biased Min-Max Readings 1. Can update at a 1 ms sample rate 2. Saves and displays minimum and maximum values Note: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Probe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors). * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the EL-38125-580 GM Approved Terminal Release Tool Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the EL-38125-580 GM Approved Terminal Release Tool Kit , ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the EL-38125-580 GM Approved Terminal Release Tool Kit label on the inside of the EL-38125-580 GM Approved Terminal Release Tool Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6154 Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/EPC Connectors AFL/EPC Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6155 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 3. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6156 View showing depressing of the lever lock release tab. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6157 6. Release the rear lower half of the wiredress cover. 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6158 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6159 Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Bosch Connectors (ECM) Bosch Connectors (ECM) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6160 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. 2. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6161 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-bladed tool to release the locking tabs and remove the dress cover. 4. The terminal positive assurance (TPA) is located in the front of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6162 5. Use a small flat-blade tool to remove TPA from the connector. 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6163 Note: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6164 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6165 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Terminal Replacement Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6166 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6167 5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Position Assurance Locks) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Terminal Position Assurance Locks) * AFL/EPC Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/AFL/EPC Connectors) * Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (BSK))Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (0.64))Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (2.8 JPT))Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (ECM)) * Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Weather Pack))Delphi Connectors (Push To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Push to Seat))Delphi Connectors Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6168 (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Pull to Seat))Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro-Pack 100W))Delphi Connectors (Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro .64))Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (12-Way)) * FCI Connectors (Lever Lock) (See: General Electrical Diagnostic Procedures/Connector Repairs/FCI Connectors (Lever Lock)) * JST Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/JST Connectors) * Kostal Connectors (Glow Plug Control Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Glow Plug Control Module))Kostal Connectors (Transmission) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Transmission)) * Molex Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Molex Connectors) * Sumitomo Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Sumitomo Connectors) * Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (CM 42-Way))Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Sensor))Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (0.25 Cap))Tyco/AMP Connectors (43-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (43-Way))Tyco/AMP Connectors (Door Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Door Module))Tyco/AMP Connectors (102-Way Inline) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (102-Way Inline))Tyco/AMP Connectors (Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Seat))Tyco/AMP Connectors (SIR) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (SIR)) * Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (2-Way))Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (16-Way)) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6169 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6170 * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6171 * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6172 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6173 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6174 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Push to Seat) Delphi Connectors (Push To Seat) Special Tools J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6175 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs). 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Terminated Lead Repair 1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice sleeves depending on the gauge size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Delphi Connectors (Pull to Seat) Delphi Connectors (Pull To Seat) Special Tools Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6176 J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Note: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6177 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. View of a typical Micro 64 connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6178 Depress the lock and pull the lever over and past the lock. View of the connector when released from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6179 View of another type of Micro 64 connector. Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6180 View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6181 Note: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6182 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6183 Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Note: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6184 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6185 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6186 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6187 1. Cut the wire as close to the terminal as possible. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6188 Terminal Replacement Procedure After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Special Tools J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Note: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals). 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12-Way) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6189 Delphi Connectors (12-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6190 4. Release the lower wire dress cover locking tab. 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6191 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6192 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors (Lever Lock) FCI Connectors (Lever Lock) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6193 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. The release tab is located on the top of the wiredress cover. 3. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6194 6. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6195 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6196 1. While depressing the lock, remove the connector from the component. 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6197 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. 4. View of the TPA when removed from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6198 5. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Glow Plug Control Module) Kostal Connectors (Glow Plug Control Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6199 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6200 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6201 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. Note: The front TPA cannot be removed from the connector. Only move it to the preset position. 6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm). 7. Use a small flat-blade tool to completely remove the rear TPA from the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6202 8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Transmission) Kostal Connectors (Transmission) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6203 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6204 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Terminal Replacement Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6205 After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6206 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6207 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6208 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6209 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6210 3. To assemble the connector, reverse the connector disassembly procedure. Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6211 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6212 7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6213 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6214 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6215 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6216 Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6217 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6218 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6219 6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (102-Way Inline) Tyco/AMP Connectors (102-Way Inline) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6220 View of a typical connector in the assembled position. 1. Pull the locking lever to the 90 degree position from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6221 2. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal. 3. Slide the male connector body out away from the guide plates. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6222 Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 4. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. 5. Using terminal release tool J 38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6223 6. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 7. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6224 8. The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool J-38125-11A or equivalent to release the locking tab and slide the connector off the female body. 9. Move the locking lever 180 degrees from the connected position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6225 10. With the locking lever in the 180 degree position the guide plates can be removed from the connector body. Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 11. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6226 12. Using terminal release tool J 38125-216, lift the terminal plate past the terminals and out of the connector body cavity. 13. Terminal plate will bind slightly on each corner. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6227 14. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 15. Using terminal release tool J 38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6228 16. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 17. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6229 18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever. 19. Slide the male connector body back inward toward the guide plates. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6230 20. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly. 21. Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Seat) Tyco/AMP Connectors (Seat) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6231 Removal Procedure 1. Grasp the locking slide lever and pull outward from the end of the connector. 2. As the slide lever is pulled out the mating connector is lifted from the seated position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6232 Note: TPA is keyed and can only be inserted in one direction. 3. Using terminal release tool J 38125-11A or equivalent, push the TPA tabs into the connector body. 4. Pull the TPA from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6233 5. Using terminal release tool J 38125-11A or equivalent, release the connector wire dress cover locking tab. 6. With the lock tab released, lift the connector wire dress cover from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6234 7. Using terminal release tool J 38125-212, press the prongs into the holes each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 8. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6235 9. Using terminal release tool J 38125-556, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (SIR) Tyco/AMP Connectors (SIR) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6236 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6237 3. Using terminal tool J-38125-11A or equivalent, release the wire dress cover locking tabs. 4. Pivot connector wire dress cover while removing from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6238 5. Using terminal tool J-38125-11A or equivalent, remove the TPA by lifting straight off the connector body. 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals Repairing Connector Terminals Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6239 Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gauge size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6240 2. Disconnect the connector from the component. 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6241 4. Relieve the tension on the nose piece retainers by inserting J 38125-12A into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. 5. Once the nose piece retainers are relaxed, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6242 6. On the opposite side of the nose piece, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6243 8. Insert the J 38125-553 tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6244 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. If the TPA is removed, be sure to reinstall it before reconnecting the connector. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6245 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Special Tools Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6246 J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Note: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6247 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6248 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6249 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6250 1. While depressing the lock, pull the two connector halves apart. Note: The TPA is fragile and may break if not done carefully. 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. 3. View of the male half of the connector with female terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6251 4. View of the female half of the connector with male terminals. 5. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. View of the female half of the connector with male terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6252 7. View of the male half of the connector with female terminals. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6253 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are a one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine if the element in the fuse is broken (2). If not broken (1), also check for continuity using a Digital Multimeter (DMM) or a continuity tester. If the element is broken or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a Digital Multimeter (DMM) at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gauge size. Repairing a Fusible Link Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6254 Flat Wire Repairs The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Special Tools J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool * J 38125-5 Ultra Torch Special Tool The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Note: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Computers and Control Systems/Information Bus/Description and Operation). GMLAN Connector Terminal Repair Note: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) for the appropriate connector repair procedure. GMLAN Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6255 Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6256 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Special Tools J-38125 Terminal Repair Kit Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6257 repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs High Temperature Wiring Repairs Special Tools J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gauge size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6258 splice. Note: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6259 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6260 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the wire insulation has been chafed, or broken, enough to show the conductive portion of the wire, and the wire is not damaged, determine the length of insulation that needs to be repaired. If the repair is less than 280 mm (11 in), cut the wire within the damaged area. Then slide the appropriate heat shrink tubing (listed below) over the wire, and repair the wire by splicing the wires together. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Once the wire is spliced together slide heat shrink tubing over the damaged area and apply heat to seal the repaired wire. If the wire is damaged, or the damaged area is larger than 280 mm (11 in), then replace the damaged wire by splicing in a new section of wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6261 SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Special Tools J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6262 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6263 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6264 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Special Tools J-38125 Terminal Repair Kit Note: Use only DuraSeal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use DuraSeal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use DuraSeal splice sleeves where there are special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6265 * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6266 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6267 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the instructions for Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Staggering the splices by 65 mm (2.5 in) is recommended. Note: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product AL-36FR to replace the damaged mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Flat Wire Repairs) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/GMLAN Wiring Repairs) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Heated Oxygen Sensor Wiring Repairs) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves) * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Twisted or Shielded Cable) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Inline Harness Diodes) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/SIR/SRS Wiring Repairs) US English/Metric Conversion US English/Metric Conversion Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6268 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6269 Testing Ground and Low Reference Circuits Testing Ground and Low Reference Circuits Because a test lamp can light with up to 200 ohm in a ground or low reference circuit they are not recommended to be used for this type of test. A low impedance test lamp can light and indicate the circuit is good when there is as much as 20-30 ohm present, while a high impedance test lamp can light with up to 200 ohm present in the circuit. This is why the Digital Multi-Meter (DMM) is used when validating a ground or low reference circuit continuity. When using the DMM there are many vehicle conditions that can affect the ground and low reference continuity testing. If these conditions are not met, a ground or low reference circuit test can fail on a good circuit. This may cause longer diagnosis time and incorrect component replacement. Any current flow through a ground or low reference circuit, while being tested, will skew the DMM continuity reading, or display a reading higher than when there is no current flowing. Performing a ground or low reference circuit continuity test, in reference to the vehicles battery negative terminal, will have the highest risk of failing a good ground or low reference circuit test than any other ground reference point. The best ground test points would be a control module housing (if the control modules housing is metal and grounded), door jamb striker (if attached to metal), under dash metal frame work, engine block, or body ground studs (other than where the negative battery cable is attached). A typical DMM ground or low reference circuit continuity reading can be as high as 100 ohm with the ignition ON, and drop to 15-25 ohm after the ignition is turned OFF. The reading will drop below 10 ohm after 30-40 seconds, then below 5 ohm after 60 seconds. Once the vehicle completely goes to sleep (generally 3-10 minutes) the reading will drop below 0.3 ohm. The following list of conditions may need to be met to ensure a valid continuity reading on a ground or low reference circuit: * Ignition OFF * Key out of the ignition switch (when not equipped with keyless entry and remote start) * Retained Accessory Power (RAP) OFF (open and close the driver door after ignition OFF) * Battery charger set at a 2 A or less charge rate * Scan tool not communicating with any vehicle control module (in some cases it may need to be disconnected from the DLC) * All entry doors closed * Headlamps OFF (auto headlamps disabled) * Any delay lighting OFF * HVAC after blow OFF * Any accessory that can work when the ignition is OFF * Wait up to 60 seconds (after all other listed conditions are met) Activating the DOOR LOCK function with a key fob can greatly reduce the time to achieve a valid ground or low reference continuity test result. Terminal Removal Terminal Removal Special Tools * EL-38125-580 - Terminal Release Tool Kit * EL-35616 - Connector Test Adapter Kit For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repair procedures. 1. Find the appropriate connector end view within the connector end view section. The connector end view has the following information: Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6270 * Diagnostic probe tool * Terminal release tool * Terminal/terminated lead part numbers Note: Not using the proper test kit probe may cause damage to the terminal(s) that are probed. 2. Determine if a terminal is damaged. * Locate the diagnostic probe tool from the connector end view. The connector end view describes the color and part number to help the technician find and use the correct tool. * Connect the probe tool to the Digital Multimeter. * Insert the probe tool into the cavity and follow the procedures from the Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter). 3. Disconnect the connector body to perform the repair. 4. Use the following procedure to remove the terminal from the connector body. Note: Several procedures for specific connector bodies are called out in the Wiring Repairs section. * The terminal position assurance (TPA) and connector position assurance (CPA) should be removed before releasing the terminal for the connector body. * Look at the connector end view to locate the cavity of the damaged terminal and find the proper terminal release tool from the terminal release tool kit. Note: Using the incorrect terminal release tool can damage the connector body. * Insert the terminal release tool into the cavity. Note: Some terminals have a lever that must be disengaged before the terminal can be released. 5. Gently pull the wire out of the back of the connector. 6. Repair the terminal by following the Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) procedure. 7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminated Lead Repair Terminated Lead Repair Special Tools * J-38125-8 - Splice Sleeve Crimp Tool Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6271 * J-38125-5 - Ultra Torch For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) procedures. Terminated leads are terminals that are crimped onto wires. The terminated lead can be used throughout the vehicle since it is designed for temperatures up to 150°C. The length of the wire is 450 mm. The DuraSeal splice sleeve has the following 2 critical features: * A special heat shrink tubing that environmentally seals the splice. The shrink tubing contains a sealing adhesive inside the shrink tubing. * A cross hatched (knurled) core crimp that provides the necessary contact integrity for sensitive low energy circuits. 1. Use the connector end view to identify the correct terminated lead. 2. The terminated lead package should include a DuraSeal splice sleeve. If not, use the chart to identify the correct part. 3. Open the harness by removing any tape: Use a sewing seam ripper, or a comparable tool, to cut open the harness, to avoid wire insulation damage. 4. Depending on how many terminals need repairs, cut the terminal and wire back at least 40 mm. Try to keep the harness wire length the same. If more than one terminated lead is required, stagger the lengths by 40 mm. This helps reduce the bundle size of the wire harness. 5. Use the EL-38125-10 - tool in order to position the DuraSeal splice sleeve in the proper color nest of the splice sleeve crimp tool. The crimp tool has four nests, one for each color. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6272 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the J-38125-5 - ultra torch , apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6273 Shift Solenoid: Connector Views Component Connector End Views Control Solenoid Valve Assembly X1 (MYC, MYD or M99) Control Solenoid Valve Assembly X2 (MYC, MYD or M99) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6274 Control Solenoid Valve Assembly X3 (MYC, MYD or M99) 1-2 Shift Solenoid (SS) Valve (M30) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6275 2-3 Shift Solenoid (SS) Valve (M30) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6276 Shift Solenoid (SS) Valve 1 (MW7) Shift Solenoid (SS) Valve 2 (MW7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6277 Shift Solenoid (SS) Valve 3 (MW7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > Control Valve Solenoid Replacement (PCS1 and PCS2) Shift Solenoid: Service and Repair Control Valve Solenoid Replacement (PCS1 and PCS2) Control Valve Solenoid Replacement (PCS1 and PCS2) Removal Procedure 1. Remove the oil pan and transmission internal oil filter. Refer to Oil Pan Replacement (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Fluid Pan/Service and Repair). 2. Disconnect the internal wiring harness from the solenoid being changed. 3. Remove the 2 bolts that fasten reverse signal pipe (1) to the control valve assembly. Remove the reverse signal pipe. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > Control Valve Solenoid Replacement (PCS1 and PCS2) > Page 6280 Note: * When the pressure control valve retaining bracket (5) is removed, there are 2 sets of accumulators (3) and springs (6) which may fall from the bores. Be sure to catch the accumulators and springs so as to prevent damage to these parts. * The pressure control valve retaining bracket (5) must not be modified. Note that the angle between the 2 bracket surfaces is less than 90 degrees. Replace the bracket if the angle is 90 degrees or more. 4. To remove the pressure control solenoid 1 (PCS1) or PCS2, remove three bolts (4) and the pressure control valve retaining bracket (5). Remove accumulators (3) and springs (6) if they do not fall out when the bracket (5) is removed. 5. Note the position of the solenoid connector and pull the solenoid (1) or (8) out of the bore in the control valve assembly. The O-ring on the solenoid provides the resistance felt during removal. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > Control Valve Solenoid Replacement (PCS1 and PCS2) > Page 6281 1. Obtain the new solenoid (1) or (8). Lubricate new O-ring (2) or (7) with clean transmission fluid. Install the O-ring and push the new solenoid into the control valve body bore with the wiring harness connector in the correct position. 2. Install the 2 accumulators (3) and springs (6) before installing the pressure control valve retaining bracket (5). The valve (3) goes in the bore first with the hollow end facing outward, followed by the spring (6) which goes inside the hollow portion of the valve. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the pressure control valve retaining bracket (5), and install the 3 bolts (4). Tighten the bolts to 12 Nm (108 lb in). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > Control Valve Solenoid Replacement (PCS1 and PCS2) > Page 6282 4. Install the reverse signal pipe (1). Install the 2 bolts that fasten reverse signal pipe to the control valve assembly. Tighten the bolts to 12 Nm (108 lb in). 5. Reconnect the internal wiring harness to the solenoid. 6. Install the oil pan and transmission internal oil filter. Refer to Oil Pan Replacement (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Fluid Pan/Service and Repair). Note: The FastLearn, adapt, procedure must be performed. This can be done in 1 step using a scan tool. If this procedure is not done, the TCM adaptive values will be at the settings that it learned for the old components and will be in slow adaptive mode. Under these conditions, it will take an unacceptably long time for the adaptive values to converge to levels suitable for the new transmission. 7. Perform the FastLearn procedure. Refer to FastLearn Procedure (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Testing and Inspection/Programming and Relearning). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > Control Valve Solenoid Replacement (PCS1 and PCS2) > Page 6283 Shift Solenoid: Service and Repair Control Valve Solenoid Replacement (SS1, SS2, SS3, TCC, and MAIN MOD) Control Valve Solenoid Replacement (SS1, SS2, SS3, TCC, and MAIN MOD) Removal Procedure 1. Remove the oil pan and the transmission internal oil filter. Refer to Oil Pan Replacement (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Fluid Pan/Service and Repair). 2. Disconnect the internal wiring harness from the solenoid being changed. 3. Remove the solenoid retainer (2) for shift solenoid 1 (SS1) (5). Note the position of the solenoid connector and pull the solenoid (5) out of the bore in the control valve assembly (1). The O-rings (3 and 4) provide the resistance felt during removal. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > Control Valve Solenoid Replacement (PCS1 and PCS2) > Page 6284 4. Remove the solenoid retainer (6) for shift solenoid 2 (SS2) (1) or shift solenoid 3 (SS3) (4), whichever is being replaced. 5. Note the position of the solenoid connector and pull the solenoid out of the bore in the control valve assembly. The O-rings (2 and 3) provide the resistance felt during removal. Note: The TCC pressure control solenoid (PCS) retaining bracket must not be modified. Note that the angle between the 2 bracket surfaces is less than 90 degrees. Replace the bracket if the angle is 90 degrees or greater. 6. Remove the TCC PCS retaining bolt and retaining bracket. 7. Remove the TCC PCS (7). Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > Control Valve Solenoid Replacement (PCS1 and PCS2) > Page 6285 1. Obtain a new SS 2 (1), SS 3 (4), TCC PCS (7), or modulated main pressure solenoid. Install O-rings (2 and 3) and lubricate with clean transmission fluid. Push the new solenoid into the control valve assembly (5) with the wiring harness connector in the correct position. 2. Install the solenoid retainer (6). Connect the internal wiring harness to the solenoids replaced. 3. For a new TCC PCS (7), install O-rings and lubricate with clean transmission fluid. Push the new TCC PCS (7) into the control valve assembly with the wiring harness connector in the correct position. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the TCC PCS retainer and bolt. Tighten the bolt to 12 Nm (108 lb in). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > Control Valve Solenoid Replacement (PCS1 and PCS2) > Page 6286 5. For a new SS 1 (5), install O-rings (3 and 4) and lubricate with clean transmission fluid. Push the new SS 1 (5) into the control valve assembly with the wiring harness connector in the correct position. Install the solenoid retainer (2). 6. Install the oil pan and transmission internal oil filter. Refer to Oil Pan Replacement (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Fluid Pan/Service and Repair). Note: The FastLearn, adapt, procedure must be performed. This can be done in 1 step using a scan tool. If this procedure is not done, the TCM adaptive values will be at the settings that it learned for the old components and will be in slow adaptive mode. Under these conditions, it will take an unacceptably long time for the adaptive values to converge to levels suitable for the new transmission. 7. Perform the FastLearn procedure. Refer to FastLearn Procedure (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Testing and Inspection/Programming and Relearning). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Torque Converter Clutch Solenoid: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Schematic Symbols Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6291 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6292 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6293 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6294 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6295 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6296 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6297 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6298 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6299 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6300 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6301 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6302 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6303 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6304 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6305 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6306 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6307 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6308 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6309 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6310 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6311 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6312 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6313 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6314 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6315 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6316 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6317 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6318 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6319 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6320 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6321 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6322 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6323 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6324 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6325 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6326 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6327 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6328 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6329 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6330 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6331 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6332 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6333 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6334 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6335 Torque Converter Clutch Solenoid: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed with Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6336 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6337 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Connector Test Adapters) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6338 Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Test Lamp) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Fused Jumper Wires) * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage Drop) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Frequency) * Testing Ground and Low Reference Circuits (See: Testing and Inspection/Component Tests and General Diagnostics/Testing Ground and Low Reference Circuits) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fuses) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Circuit Breakers) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fusible Links) Troubleshooting with a Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Testing for a Short to Voltage Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6339 Testing for a Short to Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure tests for a short to voltage in a circuit. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the Digital Multimeter (DMM) to the V (DC) position. 4. Connect the positive lead of the DMM to one end of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. Turn ON the ignition and operate all accessories. 7. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Special Tools J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure). Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents). Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6340 The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the frequency of a signal. Note: Connecting the Digital Multimeter (DMM) to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Set to Hz on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6341 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the Digital Multimeter (DMM). 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the difference in voltage potential between 2 points. 1. Set the Digital Multimeter (DMM) to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6342 Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Backprobe Note: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6343 (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for Continuity Testing for Continuity Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures verify good continuity in a circuit. With a Digital Multimeter (DMM) 1. Set the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Select the MIN MAX function on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6344 Testing for Electrical Intermittents Testing for Electrical Intermittents Special Tools J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. Note: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions). 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6345 visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing for Terminal Fretting Some intermittent conditions can be caused by wire terminal fretting corrosion. Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can pile up enough at the electrical contact spots that the electrical resistance across the connection increases. Movement between the contacting surfaces as small as 10 to 100 microns can cause fretting. To put this in perspective, a sheet of paper is about 100 microns thick, so fretting motion is small and hard to see. Vibration and thermal expansion/contraction are the main sources that create fretting motion. Since vehicles vibrate and can experience large temperature swings, they are a good source for fretting motion. Tin, copper, nickel, and iron surfaces are all susceptible to fretting corrosion. Fretting corrosion can be difficult to see but it looks like small, dark smudges on the terminals contact surface. To correct a fretting condition disconnect the suspect connector and add Nyogel lubricant 760G (dielectric grease) to both sides of the connector terminals. Then reconnect the connector and wipe away any excess lubricant. This will correct the additional terminal contact resistance due to the terminal fretting corrosion. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6346 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics). * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Ground Distribution Schematics). Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Checking Aftermarket Accessories). * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6347 Note: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures test for a short to ground in a circuit. With a Digital Multimeter (DMM) 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohms position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Danger: High voltage circuits should only be tested using a digital multimeter (DMM) and test leads with at least a CAT III rating, such as the J 39200-A Digital Multimeter. Failure to follow the procedures exactly as written may result in serious injury or death. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Digital Multimeter (DMM) Basic Requirements Service information is validated using digital multimeters that meet or exceed the following requirements. Using a multimeter that does not meet these basic requirements may give inaccurate readings which could lead to an incorrect diagnosis. Display and Settings 1. Four digits displayed 2. Voltage, amperage, resistance, frequency, diode test settings, and min-max function 3. Display positive and negative values Voltage 1. Have at least 10 M ohm input impedance Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6348 2. Test a DC voltage range of 0.1-1000 V. 3. Test an AC voltage range of 0.1-1000 V. Amperage 1. Test a DC amperage range of 0.1µA-10 A. 2. Test an AC amperage range of 0.1µA-10 A. Resistance Test a resistance range of 0.1 ohm-40 Mohm and displays infinite for a value greater than 40 M ohm (O.L. (Over-load)) Frequency Test for a frequency range of 0.5 HZ-199 K HZ Diode Test 1. Apply at least 1 mA when performing the diode bias test 2. Display the break over voltage drop (0-3 V) of a forward biased diode 3. Display infinite (O.L. (Over-load)) when a diode is reverse biased Min-Max Readings 1. Can update at a 1 ms sample rate 2. Saves and displays minimum and maximum values Note: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Probe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors). * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the EL-38125-580 GM Approved Terminal Release Tool Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the EL-38125-580 GM Approved Terminal Release Tool Kit , ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the EL-38125-580 GM Approved Terminal Release Tool Kit label on the inside of the EL-38125-580 GM Approved Terminal Release Tool Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6349 Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/EPC Connectors AFL/EPC Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6350 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 3. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6351 View showing depressing of the lever lock release tab. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6352 6. Release the rear lower half of the wiredress cover. 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6353 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6354 Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Bosch Connectors (ECM) Bosch Connectors (ECM) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6355 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. 2. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6356 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-bladed tool to release the locking tabs and remove the dress cover. 4. The terminal positive assurance (TPA) is located in the front of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6357 5. Use a small flat-blade tool to remove TPA from the connector. 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6358 Note: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6359 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6360 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Terminal Replacement Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6361 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6362 5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Position Assurance Locks) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Terminal Position Assurance Locks) * AFL/EPC Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/AFL/EPC Connectors) * Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (BSK))Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (0.64))Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (2.8 JPT))Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (ECM)) * Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Weather Pack))Delphi Connectors (Push To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Push to Seat))Delphi Connectors Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6363 (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Pull to Seat))Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro-Pack 100W))Delphi Connectors (Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro .64))Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (12-Way)) * FCI Connectors (Lever Lock) (See: General Electrical Diagnostic Procedures/Connector Repairs/FCI Connectors (Lever Lock)) * JST Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/JST Connectors) * Kostal Connectors (Glow Plug Control Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Glow Plug Control Module))Kostal Connectors (Transmission) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Transmission)) * Molex Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Molex Connectors) * Sumitomo Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Sumitomo Connectors) * Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (CM 42-Way))Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Sensor))Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (0.25 Cap))Tyco/AMP Connectors (43-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (43-Way))Tyco/AMP Connectors (Door Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Door Module))Tyco/AMP Connectors (102-Way Inline) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (102-Way Inline))Tyco/AMP Connectors (Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Seat))Tyco/AMP Connectors (SIR) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (SIR)) * Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (2-Way))Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (16-Way)) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6364 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6365 * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6366 * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6367 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6368 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6369 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Push to Seat) Delphi Connectors (Push To Seat) Special Tools J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6370 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs). 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Terminated Lead Repair 1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice sleeves depending on the gauge size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Delphi Connectors (Pull to Seat) Delphi Connectors (Pull To Seat) Special Tools Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6371 J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Note: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6372 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. View of a typical Micro 64 connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6373 Depress the lock and pull the lever over and past the lock. View of the connector when released from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6374 View of another type of Micro 64 connector. Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6375 View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6376 Note: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6377 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6378 Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Note: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6379 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6380 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6381 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6382 1. Cut the wire as close to the terminal as possible. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6383 Terminal Replacement Procedure After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Special Tools J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Note: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals). 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12-Way) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6384 Delphi Connectors (12-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6385 4. Release the lower wire dress cover locking tab. 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6386 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6387 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors (Lever Lock) FCI Connectors (Lever Lock) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6388 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. The release tab is located on the top of the wiredress cover. 3. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6389 6. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6390 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6391 1. While depressing the lock, remove the connector from the component. 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6392 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. 4. View of the TPA when removed from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6393 5. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Glow Plug Control Module) Kostal Connectors (Glow Plug Control Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6394 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6395 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6396 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. Note: The front TPA cannot be removed from the connector. Only move it to the preset position. 6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm). 7. Use a small flat-blade tool to completely remove the rear TPA from the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6397 8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Transmission) Kostal Connectors (Transmission) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6398 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6399 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Terminal Replacement Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6400 After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6401 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6402 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6403 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6404 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6405 3. To assemble the connector, reverse the connector disassembly procedure. Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6406 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6407 7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6408 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6409 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6410 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6411 Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6412 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6413 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6414 6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (102-Way Inline) Tyco/AMP Connectors (102-Way Inline) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6415 View of a typical connector in the assembled position. 1. Pull the locking lever to the 90 degree position from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6416 2. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal. 3. Slide the male connector body out away from the guide plates. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6417 Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 4. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. 5. Using terminal release tool J 38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6418 6. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 7. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6419 8. The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool J-38125-11A or equivalent to release the locking tab and slide the connector off the female body. 9. Move the locking lever 180 degrees from the connected position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6420 10. With the locking lever in the 180 degree position the guide plates can be removed from the connector body. Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 11. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6421 12. Using terminal release tool J 38125-216, lift the terminal plate past the terminals and out of the connector body cavity. 13. Terminal plate will bind slightly on each corner. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6422 14. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 15. Using terminal release tool J 38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6423 16. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 17. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6424 18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever. 19. Slide the male connector body back inward toward the guide plates. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6425 20. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly. 21. Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Seat) Tyco/AMP Connectors (Seat) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6426 Removal Procedure 1. Grasp the locking slide lever and pull outward from the end of the connector. 2. As the slide lever is pulled out the mating connector is lifted from the seated position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6427 Note: TPA is keyed and can only be inserted in one direction. 3. Using terminal release tool J 38125-11A or equivalent, push the TPA tabs into the connector body. 4. Pull the TPA from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6428 5. Using terminal release tool J 38125-11A or equivalent, release the connector wire dress cover locking tab. 6. With the lock tab released, lift the connector wire dress cover from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6429 7. Using terminal release tool J 38125-212, press the prongs into the holes each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 8. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6430 9. Using terminal release tool J 38125-556, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (SIR) Tyco/AMP Connectors (SIR) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6431 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6432 3. Using terminal tool J-38125-11A or equivalent, release the wire dress cover locking tabs. 4. Pivot connector wire dress cover while removing from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6433 5. Using terminal tool J-38125-11A or equivalent, remove the TPA by lifting straight off the connector body. 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals Repairing Connector Terminals Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6434 Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gauge size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6435 2. Disconnect the connector from the component. 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6436 4. Relieve the tension on the nose piece retainers by inserting J 38125-12A into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. 5. Once the nose piece retainers are relaxed, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6437 6. On the opposite side of the nose piece, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6438 8. Insert the J 38125-553 tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6439 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. If the TPA is removed, be sure to reinstall it before reconnecting the connector. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6440 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Special Tools Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6441 J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Note: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6442 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6443 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6444 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6445 1. While depressing the lock, pull the two connector halves apart. Note: The TPA is fragile and may break if not done carefully. 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. 3. View of the male half of the connector with female terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6446 4. View of the female half of the connector with male terminals. 5. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. View of the female half of the connector with male terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6447 7. View of the male half of the connector with female terminals. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6448 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are a one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine if the element in the fuse is broken (2). If not broken (1), also check for continuity using a Digital Multimeter (DMM) or a continuity tester. If the element is broken or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a Digital Multimeter (DMM) at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gauge size. Repairing a Fusible Link Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6449 Flat Wire Repairs The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Special Tools J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool * J 38125-5 Ultra Torch Special Tool The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Note: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Computers and Control Systems/Information Bus/Description and Operation). GMLAN Connector Terminal Repair Note: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) for the appropriate connector repair procedure. GMLAN Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6450 Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6451 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Special Tools J-38125 Terminal Repair Kit Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6452 repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs High Temperature Wiring Repairs Special Tools J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gauge size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6453 splice. Note: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6454 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6455 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the wire insulation has been chafed, or broken, enough to show the conductive portion of the wire, and the wire is not damaged, determine the length of insulation that needs to be repaired. If the repair is less than 280 mm (11 in), cut the wire within the damaged area. Then slide the appropriate heat shrink tubing (listed below) over the wire, and repair the wire by splicing the wires together. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Once the wire is spliced together slide heat shrink tubing over the damaged area and apply heat to seal the repaired wire. If the wire is damaged, or the damaged area is larger than 280 mm (11 in), then replace the damaged wire by splicing in a new section of wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6456 SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Special Tools J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6457 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6458 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6459 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Special Tools J-38125 Terminal Repair Kit Note: Use only DuraSeal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use DuraSeal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use DuraSeal splice sleeves where there are special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6460 * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6461 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6462 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the instructions for Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Staggering the splices by 65 mm (2.5 in) is recommended. Note: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product AL-36FR to replace the damaged mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Flat Wire Repairs) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/GMLAN Wiring Repairs) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Heated Oxygen Sensor Wiring Repairs) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves) * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Twisted or Shielded Cable) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Inline Harness Diodes) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/SIR/SRS Wiring Repairs) US English/Metric Conversion US English/Metric Conversion Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6463 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6464 Testing Ground and Low Reference Circuits Testing Ground and Low Reference Circuits Because a test lamp can light with up to 200 ohm in a ground or low reference circuit they are not recommended to be used for this type of test. A low impedance test lamp can light and indicate the circuit is good when there is as much as 20-30 ohm present, while a high impedance test lamp can light with up to 200 ohm present in the circuit. This is why the Digital Multi-Meter (DMM) is used when validating a ground or low reference circuit continuity. When using the DMM there are many vehicle conditions that can affect the ground and low reference continuity testing. If these conditions are not met, a ground or low reference circuit test can fail on a good circuit. This may cause longer diagnosis time and incorrect component replacement. Any current flow through a ground or low reference circuit, while being tested, will skew the DMM continuity reading, or display a reading higher than when there is no current flowing. Performing a ground or low reference circuit continuity test, in reference to the vehicles battery negative terminal, will have the highest risk of failing a good ground or low reference circuit test than any other ground reference point. The best ground test points would be a control module housing (if the control modules housing is metal and grounded), door jamb striker (if attached to metal), under dash metal frame work, engine block, or body ground studs (other than where the negative battery cable is attached). A typical DMM ground or low reference circuit continuity reading can be as high as 100 ohm with the ignition ON, and drop to 15-25 ohm after the ignition is turned OFF. The reading will drop below 10 ohm after 30-40 seconds, then below 5 ohm after 60 seconds. Once the vehicle completely goes to sleep (generally 3-10 minutes) the reading will drop below 0.3 ohm. The following list of conditions may need to be met to ensure a valid continuity reading on a ground or low reference circuit: * Ignition OFF * Key out of the ignition switch (when not equipped with keyless entry and remote start) * Retained Accessory Power (RAP) OFF (open and close the driver door after ignition OFF) * Battery charger set at a 2 A or less charge rate * Scan tool not communicating with any vehicle control module (in some cases it may need to be disconnected from the DLC) * All entry doors closed * Headlamps OFF (auto headlamps disabled) * Any delay lighting OFF * HVAC after blow OFF * Any accessory that can work when the ignition is OFF * Wait up to 60 seconds (after all other listed conditions are met) Activating the DOOR LOCK function with a key fob can greatly reduce the time to achieve a valid ground or low reference continuity test result. Terminal Removal Terminal Removal Special Tools * EL-38125-580 - Terminal Release Tool Kit * EL-35616 - Connector Test Adapter Kit For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repair procedures. 1. Find the appropriate connector end view within the connector end view section. The connector end view has the following information: Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6465 * Diagnostic probe tool * Terminal release tool * Terminal/terminated lead part numbers Note: Not using the proper test kit probe may cause damage to the terminal(s) that are probed. 2. Determine if a terminal is damaged. * Locate the diagnostic probe tool from the connector end view. The connector end view describes the color and part number to help the technician find and use the correct tool. * Connect the probe tool to the Digital Multimeter. * Insert the probe tool into the cavity and follow the procedures from the Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter). 3. Disconnect the connector body to perform the repair. 4. Use the following procedure to remove the terminal from the connector body. Note: Several procedures for specific connector bodies are called out in the Wiring Repairs section. * The terminal position assurance (TPA) and connector position assurance (CPA) should be removed before releasing the terminal for the connector body. * Look at the connector end view to locate the cavity of the damaged terminal and find the proper terminal release tool from the terminal release tool kit. Note: Using the incorrect terminal release tool can damage the connector body. * Insert the terminal release tool into the cavity. Note: Some terminals have a lever that must be disengaged before the terminal can be released. 5. Gently pull the wire out of the back of the connector. 6. Repair the terminal by following the Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) procedure. 7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminated Lead Repair Terminated Lead Repair Special Tools * J-38125-8 - Splice Sleeve Crimp Tool Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6466 * J-38125-5 - Ultra Torch For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) procedures. Terminated leads are terminals that are crimped onto wires. The terminated lead can be used throughout the vehicle since it is designed for temperatures up to 150°C. The length of the wire is 450 mm. The DuraSeal splice sleeve has the following 2 critical features: * A special heat shrink tubing that environmentally seals the splice. The shrink tubing contains a sealing adhesive inside the shrink tubing. * A cross hatched (knurled) core crimp that provides the necessary contact integrity for sensitive low energy circuits. 1. Use the connector end view to identify the correct terminated lead. 2. The terminated lead package should include a DuraSeal splice sleeve. If not, use the chart to identify the correct part. 3. Open the harness by removing any tape: Use a sewing seam ripper, or a comparable tool, to cut open the harness, to avoid wire insulation damage. 4. Depending on how many terminals need repairs, cut the terminal and wire back at least 40 mm. Try to keep the harness wire length the same. If more than one terminated lead is required, stagger the lengths by 40 mm. This helps reduce the bundle size of the wire harness. 5. Use the EL-38125-10 - tool in order to position the DuraSeal splice sleeve in the proper color nest of the splice sleeve crimp tool. The crimp tool has four nests, one for each color. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6467 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the J-38125-5 - ultra torch , apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6468 Torque Converter Clutch Solenoid: Connector Views Component Connector End Views Torque Converter Clutch (TCC) Pressure Control (PC) Solenoid Valve (MW7) Torque Converter Clutch (TCC) Pulse Width Modulated (PWM) Solenoid Valve (M30) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6469 Torque Converter Clutch (TCC) Solenoid Valve (M30) Wiring Diagram Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Differential > Actuator, Differential Lock > Component Information > Service and Repair Actuator: Service and Repair Front Drive Axle Actuator Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the engine shield, if equipped. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement). 3. Disconnect the electrical connector from the actuator. 4. Remove the actuator (1) for the 8.25 inch axle (2) or (3) for the 9.5 inch axle (4) by turning the actuator counterclockwise. Installation Procedure 1. Apply sealant to the threads of the actuator (1) for the 8.25 inch axle (2) or (3) for the 9.25 inch axle (4). Use the correct sealant. Refer to Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Differential > Actuator, Differential Lock > Component Information > Service and Repair > Page 6474 Adhesives, Fluids, Lubricants, and Sealers (See: Maintenance/Fluids/Fluid Differential/Specifications/Fluid Type Specifications). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the actuator (1 or 3). Tighten the actuator to 20 Nm (15 lb ft). 3. Connect the electrical connector to the actuator. 4. Install the engine shield, if equipped. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement). 5. Lower the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams Transfer Case Actuator: Diagrams Component Connector End Views Transfer Case Encoder Motor (NQF or NQH) Front Drive Axle Actuator (NQF, NQG or NQH) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Page 6479 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case Transfer Case Actuator: Service and Repair MP 1625/1626-NQF - Transfer Case Transfer Case Two/Four Wheel Drive Actuator Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case > Page 6482 Transfer Case Actuator: Service and Repair MP 3023/3024-NQH - Transfer Case Transfer Case Two/Four Wheel Drive Actuator Position Sensor Replacement Transfer Case Two/Four Wheel Drive Actuator Position Sensor Replacement Transfer Case Two/Four Wheel Drive Actuator Replacement Transfer Case Two/Four Wheel Drive Actuator Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case > Page 6483 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON Control Module: Customer Interest A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 6494 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 6495 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 6496 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON Control Module: All Technical Service Bulletins A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 6502 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 6503 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 6504 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 6505 Control Module: Locations Harness Routing Views Engine Chassis Harness Routing - Top Front (Diesel) 1 - Battery - Right 2 - Fuse Holder 3 - X127 4 - X108 5 - X107 6 - X123 (PTO) 7 - Fuse Block Underhood 8 - X109 9 - Battery - Left 10 - Engine Control Module (ECM) 11 - Transmission Control Module (TCM) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 6506 Control Module: Diagrams Component Connector End Views Transmission Control Module (TCM) (M30) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 6507 Transmission Control Module (TCM) (MW7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 6508 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 6509 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 6510 Control Module: Service and Repair Transmission Control Module Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Power Take-Off > Power Take-Off Relay > Component Information > Diagrams Power Take-Off Relay: Diagrams Component Connector End Views Power Take Off (PTO) Relay (PTO) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams Control Module: Diagrams Component Connector End Views Transfer Case Shift Control Module X1 (NQF or NQH) Transfer Case Shift Control Module X2 (NQF or NQH) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Page 6519 Transfer Case Shift Control Module X3 (NQF or NQH) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Page 6520 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case Control Module: Service and Repair MP 1625/1626-NQF - Transfer Case Transfer Case Shift Control Module Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case > Page 6523 Control Module: Service and Repair MP 3023/3024-NQH - Transfer Case Transfer Case Shift Control Module Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations Fluid Pressure Sensor/Switch: Locations Disassembled Views Control Valve Body Assembly 1 - Control Valve Body Assembly 2 - Shift Valve Body Assembly 3 - Separator Plate 4 - Main Valve Body Assembly 5 - Transmission Fluid Pressure (TFP) Switch 6 - Main Valve Body Assembly Bolt, M6 x 10 x 50, Flanged Head (23) 7 - Reverse Signal Pipe 8 - Reverse Signal Pipe Bolt, M6 x 10 x 50, Flanged Head 9 - Retaining Clip 10 - Modulated Main Valve Body 11 - Bolt, M6 x 10 x 65 12 Bolt, M6 x 10 x 50 13 - O-Rings 14 - Modulated Main Pressure (MAIN MOD) Solenoid 15 - 6 Speed Pipe Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 6529 Fluid Pressure Sensor/Switch: Diagrams Component Connector End Views Pressure Switch Manifold (PSM) (MW7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 6530 Fluid Pressure Sensor/Switch: Service and Repair Pressure Switch Manifold Replacement Removal Procedure Note: Individual pressure switches cannot be replaced. When any pressure switch needs replacing, the entire assembly must be replaced. Note: The modulated main pressure (MAIN MOD) solenoid has been removed for clarity. 1. Remove the oil pan and transmission internal oil filter. Refer to Oil Pan Replacement (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Fluid Pan/Service and Repair). Warning: Refer to Battery Disconnect Warning (See: Starting and Charging/Battery/Service Precautions). 2. Disconnect the internal wiring harness connector from the transmission fluid pressure (TFP) switch (2). 3. Remove six bolts (1). Remove the TFP switch (2). Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 6531 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Place the new TFP manifold assembly (2) in position and install one bolt (1) in a recessed location to hold in position. Start the remaining five bolts (1) in recessed locations and tighten the bolts by hand. Torque the bolts to 12 Nm (108 lb in). 2. Connect the internal wiring harness connector to the TFP switch. 3. Install the oil pan and transmission internal oil filter. Refer to Oil Pan Replacement (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Fluid Pan/Service and Repair). Note: The FastLearn, adapt, procedure must be performed. This can be done in 1 step using a scan tool. If this procedure is not done, the TCM adaptive values will be at the settings that it learned for the old components and will be in slow adaptive mode. Under these conditions, it will take an unacceptably long time for the adaptive values to converge to levels suitable for the new transmission. 4. Perform the FastLearn procedure. Refer to FastLearn Procedure (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Testing and Inspection/Programming and Relearning). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON Transmission Mode Switch: Customer Interest A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 6540 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 6541 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 6542 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON Transmission Mode Switch: All Technical Service Bulletins A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 6548 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 6549 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 6550 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > Page 6551 Transmission Mode Switch: Diagrams Component Connector End Views Automatic Transmission Internal Mode Switch (MW7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > Page 6552 Transmission Mode Switch: Service and Repair Transmission Internal Mode Switch Replacement Important: The Internal Mode Switch (IMS) is mounted to the manual shift shaft detent lever as an assembly. The components of the detent lever/IMS assembly cannot be individually serviced. When the IMS needs replacing, the entire assembly must be replaced. Replace the IMS. Refer to Manual Shift Shaft, Detent Lever, and Position Switch Assembly Replacement (See: Transmission Position Switch/Sensor/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams Transmission Position Switch/Sensor: Diagrams Component Connector End Views Park/Neutral Position (PNP) Switch (M30) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 6556 Transmission Position Switch/Sensor: Service and Repair Manual Shift Shaft, Detent Lever, and Position Switch Assembly Replacement Removal Procedure 1. Remove the control valve assembly from the transmission. Refer to Control Valve Body Replacement (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Valve Body/Service and Repair). Note: The detent lever/IMS retaining bolt contains patch lock material on the threads. Do not reuse the retaining bolt. 2. Remove the detent lever/IMS retaining bolt (1) using a T27 TORX(R) bit and discard the retaining bolt. Caution: DO NOT mar the transmission case surface around the spherical pin when removing or installing the spherical pin. An unmarred surface is required to maintain the seal between the control valve assembly and the transmission case. Caution: DO NOT twist the spherical pin when removing the pin from the transmission case. Damage to the transmission case can occur. 3. Place a protective plate on the transmission case surface around the spherical pin (3). Remove the spherical pin (3) from the transmission case. 4. Slide the manual shift shaft (5) through the detent lever/IMS assembly (4) and through the manual shift shaft seal. 5. Rotate the detent lever/IMS assembly to disengage the park pawl apply assembly (2). Remove the detent lever/IMS assembly (4). Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 6557 1. Place the new detent lever/IMS assembly (4) in position in the transmission case. Rotate the detent lever/IMS assembly to engage the park pawl apply assembly (2). Reinstall the manual shift shaft (5) through the manual shift shaft seal and through the detent lever/IMS assembly (4). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Push the manual shift shaft (5) into the final position in the transmission case. 3. Install the spherical pin (3) into the transmission case that retains the manual shift shaft. 4. Install the detent lever/IMS retaining bolt (1) using a T27 TORX(R) bit. Tighten the bolt (1) to 10 Nm (92 lb in). 5. Install the control valve assembly. Refer to Control Valve Body Replacement (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Valve Body/Service and Repair). Note: The FastLearn, adapt, procedure must be performed. This can be done in 1 step using a scan tool. If this procedure is not done, the TCM adaptive values will be at the settings that it learned for the old components and will be in slow adaptive mode. Under these conditions, it will take an unacceptably long time for the adaptive values to converge to levels suitable for the new transmission. 6. Perform the FastLearn procedure. Refer to FastLearn Procedure (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Testing and Inspection/Programming and Relearning). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Component Locations Transmission Speed Sensor: Component Locations Disassembled Views Automatic Transmission Case 1 - Automatic Transmission Case 2 - Transmission Case Locating Pin 3 - Transmission Vent Assembly 4 - Transmission Vent Cap 5 - Transmission Vent 6 - Nameplate Rivet 7 - Nameplate 8 Vehicle Speed Sensor Bolt, M6 x 1.0 x 13 9 - Sensor Shipping Cover 10 - Turbine Speed Sensor 11 - Vehicle Speed Sensor O-Ring 12 - Power Take-Off (PTO) Cover Gasket (2) 13 - PTO Cover (2) 14 - PTO Cover Bolt, M10 x 1.5 x 20, Flanged Head, Coated (12) 16 - Manual Shift Shaft 17 Manual Shift Shaft Seal 18 - Manual Shift Shaft Pin 19 - Manual Shift Shaft Detent Lever/Internal Mode Switch (IMS) Assembly 20 - Park Pawl Assembly 21 - Control Valve Body Locating Pin 22 Detent Lever/IMS Bolt 23 - Connector Shipping Cover 24 - Control Valve Body Assembly 25 Control Valve Body Bolt, M6 x 1.0 x 50, Flanged Head (15) 26 - Manual Shift Shaft Detent Spring 27 - Manual Shift Shaft Detent Spring Bolt M6 x 1.0 x 12. Flanged Head (2) 28 - Transmission Wiring Harness Assembly Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Component Locations > Page 6562 Transmission Speed Sensor: Connector Locations Harness Routing Views Engine Chassis Harness Routing - Rear (Diesel) 1 - X300 2 - G300 3 - Automatic Transmission Turbine Speed Sensor (MW7) 4 - Automatic Transmission (MW7) 5 - Vehicle Speed Sensor (VSS) (MW7) 6 - X124 (PTO) 7 - Power Take Off (PTO) Module (PTO) 8 - X175 (MW7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 6563 Transmission Speed Sensor: Diagrams Component Connector End Views Automatic Transmission Input Shaft Speed (ISS) Sensor (M30) Automatic Transmission Turbine Speed Sensor (MW7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 6564 Output Speed Sensor (OSS) (M99) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 6565 Transmission Speed Sensor: Service and Repair Speed Sensor Replacement Removal Procedure Warning: Refer to Battery Disconnect Warning (See: Starting and Charging/Battery/Service Precautions). 1. Be sure the vehicle ignition is turned off. 2. Disconnect the external wiring harness from the speed sensor. 3. Remove the bolt (1) from the speed sensor and carefully remove the speed sensor (2). Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 6566 Note: Do not rotate the sensor in its retaining bracket. Changing the sensor/bracket orientation may cause improper operation. 1. Install a new a O-ring on the speed sensor (2). Lubricate the O-ring with clean transmission fluid. 2. Install the new speed sensor (2) into the speed sensor bore. Align the hole in the retaining bracket with the bolt hole in the speed sensor boss. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the speed sensor bolt (1). Tighten bolt to 12 Nm (108 lb in). 4. Reconnect the external wiring harness to the speed sensor. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams Transmission Temperature Sensor/Switch: Diagrams Component Connector End Views Automatic Transmission Fluid Temperature (TFT) Sensor (M30) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Clutch Pedal Position Sensor / Switch > Component Information > Testing and Inspection Clutch Pedal Position Sensor / Switch: Testing and Inspection Clutch Pedal Position Sensor Learn Important: The clutch pedal position (CPP) sensor learn procedure is required when the following service procedures have been performed regardless of whether DTC P080A is set: * An engine control module (ECM) replacement * A CPP sensor replacement * Any repairs which affect the CPP sensor relationship 1. Install a scan tool. 2. Monitor the ECM for DTCs with a scan tool. If other DTCs are set, except DTC P080A, refer to Diagnostic Trouble Code (DTC) List - Vehicle ( See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle) for the applicable DTC that set. 3. With a scan tool, select Clutch Pedal Position Learn under Module Setup in Manual Transmission, and perform the following instructions displayed on the scan tool screen. Important: The CPP sensor learn procedure cannot be performed more than once per ignition cycle. The clutch pedal needs to be fully depressed and held steady throughout this procedure in order to perform a correct learning. 4. The scan tool will display under CPP Learn Status: Not Learned, In Process, Complete, Fail Low Volt, Fail - High Volt, or Fail Moving. The scan tool will display under CPP Learn Status Complete if the process was successful. 5. If the scan tool indicates that DTC P080A ran and passed this ignition the CPP sensor learn procedure is complete. If the scan tool indicates DTC P080A failed or did not run this ignition, refer to DTC P080A (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P080A/Tremec 5-Speed (TZ0) - Manual Transmission). If any other DTC is set, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List Vehicle) for the applicable DTC. 6. Turn OFF the ignition for 30 seconds after the learn procedure has successfully completed in order to store the CPP sensor variation values in ECM history. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Clutch Pedal Position Sensor / Switch > Component Information > Testing and Inspection > Page 6574 Clutch Pedal Position Sensor / Switch: Service and Repair Clutch Pedal Engine Start Switch Replacement Removal Procedure 1. Disconnect the clutch pedal position switch electrical connector (1). 2. Remove the plastic retainer (1) tabs from the clutch pedal position switch (2). 3. Remove the clutch pedal position switch (2) from the pushrod. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Clutch Pedal Position Sensor / Switch > Component Information > Testing and Inspection > Page 6575 1. Install the clutch pedal position switch (2) to the pushrod. 2. Install the plastic retainer (1) tabs to the clutch pedal position switch (2). 3. Connect the clutch pedal position switch electrical connector (1). Warning Replacement or reprogramming of the ECM, or replacement of the clutch pedal position sensor (CPPS) or clutch pedal requires that a CPPS learn procedure be performed. Failure to perform the CPPS learn procedure may result in personal injury or damage to the vehicle or its components if the vehicle is in gear and the starter motor is accidentally engaged. 4. Perform the clutch pedal position sensor learn procedure. Refer to DTC P080A (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P080A/Tremec 5-Speed (TZ0) - Manual Transmission) or Clutch Pedal Position Sensor Learn (See: Transmission and Drivetrain/Manual Transmission/Transaxle/Testing and Inspection/Component Tests and General Diagnostics). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Power Take-Off > Power Take-Off Switch > Component Information > Diagrams Power Take-Off Switch: Diagrams Component Connector End Views Power Take-Off (PTO) Switch (PTO) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations Four Wheel Drive Selector Switch: Locations Harness Routing Views Engine Harness Routing - Rear (4.8L/5.3L/6.0L/6.2L except LFA/HP2) 1 - Dash Panel 2 - Transmission 3 - X175 (M30) 4 - Transfer Case Shift Control Switch (NQG) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 6584 Four Wheel Drive Selector Switch: Diagrams Component Connector End Views Transfer Case Shift Control Switch (NQF or NQH) Transfer Case Shift Control Switch (NQG) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 6585 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case Four Wheel Drive Selector Switch: Service and Repair MP 1625/1626-NQF - Transfer Case Transfer Case Shift Control Switch Replacement (Without SLT) Transfer Case Shift Control Switch Replacement (Without SLT) Transfer Case Shift Control Switch Replacement (With SLT) Transfer Case Shift Control Switch Replacement (With SLT) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case > Page 6588 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case > Page 6589 Four Wheel Drive Selector Switch: Service and Repair MP 3023/3024-NQH - Transfer Case Transfer Case Shift Control Switch Replacement (With SLT) Transfer Case Shift Control Switch Replacement (With SLT) Transfer Case Shift Control Switch Replacement (Without SLT) Transfer Case Shift Control Switch Replacement (Without SLT) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case > Page 6590 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams Gear Sensor/Switch: Diagrams Component Connector End Views Transfer Case 2/4 Wheel Drive Actuator Position Sensor (NQH) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair Speed Sensor: Service and Repair Transfer Case Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the speed sensor electrical connector (4). 3. Remove the speed sensor and O-ring. 4. Discard the O-ring. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Page 6597 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the speed sensor with a NEW O-ring. Tighten the sensor to 17 Nm (13 lb ft). 2. Connect the speed sensor electrical connector (4). 3. Lower the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON PROM - Programmable Read Only Memory: Customer Interest A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 6606 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 6607 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 6608 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 08-06-04-006H > Feb > 11 > Engine Controls - Aftermarket Power-Up/Calibration ID PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls Aftermarket Power-Up/Calibration ID INFORMATION Bulletin No.: 08-06-04-006H Date: February 07, 2011 Subject: Information on Identifying Non-GM ECM Calibration Usages for Duramax(TM) Diesel Engines RPOs LBZ, LLY, LMM, LML, LGH and Power-up Hardware Detection for Duramax(TM) Diesel Engine RPO LMM - Photograph Tech 2(R) Calibration IDs and Calibration Verification Numbers (CVNs) and Transmission Data Screen Before Removing Engine/Transmission/Drivetrain Components Models: 2006-2011 Chevrolet Express, Kodiak, Silverado 2006-2011 GMC Savana, Sierra, TopKick Equipped With Duramax(TM) Diesel Engine RPOs LBZ, LLY, LMM, LML, LGH Please Refer to GMVIS Attention: In order to process an engine/transmission/drivetrain hard part WARRANTY CLAIM, you MUST photograph the required Tech 2(R) screen information BEFORE disassembly or removing engine/transmission/drivetrain components from the vehicle. Supercede: This bulletin is being revised to update the model years and RPOs. Please discard Corporate Bulletin Number 08-06-04-006G (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission, diesel oxidation catalyst (DOC) and exhaust particulate filter failures that are the result of non-GM (aftermarket Power-up Kits ) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine , transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage to the powertrain and driveline components whenever the presence of a non-GM calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of first sale, or subsequently updated by GM or its dealers with approved calibrations. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different than those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM issued engine control modifications do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines procedures to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine, transmission, transfer case or rear axle components, and before disassembly, repair or replacement of an engine, transmission, transfer case or rear axle assembly under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that the diesel oxidation catalyst (DOC) needs replacement. Note BEFORE authorizing any Duramax(TM) diesel engine or transmission replacement, the PQC will require digital photographs of the following Tech 2(R) screens: - For RPOs LLY and LBZ only: Calibration ID Numbers and Verification Numbers from the Vehicle Information screen - For RPO LMM only: Calibration ID Numbers and Verification Numbers from the Vehicle Information AND the Programming History screen. - For RPO LMM only: Transmission Data screen containing the Max Transmission Calc Engine Torque parameter. Symptoms Caused by Aftermarket Power-up Kit Some customers may have reprogrammed the engine control module (ECM) with a non-GM released calibration. The Power-Up Kit engine calibration changes fueling and timing parameters and likely contributes to the following vehicle conditions: - Poor performance - Driveability concerns - Increased emissions Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 08-06-04-006H > Feb > 11 > Engine Controls - Aftermarket Power-Up/Calibration ID > Page 6614 - Black smoke (This symptom is not valid for the Duramax(TM) diesel engine RPO LMM equipped with the exhaust particulate filter. The filter will trap black smoke unless it is cracked, melted or has been removed from the exhaust system.) - Knocking noise - Engine damage (Refer to Corporate Bulletin Number 06-06-01-007C for additional information.) 2005-2007 RPO LLY and LBZ Instructions for Confirming Calibration Verification Numbers (CVNs) - Power-up Kit Detection Important In order to process an engine/transmission/drivetrain WARRANTY CLAIM , you MUST photograph the required Tech 2(R) screen information BEFORE disassembly or removing the engine/transmission/drivetrain components from the vehicle. 1. Go to TIS2WEB 2. Select: Calibration Information (SPS Info) 3. Enter the VIN 4. Select: Get Cal ID 5. Select: ECM Engine Control Module 6. Select: Next 7. Select: Complete History 8. Print 9. Take the printout to the vehicle along with the Tech 2(R) 10. Plug in the Tech 2(R) 11. Go to diagnostics and build the vehicle 12. Select: Powertrain 13. Select: Engine 14. *Select: Engine Control Module 15. *Select: Module ID Information or I/M Information System if Module ID Information selection is not available. 16. *If: I/M Information System was selected in step 15, it may be necessary to select: Vehicle Information in order to display the calibration information. *Steps may vary by engine controller. 17. Compare the Calibration ID and Calibration Verification Number (CVN) to the CVN shown on the TIS2WEB printout. Although the part numbers will be the same for each, it is the CVN that will determine if the calibration is GM issued. The CVNs should be the same. ‹› If the CVN information is displayed as "N/A" , it will be necessary to contact the TCSC to obtain the CVN information. ‹› If the part numbers match and ANY CVNs DO NOT match the printout, it is likely that a non-GM certified calibration has been installed. ‹› If ALL of the CVNs are EXACTLY the same the calibration is GM issued. Vehicle Information Screen 18. Take clear digital picture(s) of the Tech 2(R) Vehicle Information screen(s) showing the VIN, the Calibration IDs and the Verification Numbers. Retain the printout information and the Tech 2(R) screen photographs with the repair order. 1. E-mail copies of the digital pictures to [email protected]. In the subject line of the E-mail include the phrase "Duramax(TM) diesel", the complete VIN and Dealer BAC. In the body of the E-mail include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an email reply after the calibrations have been validated. The email reply will advise the dealer if the calibrations are OEM. 2. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 3. You may call the PQC two hours after submitting the required information for authorization to replace the assembly. This will provide them time to receive, review the information and set up a case on the request. Be prepared to provide all of the usual documentation that is normally Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 08-06-04-006H > Feb > 11 > Engine Controls - Aftermarket Power-Up/Calibration ID > Page 6615 required when requesting an assembly authorization from the PQC. 2007-2011 RPO LMM Instructions for Confirming Calibration Verification Numbers (CVNs) Power-up Kit Detection Important In order to process an engine/transmission/drivetrain WARRANTY CLAIM , you MUST photograph the required Tech 2(R) screen information BEFORE disassembly or removing the engine/transmission/drivetrain components from the vehicle. For 2007-2011 applications, an engine control module (ECM) algorithm was implemented that records the engine calibration part number and calibration verification number (CVN) for the last 10 flash programming events. The ECM records the engine calibration part number because it contains the parameters for increasing torque and fueling rates. If a vehicle comes in for service for a driveability/powertrain concern as a result of a Power-Up Kit installation, the dealership technician can read the last 10 engine calibration part numbers and CVN history using a Tech 2(R). The dealership technician will input each ECM calibration part number into the TIS2WEB/SPS CVN database to confirm the CVN history information. Refer to the following Tech 2(R) path table to verify the ECM calibrations. 1. Build the vehicle with the Tech 2(R). 2. Select F0: Engine Control Module. 3. Select F5: Module Identification Information. 4. Select F1: Programming History. 5. Turn On the ignition, with the engine Off. 6. Press the ENTER Key to Continue. Important An original production engine operation part number programmed in the ECM from the supplier, which is the last part number shown, would not be in the TIS2WEB/SPS database. 7. Record the Calibration ID Numbers and Calibration Verification Numbers from the Tech 2(R) Programming History Screen. If the list of Calibration Part Numbers is less than 10, the first Calibration ID Number (bottom of the list) will not be in TIS2WEB/SPS CVN database. In this case, the first Calibration ID Number is programmed at the ECM production factory and is reprogrammed at the vehicle assembly plant. 8. From TIS2WEB/SPS, record the Calibration Part Number into the CVN Database. Get the CVN. ‹› If the CVN DOES NOT MATCH the CVN database, an unauthorized engine calibration part WAS PROGRAMMED into the ECM. ‹› If the CVN MATCHES the CVN database, the calibration/s are GM issued and an unauthorized engine calibration part WAS NOT used. Programming History Screen 9. Take a clear digital picture of the Tech 2(R) Programming History screen showing the VIN, Calibration IDs and the CVNs. Retain the printout information and the Tech 2(R) screen photograph with the repair order. Vehicle Information Screen 1. Take a clear digital picture of the Tech 2(R) Vehicle Information screen. Retain the printout information and the Tech 2(R) screen photograph with the repair order. 2. Take a clear digital picture of the Transmission Data screen that contains the Max Transmission Calc Engine Torque parameter. The path table is outlined in the following Instructions for Tech 2 Transmission Data Path section. Retain the Tech 2(R) Transmission Data screen photograph with the repair order. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 08-06-04-006H > Feb > 11 > Engine Controls - Aftermarket Power-Up/Calibration ID > Page 6616 3. E-mail copies of the digital pictures to [email protected]. In the subject line of the E-mail include the phrase "Duramax(TM) diesel", the complete VIN and Dealer BAC. In the body of the E-mail include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an email reply after the calibrations have been validated. The email reply will advise the dealer if the calibrations are OEM. 4. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 5. You may call the PQC two hours after submitting the required information for authorization to replace the assembly. This will provide them time to receive, review the information and set up a case on the request. Be prepared to provide all of the usual documentation that is normally required when requesting an assembly authorization from the PQC. 2007-2011 RPO LMM Instructions for Tech 2 Transmission Data Path - Power-up Hardware Detection Transmission Data ONLY Available With GMC Sierra, TopKick, Chevrolet Kodiak, Silverado An example of this hardware is a propane injection system. A transmission control module (TCM) algorithm has been implemented that records a maximum calculated input torque. This information is available via the Tech 2(R). 1. Build the vehicle with the Tech 2(R). 2. Select F3: Transmission Control Module 3. Select F1: Data Display 4. Select F0: Transmission Data 5. Highlight: Max Transmission Calc Engine Torque Transmission Data Screen (Max. Trans Calc. Engine Torque Parameter) 6. Take a clear digital picture of the Tech 2(R) screen showing the Transmission Data and the Max Transmission Calc Engine Torque parameter. 7. Retain the Tech 2(R) Transmission Data screen photograph with the repair order. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 08-06-04-006H > Feb > 11 > Engine Controls - Aftermarket Power-Up/Calibration ID > Page 6617 Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 06-06-01-007F > Mar > 10 > Diesel Engine - Damage Due To Power-Up Devices PROM - Programmable Read Only Memory: All Technical Service Bulletins Diesel Engine Damage Due To Power-Up Devices INFORMATION Bulletin No.: 06-06-01-007F Date: March 31, 2010 Subject: Information On Identifying Duramax(TM) Diesel LB7, LLY, LMM, LBZ Overpower Engine Breakdown or Non-Function Due to Aftermarket Power-Up Devices vs. Non Overpower Engine Non-Function of Pistons, Cylinders, Valvetrain Components and/or Turbocharger DTC P003A Set Models: 2001-2010 Chevrolet Silverado 2003-2009 Chevrolet Kodiak 2006-2010 Chevrolet Express 2001-2010 GMC Sierra 2003-2009 GMC TopKick 2006-2010 GMC Savana Equipped With Duramax(TM) Turbocharged Diesel Engine RPOs LB7, LLY, LMM, LBZ Please Refer to GMVIS Supercede: This bulletin is being revised to add text to the end of the Caution statement. Please discard Corporate Bulletin Number 06-06-01-007E (Section 06 - Engine/Propulsion System). Caution Customers should be informed if a hard part failure is observed in the engine, transmission, transfer case and/or other driveline components, it is likely that powertrain components were weakened to the point of premature failure, while subjected to the higher stresses from Aftermarket Power-Up Devices. Failures associated with the installation of Aftermarket Power-Up Devices, which have been verified, are not covered under the terms of the New Vehicle Warranty. In the majority of these cases, the Fixed Operations Manager (FOM) (in Canada, Warranty Manager) should be contacted and the remaining portion of the powertrain portion of the New Vehicle Warranty blocked. GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage. General Motors Position On Aftermarket Power-Up Devices Important General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. Refer to Service Bulletin Number 04-06-04-054A or newer - Warranty Admin. - Non-GM Parts and Accessories (Aftermarket). Important For further information on aftermarket power-up kits, refer to February 2006 Emerging Issues Course Number 10206.02D. In Canada, information on aftermarket power-up kits was covered in the April 2006 TAC TALK program. Aftermarket power-up devices are non-approved by General Motors. These devices are usually piggy-backed in the main engine harness or remain connected to the diagnostic connector to upload the calibration to the ECM. Recent warranty reviews of returned engines show engine breakdown or non-function due to power-up devices that are utilized for increased horsepower and torque. The following information will assist technicians in identifying overpower engine breakdown or non-function due to aftermarket power-up devices vs. non overpower engine breakdown or non-function. Non-GM parts can alter the design of the vehicle. GM dealers need to be aware of the quality of parts being installed on vehicles. If failure occurs as a result of installation of sub-par parts, warranty coverage may be denied. Refer to Service Bulletin Number 04-06-04-054A or newer Warranty Admin. - Non-GM Parts and Accessories (Aftermarket). Installed Power-Up Kit Aftermarket power-up kits have become a very popular add on for performance-minded customers. These devices can add horsepower and torque and can add additional stress to the engine. These aftermarket calibrations take the Duramax(TM) powertrain outside of its design torque and horsepower rating. They do this by altering air/fuel ratios and injector timing, resulting in excessive cylinder pressure and temperature. When these calibrated parameters are altered, it will upset the design balance and can lead to a reduction of engine life expectancy. Generally, in inspection of Duramax(TM) engine failure due to power-up failures, two or more cylinders will be affected. Installed Power-Up Kit - Once installed, the calibration may mask itself with the factory original calibration ID and may remain the same. Refer to Service Bulletin Number 08-06-04-006F or newer - Information on Identifying Non-GM Calibration Usage for LMM Duramax(TM) Diesel Engine. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 06-06-01-007F > Mar > 10 > Diesel Engine - Damage Due To Power-Up Devices > Page 6622 - A Tech 2(R) will not positively enable you to identify the use of a power-up device. - Some companies that offer power-up devices claim increases of 150 or more horsepower and 300 or more lb/ft pounds of torque. - A vehicle that is used to the power-up device potential 100% of the time will see earlier engine wear and breakdown. - A vehicle that takes advantage of additional power, but on a less frequent basis, may not see premature engine wear and breakdown until later in the engine's life. - A vehicle not pushed to its limits of the power-up device often may not encounter premature wear and breakdown until after the engine is out of warranty. Duramax(TM) Powertrain Horsepower / Torque Ratings The following horsepower and torque increase over the past years required new internal components to accommodate the increase. - LB7 - 300 hp with 520 ft/lb of torque for model years 2000-2004 - LLY - 310 hp with 605 ft/lb of torque for model years 2004-2008 - LBZ - 360 hp with 650 ft/lb of torque for model year 2006-2008 - LMM - 365 hp with 660 ft/lb of torque for model year 2007-2009 LBZ Improvements To reliably achieve an increase in 50 horsepower with 45 ft/lb torque, the Duramax (TM) diesel had to be revised in many areas. A few of the revisions on the 2006 LBZ were: - New pistons with a revised compression ratio. - Wrist pins that are larger in diameter. - Connecting rods with added material to increase the I section strength. - Engine block and machining changes - Cylinder heads Duramax(TM) Life Expectancy The Duramax(TM) 6.6L V8 Turbo Diesel Engine is sold with a warranty of 100,000 miles/160,000 kilometers. The Duramax(TM) has been tested to survive upwards of 200,000 miles/320,000 kilometers. The Duramax(TM) powertrain is designed for reliability, peak horsepower and torque within its design limits. When a customer installs a power-up device, it drastically reduces the mileage ratings. Important Cylinder Wall Spotting (commonly referred to leopard spots) is from the induction hardening process of the top 1/3 of the cylinder wall. This is normal for the Duramax (TM) Diesel. Identifying Fuel Related Aftermarket Power-Up Devices Aftermarket companies have developed a performance pressure relief fuel valve for Duramax(TM) diesel engines. Refer to above graphic illustration. The performance pressure relief fuel valve attaches to the fuel rail in place of the OEM valve and will not allow any fuel return to the tank, giving 100% of the fuel to be available for additional engine performance. This may cause additional fuel related driveability concerns and may set the following DTCs: - DTC P1093 Fuel Rail Pressure (FRP) Low During Power Enrichment - DTC P0087 Fuel Rail Pressure (FRP) Too Low Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 06-06-01-007F > Mar > 10 > Diesel Engine - Damage Due To Power-Up Devices > Page 6623 Aftermarket companies have developed a replacement performance/economy fuel injector nozzle. Refer to above illustration. The performance/economy fuel injector nozzles replace the OEM fuel injector nozzles. The aftermarket companies claim increased horsepower, improved fuel atomization, lower exhaust gas temperatures and increase fuel economy. This may cause additional fuel related driveability concerns and may cause internal engine damage to the pistons and fuel injector nozzles. Identifying Overpower Engine Premature Wear and Breakdown When premature wear and breakdown is encountered due to an aftermarket power-up device, it has some very specific characteristics to the internal engine components. The following list will assist in identifying these characteristics as you tear down the engine. - Pistons will be cracked in the lip area, or a hole in the pistons. - Pistons can also be melted on the lip of the combustion bowl, or the top of the pistons can be melted. - Crosshatch will be polished off the cylinder wall in the major thrust face of cylinder below ring belt travel. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 06-06-01-007F > Mar > 10 > Diesel Engine - Damage Due To Power-Up Devices > Page 6624 - Piston pin bore will show signs of scoring, the wrist pins will be discolored, and can have oil coking on them. The connecting rod bushing surface will have accelerated wear. The above illustration shows a connecting rod bushing. - Oil coking on the underside of the piston between the wrist pin bosses. - Signs of bearing fretting will also be noticed on the connecting rod and main bearing caps. Refer to the above illustration for fretting of main bearing cap 1 and back side of connection rod bearing 2. - Excessive heat in engine compartment caused by overpower device. Refer to above illustration (1). Non Overpower Engine Premature Wear and Breakdown The following pictures show results of overheat, overspeed, low/no oil pressure or injector breakdown and how they differ from aftermarket power-up device premature wear and breakdown. Engine Overheat Overheat can be caused by a loss of coolant or a general cooling system failure. Some of the indicators of overheat are: Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 06-06-01-007F > Mar > 10 > Diesel Engine - Damage Due To Power-Up Devices > Page 6625 - Melted pistons. - Head gasket breakdown or non-function. - Warped cylinder heads. - Crankshaft and connecting rod discolored. Engine Overspeed Causes If an engine has been run faster than design capability (redline), and has caused damage as a result, it may be a result of one of the following conditions: - Leaking or failed turbocharger (TC) oil seals. - Oil evident in the intake runners and compressor side of the TC. - Starting fluid use or alternative fuel added to the engine such as ether. Engine Overspeed Results The following are indicators that an overspeed event took place: - Valve train damage. - Pushrods that are bent (4). - Broken valve bridge buttons after cylinder head removal (2). - Rocker arm tip damage (1). - Dry or rusted cylinders from the use of ether, propane or nitrous oxide. - Piston to valve contact. - Cam gear pin shear. Lack of Oil Pressure Lack of lubrication causes rapid bearing wear or bearing to seize. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 06-06-01-007F > Mar > 10 > Diesel Engine - Damage Due To Power-Up Devices > Page 6626 Bearing failure. Spun main bearings. Engine Premature Wear and Breakdown Due to Improper Function of Fuel Injector A fuel injector may fracture a piston or melt a piston but the damage will be limited to that cylinder only and all other pistons and cylinder walls are OK. In some cases hydraulic lock will occur on the suspected cylinder with an over-fueling fuel injector. Hydraulic lock on the suspected cylinder will cause a bent connecting rod. This can be verified with piston protrusion measurements. 2007-2010 RPO LMM Only Turbocharger DTC P003A Set General Motors has identified a turbocharger (TC) failure mode involving Power-Up Kits that causes soot leakage and DTC P003A to be set. The Power-Up Kits create an overtemperature condition from the increased exhaust gas temperatures that results in a permanent and excessive turbine housing distortion at the TC case halves. 1. A technician may observe one or more of the following conditions: - DTC P003A being set as Current or in History. - An unusual odor emanating from the TC due to an overtemperature condition. - Soot leaking and accumulating at the V-band clamp that secures the TC case halves together. - Limited or unresponsive travel when Commanding the TC Vane Pos. Ctrl. Solenoid ON and OFF with a scan tool. 2. If DTC P003A is found as Current or in History, OR there is evidence of soot leakage (1) in the area of the V-band clamp (1), then technicians MUST verify if the engine control module (ECM) has a Power-Up Kit aftermarket calibration installed or an aftermarket hardware device has been installed. Refer to Service Bulletin Number 08-06-04-006F or newer for the calibration verification information and procedures. How to Handle a Suspect Engine Failure Due to a Power-Up Device Dealers should not automatically decline warranty assistance on engine failures due to the fact that a power-up device or modification is evident or suspected. The technician must identify that the failure is due to a power-up device by teardown analysis and diagnosis of the engine components. The following steps should be taken if an engine failure occurs and it is suspected that the modification or addition of a power-up device maybe the cause of the engine failure. If unclear of this process or direction feel free to contact your Fixed Operations Manager (in Canada, Warranty Manager) for further support. 1. The technician should use proper engine diagnostics to lead him/her to the failed engine components. The Aftermarket Power-Up Kit Check List should be followed and if it is determined that at least three of the Aftermarket Power-Up Kit Check List items match the engine component failures then it can be decided that the failure is not a warrantable claim. 2. Engine failures that meet at least three criteria of the Aftermarket Power-Up Kit Check List are considered failures that are not manufacturer's defects in workmanship or materials. 3. The dealership should contact the PQC, open a case to review the findings and make the final decision on warranty coverage. The Fixed Operations Manager (in Canada, Warranty Manager) should be notified of the PQC decision. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 06-06-01-007F > Mar > 10 > Diesel Engine - Damage Due To Power-Up Devices > Page 6627 4. Denied claims should be documented as follows: 1. The Aftermarket Power-Up Kit Check List completed with the technicians detailed written findings of the diagnosis on the repair order and retained in the repair order file. 2. Photographs of the failed parts should be retained in the repair order file. 5. The customer should be advised that the failure of their engine was not due to a manufacturer's defect in workmanship or materials and therefore the warranty claim is denied on this failure. Aftermarket Power-Up Kit Check List Important Print and use this aftermarket power-up kit check list when performing an engine disassembly investigation of overpower engine breakdown or non-function. Retain a copy of this checklist and photographs of the failed parts in the repair order file. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON PROM - Programmable Read Only Memory: All Technical Service Bulletins A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 6632 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 6633 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 6634 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 08-06-04-006H > Feb > 11 > Engine Controls - Aftermarket Power-Up/Calibration ID PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls Aftermarket Power-Up/Calibration ID INFORMATION Bulletin No.: 08-06-04-006H Date: February 07, 2011 Subject: Information on Identifying Non-GM ECM Calibration Usages for Duramax(TM) Diesel Engines RPOs LBZ, LLY, LMM, LML, LGH and Power-up Hardware Detection for Duramax(TM) Diesel Engine RPO LMM - Photograph Tech 2(R) Calibration IDs and Calibration Verification Numbers (CVNs) and Transmission Data Screen Before Removing Engine/Transmission/Drivetrain Components Models: 2006-2011 Chevrolet Express, Kodiak, Silverado 2006-2011 GMC Savana, Sierra, TopKick Equipped With Duramax(TM) Diesel Engine RPOs LBZ, LLY, LMM, LML, LGH Please Refer to GMVIS Attention: In order to process an engine/transmission/drivetrain hard part WARRANTY CLAIM, you MUST photograph the required Tech 2(R) screen information BEFORE disassembly or removing engine/transmission/drivetrain components from the vehicle. Supercede: This bulletin is being revised to update the model years and RPOs. Please discard Corporate Bulletin Number 08-06-04-006G (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission, diesel oxidation catalyst (DOC) and exhaust particulate filter failures that are the result of non-GM (aftermarket Power-up Kits ) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine , transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage to the powertrain and driveline components whenever the presence of a non-GM calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of first sale, or subsequently updated by GM or its dealers with approved calibrations. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different than those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM issued engine control modifications do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines procedures to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine, transmission, transfer case or rear axle components, and before disassembly, repair or replacement of an engine, transmission, transfer case or rear axle assembly under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that the diesel oxidation catalyst (DOC) needs replacement. Note BEFORE authorizing any Duramax(TM) diesel engine or transmission replacement, the PQC will require digital photographs of the following Tech 2(R) screens: - For RPOs LLY and LBZ only: Calibration ID Numbers and Verification Numbers from the Vehicle Information screen - For RPO LMM only: Calibration ID Numbers and Verification Numbers from the Vehicle Information AND the Programming History screen. - For RPO LMM only: Transmission Data screen containing the Max Transmission Calc Engine Torque parameter. Symptoms Caused by Aftermarket Power-up Kit Some customers may have reprogrammed the engine control module (ECM) with a non-GM released calibration. The Power-Up Kit engine calibration changes fueling and timing parameters and likely contributes to the following vehicle conditions: - Poor performance - Driveability concerns - Increased emissions Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 08-06-04-006H > Feb > 11 > Engine Controls - Aftermarket Power-Up/Calibration ID > Page 6640 - Black smoke (This symptom is not valid for the Duramax(TM) diesel engine RPO LMM equipped with the exhaust particulate filter. The filter will trap black smoke unless it is cracked, melted or has been removed from the exhaust system.) - Knocking noise - Engine damage (Refer to Corporate Bulletin Number 06-06-01-007C for additional information.) 2005-2007 RPO LLY and LBZ Instructions for Confirming Calibration Verification Numbers (CVNs) - Power-up Kit Detection Important In order to process an engine/transmission/drivetrain WARRANTY CLAIM , you MUST photograph the required Tech 2(R) screen information BEFORE disassembly or removing the engine/transmission/drivetrain components from the vehicle. 1. Go to TIS2WEB 2. Select: Calibration Information (SPS Info) 3. Enter the VIN 4. Select: Get Cal ID 5. Select: ECM Engine Control Module 6. Select: Next 7. Select: Complete History 8. Print 9. Take the printout to the vehicle along with the Tech 2(R) 10. Plug in the Tech 2(R) 11. Go to diagnostics and build the vehicle 12. Select: Powertrain 13. Select: Engine 14. *Select: Engine Control Module 15. *Select: Module ID Information or I/M Information System if Module ID Information selection is not available. 16. *If: I/M Information System was selected in step 15, it may be necessary to select: Vehicle Information in order to display the calibration information. *Steps may vary by engine controller. 17. Compare the Calibration ID and Calibration Verification Number (CVN) to the CVN shown on the TIS2WEB printout. Although the part numbers will be the same for each, it is the CVN that will determine if the calibration is GM issued. The CVNs should be the same. ‹› If the CVN information is displayed as "N/A" , it will be necessary to contact the TCSC to obtain the CVN information. ‹› If the part numbers match and ANY CVNs DO NOT match the printout, it is likely that a non-GM certified calibration has been installed. ‹› If ALL of the CVNs are EXACTLY the same the calibration is GM issued. Vehicle Information Screen 18. Take clear digital picture(s) of the Tech 2(R) Vehicle Information screen(s) showing the VIN, the Calibration IDs and the Verification Numbers. Retain the printout information and the Tech 2(R) screen photographs with the repair order. 1. E-mail copies of the digital pictures to [email protected]. In the subject line of the E-mail include the phrase "Duramax(TM) diesel", the complete VIN and Dealer BAC. In the body of the E-mail include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an email reply after the calibrations have been validated. The email reply will advise the dealer if the calibrations are OEM. 2. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 3. You may call the PQC two hours after submitting the required information for authorization to replace the assembly. This will provide them time to receive, review the information and set up a case on the request. Be prepared to provide all of the usual documentation that is normally Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 08-06-04-006H > Feb > 11 > Engine Controls - Aftermarket Power-Up/Calibration ID > Page 6641 required when requesting an assembly authorization from the PQC. 2007-2011 RPO LMM Instructions for Confirming Calibration Verification Numbers (CVNs) Power-up Kit Detection Important In order to process an engine/transmission/drivetrain WARRANTY CLAIM , you MUST photograph the required Tech 2(R) screen information BEFORE disassembly or removing the engine/transmission/drivetrain components from the vehicle. For 2007-2011 applications, an engine control module (ECM) algorithm was implemented that records the engine calibration part number and calibration verification number (CVN) for the last 10 flash programming events. The ECM records the engine calibration part number because it contains the parameters for increasing torque and fueling rates. If a vehicle comes in for service for a driveability/powertrain concern as a result of a Power-Up Kit installation, the dealership technician can read the last 10 engine calibration part numbers and CVN history using a Tech 2(R). The dealership technician will input each ECM calibration part number into the TIS2WEB/SPS CVN database to confirm the CVN history information. Refer to the following Tech 2(R) path table to verify the ECM calibrations. 1. Build the vehicle with the Tech 2(R). 2. Select F0: Engine Control Module. 3. Select F5: Module Identification Information. 4. Select F1: Programming History. 5. Turn On the ignition, with the engine Off. 6. Press the ENTER Key to Continue. Important An original production engine operation part number programmed in the ECM from the supplier, which is the last part number shown, would not be in the TIS2WEB/SPS database. 7. Record the Calibration ID Numbers and Calibration Verification Numbers from the Tech 2(R) Programming History Screen. If the list of Calibration Part Numbers is less than 10, the first Calibration ID Number (bottom of the list) will not be in TIS2WEB/SPS CVN database. In this case, the first Calibration ID Number is programmed at the ECM production factory and is reprogrammed at the vehicle assembly plant. 8. From TIS2WEB/SPS, record the Calibration Part Number into the CVN Database. Get the CVN. ‹› If the CVN DOES NOT MATCH the CVN database, an unauthorized engine calibration part WAS PROGRAMMED into the ECM. ‹› If the CVN MATCHES the CVN database, the calibration/s are GM issued and an unauthorized engine calibration part WAS NOT used. Programming History Screen 9. Take a clear digital picture of the Tech 2(R) Programming History screen showing the VIN, Calibration IDs and the CVNs. Retain the printout information and the Tech 2(R) screen photograph with the repair order. Vehicle Information Screen 1. Take a clear digital picture of the Tech 2(R) Vehicle Information screen. Retain the printout information and the Tech 2(R) screen photograph with the repair order. 2. Take a clear digital picture of the Transmission Data screen that contains the Max Transmission Calc Engine Torque parameter. The path table is outlined in the following Instructions for Tech 2 Transmission Data Path section. Retain the Tech 2(R) Transmission Data screen photograph with the repair order. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 08-06-04-006H > Feb > 11 > Engine Controls - Aftermarket Power-Up/Calibration ID > Page 6642 3. E-mail copies of the digital pictures to [email protected]. In the subject line of the E-mail include the phrase "Duramax(TM) diesel", the complete VIN and Dealer BAC. In the body of the E-mail include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an email reply after the calibrations have been validated. The email reply will advise the dealer if the calibrations are OEM. 4. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 5. You may call the PQC two hours after submitting the required information for authorization to replace the assembly. This will provide them time to receive, review the information and set up a case on the request. Be prepared to provide all of the usual documentation that is normally required when requesting an assembly authorization from the PQC. 2007-2011 RPO LMM Instructions for Tech 2 Transmission Data Path - Power-up Hardware Detection Transmission Data ONLY Available With GMC Sierra, TopKick, Chevrolet Kodiak, Silverado An example of this hardware is a propane injection system. A transmission control module (TCM) algorithm has been implemented that records a maximum calculated input torque. This information is available via the Tech 2(R). 1. Build the vehicle with the Tech 2(R). 2. Select F3: Transmission Control Module 3. Select F1: Data Display 4. Select F0: Transmission Data 5. Highlight: Max Transmission Calc Engine Torque Transmission Data Screen (Max. Trans Calc. Engine Torque Parameter) 6. Take a clear digital picture of the Tech 2(R) screen showing the Transmission Data and the Max Transmission Calc Engine Torque parameter. 7. Retain the Tech 2(R) Transmission Data screen photograph with the repair order. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 08-06-04-006H > Feb > 11 > Engine Controls - Aftermarket Power-Up/Calibration ID > Page 6643 Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 06-06-01-007F > Mar > 10 > Diesel Engine - Damage Due To Power-Up Devices PROM - Programmable Read Only Memory: All Technical Service Bulletins Diesel Engine Damage Due To Power-Up Devices INFORMATION Bulletin No.: 06-06-01-007F Date: March 31, 2010 Subject: Information On Identifying Duramax(TM) Diesel LB7, LLY, LMM, LBZ Overpower Engine Breakdown or Non-Function Due to Aftermarket Power-Up Devices vs. Non Overpower Engine Non-Function of Pistons, Cylinders, Valvetrain Components and/or Turbocharger DTC P003A Set Models: 2001-2010 Chevrolet Silverado 2003-2009 Chevrolet Kodiak 2006-2010 Chevrolet Express 2001-2010 GMC Sierra 2003-2009 GMC TopKick 2006-2010 GMC Savana Equipped With Duramax(TM) Turbocharged Diesel Engine RPOs LB7, LLY, LMM, LBZ Please Refer to GMVIS Supercede: This bulletin is being revised to add text to the end of the Caution statement. Please discard Corporate Bulletin Number 06-06-01-007E (Section 06 - Engine/Propulsion System). Caution Customers should be informed if a hard part failure is observed in the engine, transmission, transfer case and/or other driveline components, it is likely that powertrain components were weakened to the point of premature failure, while subjected to the higher stresses from Aftermarket Power-Up Devices. Failures associated with the installation of Aftermarket Power-Up Devices, which have been verified, are not covered under the terms of the New Vehicle Warranty. In the majority of these cases, the Fixed Operations Manager (FOM) (in Canada, Warranty Manager) should be contacted and the remaining portion of the powertrain portion of the New Vehicle Warranty blocked. GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage. General Motors Position On Aftermarket Power-Up Devices Important General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. Refer to Service Bulletin Number 04-06-04-054A or newer - Warranty Admin. - Non-GM Parts and Accessories (Aftermarket). Important For further information on aftermarket power-up kits, refer to February 2006 Emerging Issues Course Number 10206.02D. In Canada, information on aftermarket power-up kits was covered in the April 2006 TAC TALK program. Aftermarket power-up devices are non-approved by General Motors. These devices are usually piggy-backed in the main engine harness or remain connected to the diagnostic connector to upload the calibration to the ECM. Recent warranty reviews of returned engines show engine breakdown or non-function due to power-up devices that are utilized for increased horsepower and torque. The following information will assist technicians in identifying overpower engine breakdown or non-function due to aftermarket power-up devices vs. non overpower engine breakdown or non-function. Non-GM parts can alter the design of the vehicle. GM dealers need to be aware of the quality of parts being installed on vehicles. If failure occurs as a result of installation of sub-par parts, warranty coverage may be denied. Refer to Service Bulletin Number 04-06-04-054A or newer Warranty Admin. - Non-GM Parts and Accessories (Aftermarket). Installed Power-Up Kit Aftermarket power-up kits have become a very popular add on for performance-minded customers. These devices can add horsepower and torque and can add additional stress to the engine. These aftermarket calibrations take the Duramax(TM) powertrain outside of its design torque and horsepower rating. They do this by altering air/fuel ratios and injector timing, resulting in excessive cylinder pressure and temperature. When these calibrated parameters are altered, it will upset the design balance and can lead to a reduction of engine life expectancy. Generally, in inspection of Duramax(TM) engine failure due to power-up failures, two or more cylinders will be affected. Installed Power-Up Kit - Once installed, the calibration may mask itself with the factory original calibration ID and may remain the same. Refer to Service Bulletin Number 08-06-04-006F or newer - Information on Identifying Non-GM Calibration Usage for LMM Duramax(TM) Diesel Engine. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 06-06-01-007F > Mar > 10 > Diesel Engine - Damage Due To Power-Up Devices > Page 6648 - A Tech 2(R) will not positively enable you to identify the use of a power-up device. - Some companies that offer power-up devices claim increases of 150 or more horsepower and 300 or more lb/ft pounds of torque. - A vehicle that is used to the power-up device potential 100% of the time will see earlier engine wear and breakdown. - A vehicle that takes advantage of additional power, but on a less frequent basis, may not see premature engine wear and breakdown until later in the engine's life. - A vehicle not pushed to its limits of the power-up device often may not encounter premature wear and breakdown until after the engine is out of warranty. Duramax(TM) Powertrain Horsepower / Torque Ratings The following horsepower and torque increase over the past years required new internal components to accommodate the increase. - LB7 - 300 hp with 520 ft/lb of torque for model years 2000-2004 - LLY - 310 hp with 605 ft/lb of torque for model years 2004-2008 - LBZ - 360 hp with 650 ft/lb of torque for model year 2006-2008 - LMM - 365 hp with 660 ft/lb of torque for model year 2007-2009 LBZ Improvements To reliably achieve an increase in 50 horsepower with 45 ft/lb torque, the Duramax (TM) diesel had to be revised in many areas. A few of the revisions on the 2006 LBZ were: - New pistons with a revised compression ratio. - Wrist pins that are larger in diameter. - Connecting rods with added material to increase the I section strength. - Engine block and machining changes - Cylinder heads Duramax(TM) Life Expectancy The Duramax(TM) 6.6L V8 Turbo Diesel Engine is sold with a warranty of 100,000 miles/160,000 kilometers. The Duramax(TM) has been tested to survive upwards of 200,000 miles/320,000 kilometers. The Duramax(TM) powertrain is designed for reliability, peak horsepower and torque within its design limits. When a customer installs a power-up device, it drastically reduces the mileage ratings. Important Cylinder Wall Spotting (commonly referred to leopard spots) is from the induction hardening process of the top 1/3 of the cylinder wall. This is normal for the Duramax (TM) Diesel. Identifying Fuel Related Aftermarket Power-Up Devices Aftermarket companies have developed a performance pressure relief fuel valve for Duramax(TM) diesel engines. Refer to above graphic illustration. The performance pressure relief fuel valve attaches to the fuel rail in place of the OEM valve and will not allow any fuel return to the tank, giving 100% of the fuel to be available for additional engine performance. This may cause additional fuel related driveability concerns and may set the following DTCs: - DTC P1093 Fuel Rail Pressure (FRP) Low During Power Enrichment - DTC P0087 Fuel Rail Pressure (FRP) Too Low Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 06-06-01-007F > Mar > 10 > Diesel Engine - Damage Due To Power-Up Devices > Page 6649 Aftermarket companies have developed a replacement performance/economy fuel injector nozzle. Refer to above illustration. The performance/economy fuel injector nozzles replace the OEM fuel injector nozzles. The aftermarket companies claim increased horsepower, improved fuel atomization, lower exhaust gas temperatures and increase fuel economy. This may cause additional fuel related driveability concerns and may cause internal engine damage to the pistons and fuel injector nozzles. Identifying Overpower Engine Premature Wear and Breakdown When premature wear and breakdown is encountered due to an aftermarket power-up device, it has some very specific characteristics to the internal engine components. The following list will assist in identifying these characteristics as you tear down the engine. - Pistons will be cracked in the lip area, or a hole in the pistons. - Pistons can also be melted on the lip of the combustion bowl, or the top of the pistons can be melted. - Crosshatch will be polished off the cylinder wall in the major thrust face of cylinder below ring belt travel. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 06-06-01-007F > Mar > 10 > Diesel Engine - Damage Due To Power-Up Devices > Page 6650 - Piston pin bore will show signs of scoring, the wrist pins will be discolored, and can have oil coking on them. The connecting rod bushing surface will have accelerated wear. The above illustration shows a connecting rod bushing. - Oil coking on the underside of the piston between the wrist pin bosses. - Signs of bearing fretting will also be noticed on the connecting rod and main bearing caps. Refer to the above illustration for fretting of main bearing cap 1 and back side of connection rod bearing 2. - Excessive heat in engine compartment caused by overpower device. Refer to above illustration (1). Non Overpower Engine Premature Wear and Breakdown The following pictures show results of overheat, overspeed, low/no oil pressure or injector breakdown and how they differ from aftermarket power-up device premature wear and breakdown. Engine Overheat Overheat can be caused by a loss of coolant or a general cooling system failure. Some of the indicators of overheat are: Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 06-06-01-007F > Mar > 10 > Diesel Engine - Damage Due To Power-Up Devices > Page 6651 - Melted pistons. - Head gasket breakdown or non-function. - Warped cylinder heads. - Crankshaft and connecting rod discolored. Engine Overspeed Causes If an engine has been run faster than design capability (redline), and has caused damage as a result, it may be a result of one of the following conditions: - Leaking or failed turbocharger (TC) oil seals. - Oil evident in the intake runners and compressor side of the TC. - Starting fluid use or alternative fuel added to the engine such as ether. Engine Overspeed Results The following are indicators that an overspeed event took place: - Valve train damage. - Pushrods that are bent (4). - Broken valve bridge buttons after cylinder head removal (2). - Rocker arm tip damage (1). - Dry or rusted cylinders from the use of ether, propane or nitrous oxide. - Piston to valve contact. - Cam gear pin shear. Lack of Oil Pressure Lack of lubrication causes rapid bearing wear or bearing to seize. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 06-06-01-007F > Mar > 10 > Diesel Engine - Damage Due To Power-Up Devices > Page 6652 Bearing failure. Spun main bearings. Engine Premature Wear and Breakdown Due to Improper Function of Fuel Injector A fuel injector may fracture a piston or melt a piston but the damage will be limited to that cylinder only and all other pistons and cylinder walls are OK. In some cases hydraulic lock will occur on the suspected cylinder with an over-fueling fuel injector. Hydraulic lock on the suspected cylinder will cause a bent connecting rod. This can be verified with piston protrusion measurements. 2007-2010 RPO LMM Only Turbocharger DTC P003A Set General Motors has identified a turbocharger (TC) failure mode involving Power-Up Kits that causes soot leakage and DTC P003A to be set. The Power-Up Kits create an overtemperature condition from the increased exhaust gas temperatures that results in a permanent and excessive turbine housing distortion at the TC case halves. 1. A technician may observe one or more of the following conditions: - DTC P003A being set as Current or in History. - An unusual odor emanating from the TC due to an overtemperature condition. - Soot leaking and accumulating at the V-band clamp that secures the TC case halves together. - Limited or unresponsive travel when Commanding the TC Vane Pos. Ctrl. Solenoid ON and OFF with a scan tool. 2. If DTC P003A is found as Current or in History, OR there is evidence of soot leakage (1) in the area of the V-band clamp (1), then technicians MUST verify if the engine control module (ECM) has a Power-Up Kit aftermarket calibration installed or an aftermarket hardware device has been installed. Refer to Service Bulletin Number 08-06-04-006F or newer for the calibration verification information and procedures. How to Handle a Suspect Engine Failure Due to a Power-Up Device Dealers should not automatically decline warranty assistance on engine failures due to the fact that a power-up device or modification is evident or suspected. The technician must identify that the failure is due to a power-up device by teardown analysis and diagnosis of the engine components. The following steps should be taken if an engine failure occurs and it is suspected that the modification or addition of a power-up device maybe the cause of the engine failure. If unclear of this process or direction feel free to contact your Fixed Operations Manager (in Canada, Warranty Manager) for further support. 1. The technician should use proper engine diagnostics to lead him/her to the failed engine components. The Aftermarket Power-Up Kit Check List should be followed and if it is determined that at least three of the Aftermarket Power-Up Kit Check List items match the engine component failures then it can be decided that the failure is not a warrantable claim. 2. Engine failures that meet at least three criteria of the Aftermarket Power-Up Kit Check List are considered failures that are not manufacturer's defects in workmanship or materials. 3. The dealership should contact the PQC, open a case to review the findings and make the final decision on warranty coverage. The Fixed Operations Manager (in Canada, Warranty Manager) should be notified of the PQC decision. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 06-06-01-007F > Mar > 10 > Diesel Engine - Damage Due To Power-Up Devices > Page 6653 4. Denied claims should be documented as follows: 1. The Aftermarket Power-Up Kit Check List completed with the technicians detailed written findings of the diagnosis on the repair order and retained in the repair order file. 2. Photographs of the failed parts should be retained in the repair order file. 5. The customer should be advised that the failure of their engine was not due to a manufacturer's defect in workmanship or materials and therefore the warranty claim is denied on this failure. Aftermarket Power-Up Kit Check List Important Print and use this aftermarket power-up kit check list when performing an engine disassembly investigation of overpower engine breakdown or non-function. Retain a copy of this checklist and photographs of the failed parts in the repair order file. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams Pressure Regulating Solenoid: Diagrams Component Connector End Views Pressure Control (PC) Solenoid Valve (M30) Pressure Control (PC) Solenoid Valve 1 (MW7) Pressure Control (PC) Solenoid Valve 2 (MW7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 6660 Modulated Main Pressure Control (PC) Solenoid Valve (MW7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Service and Repair Shift Interlock Solenoid: Service and Repair Automatic Transmission Shift Lock Control Actuator Replacement Removal Procedure 1. Disable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair). 2. Remove the knee bolster. Refer to Knee Bolster Replacement (With SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (With SLT))Knee Bolster Replacement (Without SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (Without SLT)). 3. Put the shift lever clevis into the neutral position. 4. Disconnect the electrical connector. 5. Using a small screwdriver, pry the automatic transmission shift lock control actuator away from the steering column jacket and the cable shift cam. 6. Remove the shift lock control actuator. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Service and Repair > Page 6664 1. Firmly install the shift lock control actuator onto the steering column jacket and the cable shift cam. 2. Connect the electrical connector. 3. Adjust the shift lock control actuator (with the shift lever clevis in the neutral position) in the following way: 1. Pull out the tab (1) on the adjuster block side (2) of the shift lock control actuator. 2. Press on the adjuster block (2) to compress the internal adjuster spring which disengages the adjuster teeth. Slide the adjuster block (2) as far away from the actuator as possible. 3. Lock the adjuster block (2) in place by pushing in on the tab (1). 4. Inspect the shift lock control actuator for the following items: 1. The shift lock control actuator must lock the shift lever clevis when the shift lever clevis is put into the park position. 2. Depress the brake pedal to move the shift lever out of the park position. 3. The actuator will be energized. 4. Readjust the shift lock control actuator if needed. 5. Install the knee bolster. Refer to Knee Bolster Replacement (With SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (With SLT))Knee Bolster Replacement (Without SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (Without SLT)). 6. Enable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations Shift Solenoid: Locations Disassembled Views Main Valve Body Assembly 1 - Main Valve Body Assembly 2 - Retaining Clip 3 - Exhaust Pressure Regulator Valve Spring 4 Exhaust Pressure Regulator Valve 5 - Retaining Clip 6 - Control Relief Spring 7 - Control Relief Valve 8 - Main Valve Body 9 - Locating Pin (4) 10 - Locating Pin 11 - Pressure Control Solenoid 1 (PCS1) Spring 12 - PCS1 Valve 13 - PCS1 Spring 14 - Trim Gain Valve 15 - PCS1 16 - PCS1 O-Ring 17 - PCS2 Spring 18 - PCS2 Valve 19 - Trim Gain Valve 20 - PCS2 21 - PCS2 O-Ring 22 Shift Solenoid (SS) 3 23 - SS3 O-Ring 24 - SS3 O-Ring 25 - SS2 26 - SS2 O-Ring 27 - SS2 O-Ring Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Page 6668 28 - Torque Converter Clutch Pressure Control Solenoid (TCC PCS) Spring 29 - TCC PCS Valve 31 - TCC PCS 32 - TCC PCS O-Ring 33 - TCC PCS O-Ring 34 - TCC PCS Retaining Bracket 35 SS2 and SS3 Retainers (2) 36 - Accumulator Plug (2) 37 - Accumulator Spring (2) 38 - PCS1 and PCS2 Retaining Bracket Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Shift Solenoid: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Schematic Symbols Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6671 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6672 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6673 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6674 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6675 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6676 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6677 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6678 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6679 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6680 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6681 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6682 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6683 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6684 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6685 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6686 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6687 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6688 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6689 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6690 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6691 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6692 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6693 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6694 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6695 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6696 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6697 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6698 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6699 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6700 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6701 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6702 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6703 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6704 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6705 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6706 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6707 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6708 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6709 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6710 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6711 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6712 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6713 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6714 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6715 Shift Solenoid: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed with Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6716 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6717 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Connector Test Adapters) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6718 Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Test Lamp) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Fused Jumper Wires) * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage Drop) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Frequency) * Testing Ground and Low Reference Circuits (See: Testing and Inspection/Component Tests and General Diagnostics/Testing Ground and Low Reference Circuits) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fuses) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Circuit Breakers) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fusible Links) Troubleshooting with a Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Testing for a Short to Voltage Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6719 Testing for a Short to Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure tests for a short to voltage in a circuit. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the Digital Multimeter (DMM) to the V (DC) position. 4. Connect the positive lead of the DMM to one end of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. Turn ON the ignition and operate all accessories. 7. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Special Tools J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure). Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents). Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6720 The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the frequency of a signal. Note: Connecting the Digital Multimeter (DMM) to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Set to Hz on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6721 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the Digital Multimeter (DMM). 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the difference in voltage potential between 2 points. 1. Set the Digital Multimeter (DMM) to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6722 Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Backprobe Note: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6723 (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for Continuity Testing for Continuity Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures verify good continuity in a circuit. With a Digital Multimeter (DMM) 1. Set the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Select the MIN MAX function on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6724 Testing for Electrical Intermittents Testing for Electrical Intermittents Special Tools J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. Note: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions). 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6725 visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing for Terminal Fretting Some intermittent conditions can be caused by wire terminal fretting corrosion. Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can pile up enough at the electrical contact spots that the electrical resistance across the connection increases. Movement between the contacting surfaces as small as 10 to 100 microns can cause fretting. To put this in perspective, a sheet of paper is about 100 microns thick, so fretting motion is small and hard to see. Vibration and thermal expansion/contraction are the main sources that create fretting motion. Since vehicles vibrate and can experience large temperature swings, they are a good source for fretting motion. Tin, copper, nickel, and iron surfaces are all susceptible to fretting corrosion. Fretting corrosion can be difficult to see but it looks like small, dark smudges on the terminals contact surface. To correct a fretting condition disconnect the suspect connector and add Nyogel lubricant 760G (dielectric grease) to both sides of the connector terminals. Then reconnect the connector and wipe away any excess lubricant. This will correct the additional terminal contact resistance due to the terminal fretting corrosion. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6726 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics). * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Ground Distribution Schematics). Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Checking Aftermarket Accessories). * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6727 Note: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures test for a short to ground in a circuit. With a Digital Multimeter (DMM) 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohms position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Danger: High voltage circuits should only be tested using a digital multimeter (DMM) and test leads with at least a CAT III rating, such as the J 39200-A Digital Multimeter. Failure to follow the procedures exactly as written may result in serious injury or death. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Digital Multimeter (DMM) Basic Requirements Service information is validated using digital multimeters that meet or exceed the following requirements. Using a multimeter that does not meet these basic requirements may give inaccurate readings which could lead to an incorrect diagnosis. Display and Settings 1. Four digits displayed 2. Voltage, amperage, resistance, frequency, diode test settings, and min-max function 3. Display positive and negative values Voltage 1. Have at least 10 M ohm input impedance Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6728 2. Test a DC voltage range of 0.1-1000 V. 3. Test an AC voltage range of 0.1-1000 V. Amperage 1. Test a DC amperage range of 0.1µA-10 A. 2. Test an AC amperage range of 0.1µA-10 A. Resistance Test a resistance range of 0.1 ohm-40 Mohm and displays infinite for a value greater than 40 M ohm (O.L. (Over-load)) Frequency Test for a frequency range of 0.5 HZ-199 K HZ Diode Test 1. Apply at least 1 mA when performing the diode bias test 2. Display the break over voltage drop (0-3 V) of a forward biased diode 3. Display infinite (O.L. (Over-load)) when a diode is reverse biased Min-Max Readings 1. Can update at a 1 ms sample rate 2. Saves and displays minimum and maximum values Note: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Probe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors). * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the EL-38125-580 GM Approved Terminal Release Tool Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the EL-38125-580 GM Approved Terminal Release Tool Kit , ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the EL-38125-580 GM Approved Terminal Release Tool Kit label on the inside of the EL-38125-580 GM Approved Terminal Release Tool Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6729 Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/EPC Connectors AFL/EPC Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6730 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 3. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6731 View showing depressing of the lever lock release tab. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6732 6. Release the rear lower half of the wiredress cover. 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6733 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6734 Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Bosch Connectors (ECM) Bosch Connectors (ECM) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6735 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. 2. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6736 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-bladed tool to release the locking tabs and remove the dress cover. 4. The terminal positive assurance (TPA) is located in the front of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6737 5. Use a small flat-blade tool to remove TPA from the connector. 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6738 Note: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6739 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6740 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Terminal Replacement Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6741 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6742 5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Position Assurance Locks) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Terminal Position Assurance Locks) * AFL/EPC Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/AFL/EPC Connectors) * Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (BSK))Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (0.64))Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (2.8 JPT))Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (ECM)) * Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Weather Pack))Delphi Connectors (Push To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Push to Seat))Delphi Connectors Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6743 (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Pull to Seat))Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro-Pack 100W))Delphi Connectors (Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro .64))Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (12-Way)) * FCI Connectors (Lever Lock) (See: General Electrical Diagnostic Procedures/Connector Repairs/FCI Connectors (Lever Lock)) * JST Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/JST Connectors) * Kostal Connectors (Glow Plug Control Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Glow Plug Control Module))Kostal Connectors (Transmission) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Transmission)) * Molex Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Molex Connectors) * Sumitomo Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Sumitomo Connectors) * Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (CM 42-Way))Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Sensor))Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (0.25 Cap))Tyco/AMP Connectors (43-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (43-Way))Tyco/AMP Connectors (Door Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Door Module))Tyco/AMP Connectors (102-Way Inline) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (102-Way Inline))Tyco/AMP Connectors (Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Seat))Tyco/AMP Connectors (SIR) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (SIR)) * Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (2-Way))Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (16-Way)) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6744 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6745 * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6746 * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6747 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6748 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6749 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Push to Seat) Delphi Connectors (Push To Seat) Special Tools J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6750 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs). 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Terminated Lead Repair 1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice sleeves depending on the gauge size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Delphi Connectors (Pull to Seat) Delphi Connectors (Pull To Seat) Special Tools Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6751 J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Note: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6752 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. View of a typical Micro 64 connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6753 Depress the lock and pull the lever over and past the lock. View of the connector when released from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6754 View of another type of Micro 64 connector. Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6755 View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6756 Note: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6757 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6758 Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Note: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6759 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6760 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6761 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6762 1. Cut the wire as close to the terminal as possible. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6763 Terminal Replacement Procedure After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Special Tools J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Note: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals). 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12-Way) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6764 Delphi Connectors (12-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6765 4. Release the lower wire dress cover locking tab. 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6766 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6767 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors (Lever Lock) FCI Connectors (Lever Lock) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6768 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. The release tab is located on the top of the wiredress cover. 3. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6769 6. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6770 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6771 1. While depressing the lock, remove the connector from the component. 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6772 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. 4. View of the TPA when removed from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6773 5. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Glow Plug Control Module) Kostal Connectors (Glow Plug Control Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6774 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6775 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6776 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. Note: The front TPA cannot be removed from the connector. Only move it to the preset position. 6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm). 7. Use a small flat-blade tool to completely remove the rear TPA from the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6777 8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Transmission) Kostal Connectors (Transmission) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6778 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6779 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Terminal Replacement Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6780 After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6781 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6782 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6783 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6784 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6785 3. To assemble the connector, reverse the connector disassembly procedure. Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6786 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6787 7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6788 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6789 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6790 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6791 Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6792 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6793 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6794 6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (102-Way Inline) Tyco/AMP Connectors (102-Way Inline) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6795 View of a typical connector in the assembled position. 1. Pull the locking lever to the 90 degree position from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6796 2. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal. 3. Slide the male connector body out away from the guide plates. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6797 Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 4. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. 5. Using terminal release tool J 38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6798 6. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 7. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6799 8. The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool J-38125-11A or equivalent to release the locking tab and slide the connector off the female body. 9. Move the locking lever 180 degrees from the connected position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6800 10. With the locking lever in the 180 degree position the guide plates can be removed from the connector body. Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 11. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6801 12. Using terminal release tool J 38125-216, lift the terminal plate past the terminals and out of the connector body cavity. 13. Terminal plate will bind slightly on each corner. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6802 14. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 15. Using terminal release tool J 38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6803 16. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 17. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6804 18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever. 19. Slide the male connector body back inward toward the guide plates. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6805 20. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly. 21. Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Seat) Tyco/AMP Connectors (Seat) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6806 Removal Procedure 1. Grasp the locking slide lever and pull outward from the end of the connector. 2. As the slide lever is pulled out the mating connector is lifted from the seated position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6807 Note: TPA is keyed and can only be inserted in one direction. 3. Using terminal release tool J 38125-11A or equivalent, push the TPA tabs into the connector body. 4. Pull the TPA from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6808 5. Using terminal release tool J 38125-11A or equivalent, release the connector wire dress cover locking tab. 6. With the lock tab released, lift the connector wire dress cover from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6809 7. Using terminal release tool J 38125-212, press the prongs into the holes each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 8. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6810 9. Using terminal release tool J 38125-556, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (SIR) Tyco/AMP Connectors (SIR) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6811 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6812 3. Using terminal tool J-38125-11A or equivalent, release the wire dress cover locking tabs. 4. Pivot connector wire dress cover while removing from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6813 5. Using terminal tool J-38125-11A or equivalent, remove the TPA by lifting straight off the connector body. 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals Repairing Connector Terminals Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6814 Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gauge size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6815 2. Disconnect the connector from the component. 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6816 4. Relieve the tension on the nose piece retainers by inserting J 38125-12A into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. 5. Once the nose piece retainers are relaxed, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6817 6. On the opposite side of the nose piece, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6818 8. Insert the J 38125-553 tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6819 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. If the TPA is removed, be sure to reinstall it before reconnecting the connector. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6820 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Special Tools Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6821 J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Note: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6822 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6823 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6824 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6825 1. While depressing the lock, pull the two connector halves apart. Note: The TPA is fragile and may break if not done carefully. 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. 3. View of the male half of the connector with female terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6826 4. View of the female half of the connector with male terminals. 5. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. View of the female half of the connector with male terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6827 7. View of the male half of the connector with female terminals. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6828 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are a one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine if the element in the fuse is broken (2). If not broken (1), also check for continuity using a Digital Multimeter (DMM) or a continuity tester. If the element is broken or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a Digital Multimeter (DMM) at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gauge size. Repairing a Fusible Link Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6829 Flat Wire Repairs The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Special Tools J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool * J 38125-5 Ultra Torch Special Tool The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Note: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation). GMLAN Connector Terminal Repair Note: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) for the appropriate connector repair procedure. GMLAN Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6830 Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6831 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Special Tools J-38125 Terminal Repair Kit Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6832 repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs High Temperature Wiring Repairs Special Tools J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gauge size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6833 splice. Note: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6834 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6835 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the wire insulation has been chafed, or broken, enough to show the conductive portion of the wire, and the wire is not damaged, determine the length of insulation that needs to be repaired. If the repair is less than 280 mm (11 in), cut the wire within the damaged area. Then slide the appropriate heat shrink tubing (listed below) over the wire, and repair the wire by splicing the wires together. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Once the wire is spliced together slide heat shrink tubing over the damaged area and apply heat to seal the repaired wire. If the wire is damaged, or the damaged area is larger than 280 mm (11 in), then replace the damaged wire by splicing in a new section of wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6836 SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Special Tools J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6837 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6838 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6839 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Special Tools J-38125 Terminal Repair Kit Note: Use only DuraSeal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use DuraSeal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use DuraSeal splice sleeves where there are special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6840 * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6841 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6842 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the instructions for Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Staggering the splices by 65 mm (2.5 in) is recommended. Note: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product AL-36FR to replace the damaged mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Flat Wire Repairs) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/GMLAN Wiring Repairs) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Heated Oxygen Sensor Wiring Repairs) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves) * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Twisted or Shielded Cable) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Inline Harness Diodes) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/SIR/SRS Wiring Repairs) US English/Metric Conversion US English/Metric Conversion Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6843 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6844 Testing Ground and Low Reference Circuits Testing Ground and Low Reference Circuits Because a test lamp can light with up to 200 ohm in a ground or low reference circuit they are not recommended to be used for this type of test. A low impedance test lamp can light and indicate the circuit is good when there is as much as 20-30 ohm present, while a high impedance test lamp can light with up to 200 ohm present in the circuit. This is why the Digital Multi-Meter (DMM) is used when validating a ground or low reference circuit continuity. When using the DMM there are many vehicle conditions that can affect the ground and low reference continuity testing. If these conditions are not met, a ground or low reference circuit test can fail on a good circuit. This may cause longer diagnosis time and incorrect component replacement. Any current flow through a ground or low reference circuit, while being tested, will skew the DMM continuity reading, or display a reading higher than when there is no current flowing. Performing a ground or low reference circuit continuity test, in reference to the vehicles battery negative terminal, will have the highest risk of failing a good ground or low reference circuit test than any other ground reference point. The best ground test points would be a control module housing (if the control modules housing is metal and grounded), door jamb striker (if attached to metal), under dash metal frame work, engine block, or body ground studs (other than where the negative battery cable is attached). A typical DMM ground or low reference circuit continuity reading can be as high as 100 ohm with the ignition ON, and drop to 15-25 ohm after the ignition is turned OFF. The reading will drop below 10 ohm after 30-40 seconds, then below 5 ohm after 60 seconds. Once the vehicle completely goes to sleep (generally 3-10 minutes) the reading will drop below 0.3 ohm. The following list of conditions may need to be met to ensure a valid continuity reading on a ground or low reference circuit: * Ignition OFF * Key out of the ignition switch (when not equipped with keyless entry and remote start) * Retained Accessory Power (RAP) OFF (open and close the driver door after ignition OFF) * Battery charger set at a 2 A or less charge rate * Scan tool not communicating with any vehicle control module (in some cases it may need to be disconnected from the DLC) * All entry doors closed * Headlamps OFF (auto headlamps disabled) * Any delay lighting OFF * HVAC after blow OFF * Any accessory that can work when the ignition is OFF * Wait up to 60 seconds (after all other listed conditions are met) Activating the DOOR LOCK function with a key fob can greatly reduce the time to achieve a valid ground or low reference continuity test result. Terminal Removal Terminal Removal Special Tools * EL-38125-580 - Terminal Release Tool Kit * EL-35616 - Connector Test Adapter Kit For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repair procedures. 1. Find the appropriate connector end view within the connector end view section. The connector end view has the following information: Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6845 * Diagnostic probe tool * Terminal release tool * Terminal/terminated lead part numbers Note: Not using the proper test kit probe may cause damage to the terminal(s) that are probed. 2. Determine if a terminal is damaged. * Locate the diagnostic probe tool from the connector end view. The connector end view describes the color and part number to help the technician find and use the correct tool. * Connect the probe tool to the Digital Multimeter. * Insert the probe tool into the cavity and follow the procedures from the Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter). 3. Disconnect the connector body to perform the repair. 4. Use the following procedure to remove the terminal from the connector body. Note: Several procedures for specific connector bodies are called out in the Wiring Repairs section. * The terminal position assurance (TPA) and connector position assurance (CPA) should be removed before releasing the terminal for the connector body. * Look at the connector end view to locate the cavity of the damaged terminal and find the proper terminal release tool from the terminal release tool kit. Note: Using the incorrect terminal release tool can damage the connector body. * Insert the terminal release tool into the cavity. Note: Some terminals have a lever that must be disengaged before the terminal can be released. 5. Gently pull the wire out of the back of the connector. 6. Repair the terminal by following the Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) procedure. 7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminated Lead Repair Terminated Lead Repair Special Tools * J-38125-8 - Splice Sleeve Crimp Tool Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6846 * J-38125-5 - Ultra Torch For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) procedures. Terminated leads are terminals that are crimped onto wires. The terminated lead can be used throughout the vehicle since it is designed for temperatures up to 150°C. The length of the wire is 450 mm. The DuraSeal splice sleeve has the following 2 critical features: * A special heat shrink tubing that environmentally seals the splice. The shrink tubing contains a sealing adhesive inside the shrink tubing. * A cross hatched (knurled) core crimp that provides the necessary contact integrity for sensitive low energy circuits. 1. Use the connector end view to identify the correct terminated lead. 2. The terminated lead package should include a DuraSeal splice sleeve. If not, use the chart to identify the correct part. 3. Open the harness by removing any tape: Use a sewing seam ripper, or a comparable tool, to cut open the harness, to avoid wire insulation damage. 4. Depending on how many terminals need repairs, cut the terminal and wire back at least 40 mm. Try to keep the harness wire length the same. If more than one terminated lead is required, stagger the lengths by 40 mm. This helps reduce the bundle size of the wire harness. 5. Use the EL-38125-10 - tool in order to position the DuraSeal splice sleeve in the proper color nest of the splice sleeve crimp tool. The crimp tool has four nests, one for each color. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6847 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the J-38125-5 - ultra torch , apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6848 Shift Solenoid: Connector Views Component Connector End Views Control Solenoid Valve Assembly X1 (MYC, MYD or M99) Control Solenoid Valve Assembly X2 (MYC, MYD or M99) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6849 Control Solenoid Valve Assembly X3 (MYC, MYD or M99) 1-2 Shift Solenoid (SS) Valve (M30) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6850 2-3 Shift Solenoid (SS) Valve (M30) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6851 Shift Solenoid (SS) Valve 1 (MW7) Shift Solenoid (SS) Valve 2 (MW7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6852 Shift Solenoid (SS) Valve 3 (MW7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > Control Valve Solenoid Replacement (PCS1 and PCS2) Shift Solenoid: Service and Repair Control Valve Solenoid Replacement (PCS1 and PCS2) Control Valve Solenoid Replacement (PCS1 and PCS2) Removal Procedure 1. Remove the oil pan and transmission internal oil filter. Refer to Oil Pan Replacement (See: Automatic Transmission/Transaxle/Fluid Pan/Service and Repair). 2. Disconnect the internal wiring harness from the solenoid being changed. 3. Remove the 2 bolts that fasten reverse signal pipe (1) to the control valve assembly. Remove the reverse signal pipe. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > Control Valve Solenoid Replacement (PCS1 and PCS2) > Page 6855 Note: * When the pressure control valve retaining bracket (5) is removed, there are 2 sets of accumulators (3) and springs (6) which may fall from the bores. Be sure to catch the accumulators and springs so as to prevent damage to these parts. * The pressure control valve retaining bracket (5) must not be modified. Note that the angle between the 2 bracket surfaces is less than 90 degrees. Replace the bracket if the angle is 90 degrees or more. 4. To remove the pressure control solenoid 1 (PCS1) or PCS2, remove three bolts (4) and the pressure control valve retaining bracket (5). Remove accumulators (3) and springs (6) if they do not fall out when the bracket (5) is removed. 5. Note the position of the solenoid connector and pull the solenoid (1) or (8) out of the bore in the control valve assembly. The O-ring on the solenoid provides the resistance felt during removal. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > Control Valve Solenoid Replacement (PCS1 and PCS2) > Page 6856 1. Obtain the new solenoid (1) or (8). Lubricate new O-ring (2) or (7) with clean transmission fluid. Install the O-ring and push the new solenoid into the control valve body bore with the wiring harness connector in the correct position. 2. Install the 2 accumulators (3) and springs (6) before installing the pressure control valve retaining bracket (5). The valve (3) goes in the bore first with the hollow end facing outward, followed by the spring (6) which goes inside the hollow portion of the valve. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the pressure control valve retaining bracket (5), and install the 3 bolts (4). Tighten the bolts to 12 Nm (108 lb in). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > Control Valve Solenoid Replacement (PCS1 and PCS2) > Page 6857 4. Install the reverse signal pipe (1). Install the 2 bolts that fasten reverse signal pipe to the control valve assembly. Tighten the bolts to 12 Nm (108 lb in). 5. Reconnect the internal wiring harness to the solenoid. 6. Install the oil pan and transmission internal oil filter. Refer to Oil Pan Replacement (See: Automatic Transmission/Transaxle/Fluid Pan/Service and Repair). Note: The FastLearn, adapt, procedure must be performed. This can be done in 1 step using a scan tool. If this procedure is not done, the TCM adaptive values will be at the settings that it learned for the old components and will be in slow adaptive mode. Under these conditions, it will take an unacceptably long time for the adaptive values to converge to levels suitable for the new transmission. 7. Perform the FastLearn procedure. Refer to FastLearn Procedure (See: Automatic Transmission/Transaxle/Testing and Inspection/Programming and Relearning). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > Control Valve Solenoid Replacement (PCS1 and PCS2) > Page 6858 Shift Solenoid: Service and Repair Control Valve Solenoid Replacement (SS1, SS2, SS3, TCC, and MAIN MOD) Control Valve Solenoid Replacement (SS1, SS2, SS3, TCC, and MAIN MOD) Removal Procedure 1. Remove the oil pan and the transmission internal oil filter. Refer to Oil Pan Replacement (See: Automatic Transmission/Transaxle/Fluid Pan/Service and Repair). 2. Disconnect the internal wiring harness from the solenoid being changed. 3. Remove the solenoid retainer (2) for shift solenoid 1 (SS1) (5). Note the position of the solenoid connector and pull the solenoid (5) out of the bore in the control valve assembly (1). The O-rings (3 and 4) provide the resistance felt during removal. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > Control Valve Solenoid Replacement (PCS1 and PCS2) > Page 6859 4. Remove the solenoid retainer (6) for shift solenoid 2 (SS2) (1) or shift solenoid 3 (SS3) (4), whichever is being replaced. 5. Note the position of the solenoid connector and pull the solenoid out of the bore in the control valve assembly. The O-rings (2 and 3) provide the resistance felt during removal. Note: The TCC pressure control solenoid (PCS) retaining bracket must not be modified. Note that the angle between the 2 bracket surfaces is less than 90 degrees. Replace the bracket if the angle is 90 degrees or greater. 6. Remove the TCC PCS retaining bolt and retaining bracket. 7. Remove the TCC PCS (7). Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > Control Valve Solenoid Replacement (PCS1 and PCS2) > Page 6860 1. Obtain a new SS 2 (1), SS 3 (4), TCC PCS (7), or modulated main pressure solenoid. Install O-rings (2 and 3) and lubricate with clean transmission fluid. Push the new solenoid into the control valve assembly (5) with the wiring harness connector in the correct position. 2. Install the solenoid retainer (6). Connect the internal wiring harness to the solenoids replaced. 3. For a new TCC PCS (7), install O-rings and lubricate with clean transmission fluid. Push the new TCC PCS (7) into the control valve assembly with the wiring harness connector in the correct position. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the TCC PCS retainer and bolt. Tighten the bolt to 12 Nm (108 lb in). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > Control Valve Solenoid Replacement (PCS1 and PCS2) > Page 6861 5. For a new SS 1 (5), install O-rings (3 and 4) and lubricate with clean transmission fluid. Push the new SS 1 (5) into the control valve assembly with the wiring harness connector in the correct position. Install the solenoid retainer (2). 6. Install the oil pan and transmission internal oil filter. Refer to Oil Pan Replacement (See: Automatic Transmission/Transaxle/Fluid Pan/Service and Repair). Note: The FastLearn, adapt, procedure must be performed. This can be done in 1 step using a scan tool. If this procedure is not done, the TCM adaptive values will be at the settings that it learned for the old components and will be in slow adaptive mode. Under these conditions, it will take an unacceptably long time for the adaptive values to converge to levels suitable for the new transmission. 7. Perform the FastLearn procedure. Refer to FastLearn Procedure (See: Automatic Transmission/Transaxle/Testing and Inspection/Programming and Relearning). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Torque Converter Clutch Solenoid: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Schematic Symbols Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6866 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6867 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6868 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6869 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6870 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6871 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6872 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6873 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6874 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6875 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6876 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6877 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6878 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6879 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6880 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6881 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6882 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6883 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6884 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6885 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6886 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6887 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6888 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6889 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6890 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6891 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6892 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6893 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6894 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6895 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6896 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6897 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6898 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6899 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6900 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6901 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6902 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6903 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6904 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6905 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6906 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6907 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6908 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6909 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6910 Torque Converter Clutch Solenoid: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed with Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6911 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6912 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Connector Test Adapters) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6913 Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Test Lamp) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Fused Jumper Wires) * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage Drop) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Frequency) * Testing Ground and Low Reference Circuits (See: Testing and Inspection/Component Tests and General Diagnostics/Testing Ground and Low Reference Circuits) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fuses) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Circuit Breakers) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fusible Links) Troubleshooting with a Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Testing for a Short to Voltage Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6914 Testing for a Short to Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure tests for a short to voltage in a circuit. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the Digital Multimeter (DMM) to the V (DC) position. 4. Connect the positive lead of the DMM to one end of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. Turn ON the ignition and operate all accessories. 7. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Special Tools J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure). Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents). Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6915 The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the frequency of a signal. Note: Connecting the Digital Multimeter (DMM) to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Set to Hz on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6916 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the Digital Multimeter (DMM). 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the difference in voltage potential between 2 points. 1. Set the Digital Multimeter (DMM) to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6917 Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Backprobe Note: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6918 (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for Continuity Testing for Continuity Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures verify good continuity in a circuit. With a Digital Multimeter (DMM) 1. Set the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Select the MIN MAX function on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6919 Testing for Electrical Intermittents Testing for Electrical Intermittents Special Tools J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. Note: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions). 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6920 visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing for Terminal Fretting Some intermittent conditions can be caused by wire terminal fretting corrosion. Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can pile up enough at the electrical contact spots that the electrical resistance across the connection increases. Movement between the contacting surfaces as small as 10 to 100 microns can cause fretting. To put this in perspective, a sheet of paper is about 100 microns thick, so fretting motion is small and hard to see. Vibration and thermal expansion/contraction are the main sources that create fretting motion. Since vehicles vibrate and can experience large temperature swings, they are a good source for fretting motion. Tin, copper, nickel, and iron surfaces are all susceptible to fretting corrosion. Fretting corrosion can be difficult to see but it looks like small, dark smudges on the terminals contact surface. To correct a fretting condition disconnect the suspect connector and add Nyogel lubricant 760G (dielectric grease) to both sides of the connector terminals. Then reconnect the connector and wipe away any excess lubricant. This will correct the additional terminal contact resistance due to the terminal fretting corrosion. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6921 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics). * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Ground Distribution Schematics). Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Checking Aftermarket Accessories). * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6922 Note: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures test for a short to ground in a circuit. With a Digital Multimeter (DMM) 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohms position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Danger: High voltage circuits should only be tested using a digital multimeter (DMM) and test leads with at least a CAT III rating, such as the J 39200-A Digital Multimeter. Failure to follow the procedures exactly as written may result in serious injury or death. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Digital Multimeter (DMM) Basic Requirements Service information is validated using digital multimeters that meet or exceed the following requirements. Using a multimeter that does not meet these basic requirements may give inaccurate readings which could lead to an incorrect diagnosis. Display and Settings 1. Four digits displayed 2. Voltage, amperage, resistance, frequency, diode test settings, and min-max function 3. Display positive and negative values Voltage 1. Have at least 10 M ohm input impedance Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6923 2. Test a DC voltage range of 0.1-1000 V. 3. Test an AC voltage range of 0.1-1000 V. Amperage 1. Test a DC amperage range of 0.1µA-10 A. 2. Test an AC amperage range of 0.1µA-10 A. Resistance Test a resistance range of 0.1 ohm-40 Mohm and displays infinite for a value greater than 40 M ohm (O.L. (Over-load)) Frequency Test for a frequency range of 0.5 HZ-199 K HZ Diode Test 1. Apply at least 1 mA when performing the diode bias test 2. Display the break over voltage drop (0-3 V) of a forward biased diode 3. Display infinite (O.L. (Over-load)) when a diode is reverse biased Min-Max Readings 1. Can update at a 1 ms sample rate 2. Saves and displays minimum and maximum values Note: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Probe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors). * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the EL-38125-580 GM Approved Terminal Release Tool Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the EL-38125-580 GM Approved Terminal Release Tool Kit , ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the EL-38125-580 GM Approved Terminal Release Tool Kit label on the inside of the EL-38125-580 GM Approved Terminal Release Tool Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6924 Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/EPC Connectors AFL/EPC Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6925 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 3. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6926 View showing depressing of the lever lock release tab. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6927 6. Release the rear lower half of the wiredress cover. 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6928 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6929 Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Bosch Connectors (ECM) Bosch Connectors (ECM) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6930 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. 2. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6931 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-bladed tool to release the locking tabs and remove the dress cover. 4. The terminal positive assurance (TPA) is located in the front of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6932 5. Use a small flat-blade tool to remove TPA from the connector. 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6933 Note: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6934 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6935 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Terminal Replacement Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6936 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6937 5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Position Assurance Locks) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Terminal Position Assurance Locks) * AFL/EPC Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/AFL/EPC Connectors) * Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (BSK))Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (0.64))Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (2.8 JPT))Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (ECM)) * Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Weather Pack))Delphi Connectors (Push To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Push to Seat))Delphi Connectors Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6938 (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Pull to Seat))Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro-Pack 100W))Delphi Connectors (Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro .64))Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (12-Way)) * FCI Connectors (Lever Lock) (See: General Electrical Diagnostic Procedures/Connector Repairs/FCI Connectors (Lever Lock)) * JST Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/JST Connectors) * Kostal Connectors (Glow Plug Control Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Glow Plug Control Module))Kostal Connectors (Transmission) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Transmission)) * Molex Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Molex Connectors) * Sumitomo Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Sumitomo Connectors) * Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (CM 42-Way))Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Sensor))Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (0.25 Cap))Tyco/AMP Connectors (43-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (43-Way))Tyco/AMP Connectors (Door Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Door Module))Tyco/AMP Connectors (102-Way Inline) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (102-Way Inline))Tyco/AMP Connectors (Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Seat))Tyco/AMP Connectors (SIR) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (SIR)) * Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (2-Way))Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (16-Way)) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6939 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6940 * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6941 * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6942 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6943 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6944 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Push to Seat) Delphi Connectors (Push To Seat) Special Tools J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6945 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs). 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Terminated Lead Repair 1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice sleeves depending on the gauge size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Delphi Connectors (Pull to Seat) Delphi Connectors (Pull To Seat) Special Tools Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6946 J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Note: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6947 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. View of a typical Micro 64 connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6948 Depress the lock and pull the lever over and past the lock. View of the connector when released from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6949 View of another type of Micro 64 connector. Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6950 View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6951 Note: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6952 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6953 Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Note: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6954 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6955 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6956 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6957 1. Cut the wire as close to the terminal as possible. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6958 Terminal Replacement Procedure After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Special Tools J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Note: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals). 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12-Way) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6959 Delphi Connectors (12-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6960 4. Release the lower wire dress cover locking tab. 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6961 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6962 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors (Lever Lock) FCI Connectors (Lever Lock) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6963 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. The release tab is located on the top of the wiredress cover. 3. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6964 6. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6965 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6966 1. While depressing the lock, remove the connector from the component. 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6967 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. 4. View of the TPA when removed from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6968 5. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Glow Plug Control Module) Kostal Connectors (Glow Plug Control Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6969 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6970 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6971 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. Note: The front TPA cannot be removed from the connector. Only move it to the preset position. 6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm). 7. Use a small flat-blade tool to completely remove the rear TPA from the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6972 8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Transmission) Kostal Connectors (Transmission) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6973 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6974 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Terminal Replacement Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6975 After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6976 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6977 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6978 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6979 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6980 3. To assemble the connector, reverse the connector disassembly procedure. Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6981 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6982 7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6983 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6984 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6985 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6986 Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6987 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6988 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6989 6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (102-Way Inline) Tyco/AMP Connectors (102-Way Inline) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6990 View of a typical connector in the assembled position. 1. Pull the locking lever to the 90 degree position from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6991 2. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal. 3. Slide the male connector body out away from the guide plates. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6992 Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 4. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. 5. Using terminal release tool J 38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6993 6. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 7. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6994 8. The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool J-38125-11A or equivalent to release the locking tab and slide the connector off the female body. 9. Move the locking lever 180 degrees from the connected position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6995 10. With the locking lever in the 180 degree position the guide plates can be removed from the connector body. Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 11. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6996 12. Using terminal release tool J 38125-216, lift the terminal plate past the terminals and out of the connector body cavity. 13. Terminal plate will bind slightly on each corner. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6997 14. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 15. Using terminal release tool J 38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6998 16. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 17. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6999 18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever. 19. Slide the male connector body back inward toward the guide plates. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7000 20. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly. 21. Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Seat) Tyco/AMP Connectors (Seat) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7001 Removal Procedure 1. Grasp the locking slide lever and pull outward from the end of the connector. 2. As the slide lever is pulled out the mating connector is lifted from the seated position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7002 Note: TPA is keyed and can only be inserted in one direction. 3. Using terminal release tool J 38125-11A or equivalent, push the TPA tabs into the connector body. 4. Pull the TPA from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7003 5. Using terminal release tool J 38125-11A or equivalent, release the connector wire dress cover locking tab. 6. With the lock tab released, lift the connector wire dress cover from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7004 7. Using terminal release tool J 38125-212, press the prongs into the holes each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 8. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7005 9. Using terminal release tool J 38125-556, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (SIR) Tyco/AMP Connectors (SIR) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7006 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7007 3. Using terminal tool J-38125-11A or equivalent, release the wire dress cover locking tabs. 4. Pivot connector wire dress cover while removing from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7008 5. Using terminal tool J-38125-11A or equivalent, remove the TPA by lifting straight off the connector body. 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals Repairing Connector Terminals Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7009 Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gauge size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7010 2. Disconnect the connector from the component. 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7011 4. Relieve the tension on the nose piece retainers by inserting J 38125-12A into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. 5. Once the nose piece retainers are relaxed, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7012 6. On the opposite side of the nose piece, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7013 8. Insert the J 38125-553 tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7014 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. If the TPA is removed, be sure to reinstall it before reconnecting the connector. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7015 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Special Tools Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7016 J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Note: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7017 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7018 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7019 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7020 1. While depressing the lock, pull the two connector halves apart. Note: The TPA is fragile and may break if not done carefully. 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. 3. View of the male half of the connector with female terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7021 4. View of the female half of the connector with male terminals. 5. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. View of the female half of the connector with male terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7022 7. View of the male half of the connector with female terminals. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7023 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are a one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine if the element in the fuse is broken (2). If not broken (1), also check for continuity using a Digital Multimeter (DMM) or a continuity tester. If the element is broken or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a Digital Multimeter (DMM) at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gauge size. Repairing a Fusible Link Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7024 Flat Wire Repairs The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Special Tools J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool * J 38125-5 Ultra Torch Special Tool The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Note: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation). GMLAN Connector Terminal Repair Note: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) for the appropriate connector repair procedure. GMLAN Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7025 Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7026 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Special Tools J-38125 Terminal Repair Kit Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7027 repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs High Temperature Wiring Repairs Special Tools J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gauge size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7028 splice. Note: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7029 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7030 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the wire insulation has been chafed, or broken, enough to show the conductive portion of the wire, and the wire is not damaged, determine the length of insulation that needs to be repaired. If the repair is less than 280 mm (11 in), cut the wire within the damaged area. Then slide the appropriate heat shrink tubing (listed below) over the wire, and repair the wire by splicing the wires together. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Once the wire is spliced together slide heat shrink tubing over the damaged area and apply heat to seal the repaired wire. If the wire is damaged, or the damaged area is larger than 280 mm (11 in), then replace the damaged wire by splicing in a new section of wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7031 SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Special Tools J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7032 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7033 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7034 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Special Tools J-38125 Terminal Repair Kit Note: Use only DuraSeal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use DuraSeal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use DuraSeal splice sleeves where there are special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7035 * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7036 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7037 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the instructions for Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Staggering the splices by 65 mm (2.5 in) is recommended. Note: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product AL-36FR to replace the damaged mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Flat Wire Repairs) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/GMLAN Wiring Repairs) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Heated Oxygen Sensor Wiring Repairs) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves) * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Twisted or Shielded Cable) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Inline Harness Diodes) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/SIR/SRS Wiring Repairs) US English/Metric Conversion US English/Metric Conversion Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7038 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7039 Testing Ground and Low Reference Circuits Testing Ground and Low Reference Circuits Because a test lamp can light with up to 200 ohm in a ground or low reference circuit they are not recommended to be used for this type of test. A low impedance test lamp can light and indicate the circuit is good when there is as much as 20-30 ohm present, while a high impedance test lamp can light with up to 200 ohm present in the circuit. This is why the Digital Multi-Meter (DMM) is used when validating a ground or low reference circuit continuity. When using the DMM there are many vehicle conditions that can affect the ground and low reference continuity testing. If these conditions are not met, a ground or low reference circuit test can fail on a good circuit. This may cause longer diagnosis time and incorrect component replacement. Any current flow through a ground or low reference circuit, while being tested, will skew the DMM continuity reading, or display a reading higher than when there is no current flowing. Performing a ground or low reference circuit continuity test, in reference to the vehicles battery negative terminal, will have the highest risk of failing a good ground or low reference circuit test than any other ground reference point. The best ground test points would be a control module housing (if the control modules housing is metal and grounded), door jamb striker (if attached to metal), under dash metal frame work, engine block, or body ground studs (other than where the negative battery cable is attached). A typical DMM ground or low reference circuit continuity reading can be as high as 100 ohm with the ignition ON, and drop to 15-25 ohm after the ignition is turned OFF. The reading will drop below 10 ohm after 30-40 seconds, then below 5 ohm after 60 seconds. Once the vehicle completely goes to sleep (generally 3-10 minutes) the reading will drop below 0.3 ohm. The following list of conditions may need to be met to ensure a valid continuity reading on a ground or low reference circuit: * Ignition OFF * Key out of the ignition switch (when not equipped with keyless entry and remote start) * Retained Accessory Power (RAP) OFF (open and close the driver door after ignition OFF) * Battery charger set at a 2 A or less charge rate * Scan tool not communicating with any vehicle control module (in some cases it may need to be disconnected from the DLC) * All entry doors closed * Headlamps OFF (auto headlamps disabled) * Any delay lighting OFF * HVAC after blow OFF * Any accessory that can work when the ignition is OFF * Wait up to 60 seconds (after all other listed conditions are met) Activating the DOOR LOCK function with a key fob can greatly reduce the time to achieve a valid ground or low reference continuity test result. Terminal Removal Terminal Removal Special Tools * EL-38125-580 - Terminal Release Tool Kit * EL-35616 - Connector Test Adapter Kit For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repair procedures. 1. Find the appropriate connector end view within the connector end view section. The connector end view has the following information: Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7040 * Diagnostic probe tool * Terminal release tool * Terminal/terminated lead part numbers Note: Not using the proper test kit probe may cause damage to the terminal(s) that are probed. 2. Determine if a terminal is damaged. * Locate the diagnostic probe tool from the connector end view. The connector end view describes the color and part number to help the technician find and use the correct tool. * Connect the probe tool to the Digital Multimeter. * Insert the probe tool into the cavity and follow the procedures from the Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter). 3. Disconnect the connector body to perform the repair. 4. Use the following procedure to remove the terminal from the connector body. Note: Several procedures for specific connector bodies are called out in the Wiring Repairs section. * The terminal position assurance (TPA) and connector position assurance (CPA) should be removed before releasing the terminal for the connector body. * Look at the connector end view to locate the cavity of the damaged terminal and find the proper terminal release tool from the terminal release tool kit. Note: Using the incorrect terminal release tool can damage the connector body. * Insert the terminal release tool into the cavity. Note: Some terminals have a lever that must be disengaged before the terminal can be released. 5. Gently pull the wire out of the back of the connector. 6. Repair the terminal by following the Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) procedure. 7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminated Lead Repair Terminated Lead Repair Special Tools * J-38125-8 - Splice Sleeve Crimp Tool Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7041 * J-38125-5 - Ultra Torch For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) procedures. Terminated leads are terminals that are crimped onto wires. The terminated lead can be used throughout the vehicle since it is designed for temperatures up to 150°C. The length of the wire is 450 mm. The DuraSeal splice sleeve has the following 2 critical features: * A special heat shrink tubing that environmentally seals the splice. The shrink tubing contains a sealing adhesive inside the shrink tubing. * A cross hatched (knurled) core crimp that provides the necessary contact integrity for sensitive low energy circuits. 1. Use the connector end view to identify the correct terminated lead. 2. The terminated lead package should include a DuraSeal splice sleeve. If not, use the chart to identify the correct part. 3. Open the harness by removing any tape: Use a sewing seam ripper, or a comparable tool, to cut open the harness, to avoid wire insulation damage. 4. Depending on how many terminals need repairs, cut the terminal and wire back at least 40 mm. Try to keep the harness wire length the same. If more than one terminated lead is required, stagger the lengths by 40 mm. This helps reduce the bundle size of the wire harness. 5. Use the EL-38125-10 - tool in order to position the DuraSeal splice sleeve in the proper color nest of the splice sleeve crimp tool. The crimp tool has four nests, one for each color. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7042 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the J-38125-5 - ultra torch , apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7043 Torque Converter Clutch Solenoid: Connector Views Component Connector End Views Torque Converter Clutch (TCC) Pressure Control (PC) Solenoid Valve (MW7) Torque Converter Clutch (TCC) Pulse Width Modulated (PWM) Solenoid Valve (M30) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7044 Torque Converter Clutch (TCC) Solenoid Valve (M30) Wiring Diagram Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Differential > Actuator, Differential Lock > Component Information > Service and Repair Actuator: Service and Repair Front Drive Axle Actuator Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the engine shield, if equipped. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement). 3. Disconnect the electrical connector from the actuator. 4. Remove the actuator (1) for the 8.25 inch axle (2) or (3) for the 9.5 inch axle (4) by turning the actuator counterclockwise. Installation Procedure 1. Apply sealant to the threads of the actuator (1) for the 8.25 inch axle (2) or (3) for the 9.25 inch axle (4). Use the correct sealant. Refer to Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Differential > Actuator, Differential Lock > Component Information > Service and Repair > Page 7049 Adhesives, Fluids, Lubricants, and Sealers (See: Differential Assembly/Fluid Differential/Specifications/Fluid Type Specifications). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the actuator (1 or 3). Tighten the actuator to 20 Nm (15 lb ft). 3. Connect the electrical connector to the actuator. 4. Install the engine shield, if equipped. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement). 5. Lower the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams Transfer Case Actuator: Diagrams Component Connector End Views Transfer Case Encoder Motor (NQF or NQH) Front Drive Axle Actuator (NQF, NQG or NQH) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Page 7054 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case Transfer Case Actuator: Service and Repair MP 1625/1626-NQF - Transfer Case Transfer Case Two/Four Wheel Drive Actuator Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case > Page 7057 Transfer Case Actuator: Service and Repair MP 3023/3024-NQH - Transfer Case Transfer Case Two/Four Wheel Drive Actuator Position Sensor Replacement Transfer Case Two/Four Wheel Drive Actuator Position Sensor Replacement Transfer Case Two/Four Wheel Drive Actuator Replacement Transfer Case Two/Four Wheel Drive Actuator Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case > Page 7058 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams Pressure Regulating Solenoid: Diagrams Component Connector End Views Pressure Control (PC) Solenoid Valve (M30) Pressure Control (PC) Solenoid Valve 1 (MW7) Pressure Control (PC) Solenoid Valve 2 (MW7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 7064 Modulated Main Pressure Control (PC) Solenoid Valve (MW7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Service and Repair Shift Interlock Solenoid: Service and Repair Automatic Transmission Shift Lock Control Actuator Replacement Removal Procedure 1. Disable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair). 2. Remove the knee bolster. Refer to Knee Bolster Replacement (With SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (With SLT))Knee Bolster Replacement (Without SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (Without SLT)). 3. Put the shift lever clevis into the neutral position. 4. Disconnect the electrical connector. 5. Using a small screwdriver, pry the automatic transmission shift lock control actuator away from the steering column jacket and the cable shift cam. 6. Remove the shift lock control actuator. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Service and Repair > Page 7068 1. Firmly install the shift lock control actuator onto the steering column jacket and the cable shift cam. 2. Connect the electrical connector. 3. Adjust the shift lock control actuator (with the shift lever clevis in the neutral position) in the following way: 1. Pull out the tab (1) on the adjuster block side (2) of the shift lock control actuator. 2. Press on the adjuster block (2) to compress the internal adjuster spring which disengages the adjuster teeth. Slide the adjuster block (2) as far away from the actuator as possible. 3. Lock the adjuster block (2) in place by pushing in on the tab (1). 4. Inspect the shift lock control actuator for the following items: 1. The shift lock control actuator must lock the shift lever clevis when the shift lever clevis is put into the park position. 2. Depress the brake pedal to move the shift lever out of the park position. 3. The actuator will be energized. 4. Readjust the shift lock control actuator if needed. 5. Install the knee bolster. Refer to Knee Bolster Replacement (With SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (With SLT))Knee Bolster Replacement (Without SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (Without SLT)). 6. Enable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations Shift Solenoid: Locations Disassembled Views Main Valve Body Assembly 1 - Main Valve Body Assembly 2 - Retaining Clip 3 - Exhaust Pressure Regulator Valve Spring 4 Exhaust Pressure Regulator Valve 5 - Retaining Clip 6 - Control Relief Spring 7 - Control Relief Valve 8 - Main Valve Body 9 - Locating Pin (4) 10 - Locating Pin 11 - Pressure Control Solenoid 1 (PCS1) Spring 12 - PCS1 Valve 13 - PCS1 Spring 14 - Trim Gain Valve 15 - PCS1 16 - PCS1 O-Ring 17 - PCS2 Spring 18 - PCS2 Valve 19 - Trim Gain Valve 20 - PCS2 21 - PCS2 O-Ring 22 Shift Solenoid (SS) 3 23 - SS3 O-Ring 24 - SS3 O-Ring 25 - SS2 26 - SS2 O-Ring 27 - SS2 O-Ring Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Page 7072 28 - Torque Converter Clutch Pressure Control Solenoid (TCC PCS) Spring 29 - TCC PCS Valve 31 - TCC PCS 32 - TCC PCS O-Ring 33 - TCC PCS O-Ring 34 - TCC PCS Retaining Bracket 35 SS2 and SS3 Retainers (2) 36 - Accumulator Plug (2) 37 - Accumulator Spring (2) 38 - PCS1 and PCS2 Retaining Bracket Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Shift Solenoid: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Schematic Symbols Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7075 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7076 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7077 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7078 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7079 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7080 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7081 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7082 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7083 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7084 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7085 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7086 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7087 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7088 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7089 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7090 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7091 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7092 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7093 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7094 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7095 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7096 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7097 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7098 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7099 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7100 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7101 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7102 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7103 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7104 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7105 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7106 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7107 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7108 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7109 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7110 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7111 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7112 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7113 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7114 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7115 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7116 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7117 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7118 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7119 Shift Solenoid: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed with Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7120 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7121 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Connector Test Adapters) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7122 Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Test Lamp) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Fused Jumper Wires) * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage Drop) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Frequency) * Testing Ground and Low Reference Circuits (See: Testing and Inspection/Component Tests and General Diagnostics/Testing Ground and Low Reference Circuits) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fuses) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Circuit Breakers) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fusible Links) Troubleshooting with a Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Testing for a Short to Voltage Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7123 Testing for a Short to Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure tests for a short to voltage in a circuit. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the Digital Multimeter (DMM) to the V (DC) position. 4. Connect the positive lead of the DMM to one end of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. Turn ON the ignition and operate all accessories. 7. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Special Tools J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure). Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents). Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7124 The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the frequency of a signal. Note: Connecting the Digital Multimeter (DMM) to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Set to Hz on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7125 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the Digital Multimeter (DMM). 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the difference in voltage potential between 2 points. 1. Set the Digital Multimeter (DMM) to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7126 Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Backprobe Note: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7127 (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for Continuity Testing for Continuity Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures verify good continuity in a circuit. With a Digital Multimeter (DMM) 1. Set the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Select the MIN MAX function on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7128 Testing for Electrical Intermittents Testing for Electrical Intermittents Special Tools J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. Note: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions). 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7129 visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing for Terminal Fretting Some intermittent conditions can be caused by wire terminal fretting corrosion. Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can pile up enough at the electrical contact spots that the electrical resistance across the connection increases. Movement between the contacting surfaces as small as 10 to 100 microns can cause fretting. To put this in perspective, a sheet of paper is about 100 microns thick, so fretting motion is small and hard to see. Vibration and thermal expansion/contraction are the main sources that create fretting motion. Since vehicles vibrate and can experience large temperature swings, they are a good source for fretting motion. Tin, copper, nickel, and iron surfaces are all susceptible to fretting corrosion. Fretting corrosion can be difficult to see but it looks like small, dark smudges on the terminals contact surface. To correct a fretting condition disconnect the suspect connector and add Nyogel lubricant 760G (dielectric grease) to both sides of the connector terminals. Then reconnect the connector and wipe away any excess lubricant. This will correct the additional terminal contact resistance due to the terminal fretting corrosion. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7130 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics). * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Ground Distribution Schematics). Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Checking Aftermarket Accessories). * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7131 Note: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures test for a short to ground in a circuit. With a Digital Multimeter (DMM) 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohms position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Danger: High voltage circuits should only be tested using a digital multimeter (DMM) and test leads with at least a CAT III rating, such as the J 39200-A Digital Multimeter. Failure to follow the procedures exactly as written may result in serious injury or death. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Digital Multimeter (DMM) Basic Requirements Service information is validated using digital multimeters that meet or exceed the following requirements. Using a multimeter that does not meet these basic requirements may give inaccurate readings which could lead to an incorrect diagnosis. Display and Settings 1. Four digits displayed 2. Voltage, amperage, resistance, frequency, diode test settings, and min-max function 3. Display positive and negative values Voltage 1. Have at least 10 M ohm input impedance Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7132 2. Test a DC voltage range of 0.1-1000 V. 3. Test an AC voltage range of 0.1-1000 V. Amperage 1. Test a DC amperage range of 0.1µA-10 A. 2. Test an AC amperage range of 0.1µA-10 A. Resistance Test a resistance range of 0.1 ohm-40 Mohm and displays infinite for a value greater than 40 M ohm (O.L. (Over-load)) Frequency Test for a frequency range of 0.5 HZ-199 K HZ Diode Test 1. Apply at least 1 mA when performing the diode bias test 2. Display the break over voltage drop (0-3 V) of a forward biased diode 3. Display infinite (O.L. (Over-load)) when a diode is reverse biased Min-Max Readings 1. Can update at a 1 ms sample rate 2. Saves and displays minimum and maximum values Note: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Probe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors). * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the EL-38125-580 GM Approved Terminal Release Tool Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the EL-38125-580 GM Approved Terminal Release Tool Kit , ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the EL-38125-580 GM Approved Terminal Release Tool Kit label on the inside of the EL-38125-580 GM Approved Terminal Release Tool Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7133 Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/EPC Connectors AFL/EPC Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7134 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 3. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7135 View showing depressing of the lever lock release tab. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7136 6. Release the rear lower half of the wiredress cover. 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7137 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7138 Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Bosch Connectors (ECM) Bosch Connectors (ECM) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7139 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. 2. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7140 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-bladed tool to release the locking tabs and remove the dress cover. 4. The terminal positive assurance (TPA) is located in the front of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7141 5. Use a small flat-blade tool to remove TPA from the connector. 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7142 Note: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7143 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7144 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Terminal Replacement Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7145 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7146 5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Position Assurance Locks) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Terminal Position Assurance Locks) * AFL/EPC Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/AFL/EPC Connectors) * Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (BSK))Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (0.64))Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (2.8 JPT))Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (ECM)) * Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Weather Pack))Delphi Connectors (Push To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Push to Seat))Delphi Connectors Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7147 (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Pull to Seat))Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro-Pack 100W))Delphi Connectors (Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro .64))Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (12-Way)) * FCI Connectors (Lever Lock) (See: General Electrical Diagnostic Procedures/Connector Repairs/FCI Connectors (Lever Lock)) * JST Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/JST Connectors) * Kostal Connectors (Glow Plug Control Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Glow Plug Control Module))Kostal Connectors (Transmission) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Transmission)) * Molex Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Molex Connectors) * Sumitomo Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Sumitomo Connectors) * Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (CM 42-Way))Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Sensor))Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (0.25 Cap))Tyco/AMP Connectors (43-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (43-Way))Tyco/AMP Connectors (Door Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Door Module))Tyco/AMP Connectors (102-Way Inline) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (102-Way Inline))Tyco/AMP Connectors (Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Seat))Tyco/AMP Connectors (SIR) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (SIR)) * Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (2-Way))Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (16-Way)) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7148 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7149 * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7150 * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7151 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7152 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7153 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Push to Seat) Delphi Connectors (Push To Seat) Special Tools J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7154 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs). 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Terminated Lead Repair 1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice sleeves depending on the gauge size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Delphi Connectors (Pull to Seat) Delphi Connectors (Pull To Seat) Special Tools Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7155 J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Note: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7156 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. View of a typical Micro 64 connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7157 Depress the lock and pull the lever over and past the lock. View of the connector when released from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7158 View of another type of Micro 64 connector. Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7159 View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7160 Note: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7161 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7162 Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Note: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7163 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7164 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7165 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7166 1. Cut the wire as close to the terminal as possible. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7167 Terminal Replacement Procedure After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Special Tools J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Note: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals). 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12-Way) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7168 Delphi Connectors (12-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7169 4. Release the lower wire dress cover locking tab. 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7170 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7171 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors (Lever Lock) FCI Connectors (Lever Lock) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7172 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. The release tab is located on the top of the wiredress cover. 3. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7173 6. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7174 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7175 1. While depressing the lock, remove the connector from the component. 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7176 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. 4. View of the TPA when removed from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7177 5. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Glow Plug Control Module) Kostal Connectors (Glow Plug Control Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7178 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7179 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7180 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. Note: The front TPA cannot be removed from the connector. Only move it to the preset position. 6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm). 7. Use a small flat-blade tool to completely remove the rear TPA from the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7181 8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Transmission) Kostal Connectors (Transmission) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7182 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7183 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Terminal Replacement Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7184 After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7185 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7186 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7187 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7188 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7189 3. To assemble the connector, reverse the connector disassembly procedure. Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7190 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7191 7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7192 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7193 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7194 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7195 Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7196 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7197 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7198 6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (102-Way Inline) Tyco/AMP Connectors (102-Way Inline) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7199 View of a typical connector in the assembled position. 1. Pull the locking lever to the 90 degree position from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7200 2. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal. 3. Slide the male connector body out away from the guide plates. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7201 Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 4. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. 5. Using terminal release tool J 38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7202 6. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 7. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7203 8. The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool J-38125-11A or equivalent to release the locking tab and slide the connector off the female body. 9. Move the locking lever 180 degrees from the connected position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7204 10. With the locking lever in the 180 degree position the guide plates can be removed from the connector body. Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 11. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7205 12. Using terminal release tool J 38125-216, lift the terminal plate past the terminals and out of the connector body cavity. 13. Terminal plate will bind slightly on each corner. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7206 14. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 15. Using terminal release tool J 38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7207 16. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 17. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7208 18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever. 19. Slide the male connector body back inward toward the guide plates. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7209 20. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly. 21. Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Seat) Tyco/AMP Connectors (Seat) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7210 Removal Procedure 1. Grasp the locking slide lever and pull outward from the end of the connector. 2. As the slide lever is pulled out the mating connector is lifted from the seated position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7211 Note: TPA is keyed and can only be inserted in one direction. 3. Using terminal release tool J 38125-11A or equivalent, push the TPA tabs into the connector body. 4. Pull the TPA from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7212 5. Using terminal release tool J 38125-11A or equivalent, release the connector wire dress cover locking tab. 6. With the lock tab released, lift the connector wire dress cover from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7213 7. Using terminal release tool J 38125-212, press the prongs into the holes each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 8. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7214 9. Using terminal release tool J 38125-556, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (SIR) Tyco/AMP Connectors (SIR) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7215 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7216 3. Using terminal tool J-38125-11A or equivalent, release the wire dress cover locking tabs. 4. Pivot connector wire dress cover while removing from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7217 5. Using terminal tool J-38125-11A or equivalent, remove the TPA by lifting straight off the connector body. 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals Repairing Connector Terminals Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7218 Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gauge size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7219 2. Disconnect the connector from the component. 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7220 4. Relieve the tension on the nose piece retainers by inserting J 38125-12A into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. 5. Once the nose piece retainers are relaxed, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7221 6. On the opposite side of the nose piece, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7222 8. Insert the J 38125-553 tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7223 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. If the TPA is removed, be sure to reinstall it before reconnecting the connector. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7224 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Special Tools Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7225 J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Note: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7226 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7227 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7228 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7229 1. While depressing the lock, pull the two connector halves apart. Note: The TPA is fragile and may break if not done carefully. 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. 3. View of the male half of the connector with female terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7230 4. View of the female half of the connector with male terminals. 5. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. View of the female half of the connector with male terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7231 7. View of the male half of the connector with female terminals. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7232 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are a one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine if the element in the fuse is broken (2). If not broken (1), also check for continuity using a Digital Multimeter (DMM) or a continuity tester. If the element is broken or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a Digital Multimeter (DMM) at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gauge size. Repairing a Fusible Link Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7233 Flat Wire Repairs The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Special Tools J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool * J 38125-5 Ultra Torch Special Tool The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Note: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation). GMLAN Connector Terminal Repair Note: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) for the appropriate connector repair procedure. GMLAN Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7234 Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7235 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Special Tools J-38125 Terminal Repair Kit Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7236 repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs High Temperature Wiring Repairs Special Tools J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gauge size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7237 splice. Note: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7238 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7239 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the wire insulation has been chafed, or broken, enough to show the conductive portion of the wire, and the wire is not damaged, determine the length of insulation that needs to be repaired. If the repair is less than 280 mm (11 in), cut the wire within the damaged area. Then slide the appropriate heat shrink tubing (listed below) over the wire, and repair the wire by splicing the wires together. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Once the wire is spliced together slide heat shrink tubing over the damaged area and apply heat to seal the repaired wire. If the wire is damaged, or the damaged area is larger than 280 mm (11 in), then replace the damaged wire by splicing in a new section of wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7240 SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Special Tools J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7241 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7242 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7243 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Special Tools J-38125 Terminal Repair Kit Note: Use only DuraSeal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use DuraSeal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use DuraSeal splice sleeves where there are special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7244 * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7245 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7246 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the instructions for Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Staggering the splices by 65 mm (2.5 in) is recommended. Note: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product AL-36FR to replace the damaged mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Flat Wire Repairs) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/GMLAN Wiring Repairs) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Heated Oxygen Sensor Wiring Repairs) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves) * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Twisted or Shielded Cable) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Inline Harness Diodes) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/SIR/SRS Wiring Repairs) US English/Metric Conversion US English/Metric Conversion Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7247 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7248 Testing Ground and Low Reference Circuits Testing Ground and Low Reference Circuits Because a test lamp can light with up to 200 ohm in a ground or low reference circuit they are not recommended to be used for this type of test. A low impedance test lamp can light and indicate the circuit is good when there is as much as 20-30 ohm present, while a high impedance test lamp can light with up to 200 ohm present in the circuit. This is why the Digital Multi-Meter (DMM) is used when validating a ground or low reference circuit continuity. When using the DMM there are many vehicle conditions that can affect the ground and low reference continuity testing. If these conditions are not met, a ground or low reference circuit test can fail on a good circuit. This may cause longer diagnosis time and incorrect component replacement. Any current flow through a ground or low reference circuit, while being tested, will skew the DMM continuity reading, or display a reading higher than when there is no current flowing. Performing a ground or low reference circuit continuity test, in reference to the vehicles battery negative terminal, will have the highest risk of failing a good ground or low reference circuit test than any other ground reference point. The best ground test points would be a control module housing (if the control modules housing is metal and grounded), door jamb striker (if attached to metal), under dash metal frame work, engine block, or body ground studs (other than where the negative battery cable is attached). A typical DMM ground or low reference circuit continuity reading can be as high as 100 ohm with the ignition ON, and drop to 15-25 ohm after the ignition is turned OFF. The reading will drop below 10 ohm after 30-40 seconds, then below 5 ohm after 60 seconds. Once the vehicle completely goes to sleep (generally 3-10 minutes) the reading will drop below 0.3 ohm. The following list of conditions may need to be met to ensure a valid continuity reading on a ground or low reference circuit: * Ignition OFF * Key out of the ignition switch (when not equipped with keyless entry and remote start) * Retained Accessory Power (RAP) OFF (open and close the driver door after ignition OFF) * Battery charger set at a 2 A or less charge rate * Scan tool not communicating with any vehicle control module (in some cases it may need to be disconnected from the DLC) * All entry doors closed * Headlamps OFF (auto headlamps disabled) * Any delay lighting OFF * HVAC after blow OFF * Any accessory that can work when the ignition is OFF * Wait up to 60 seconds (after all other listed conditions are met) Activating the DOOR LOCK function with a key fob can greatly reduce the time to achieve a valid ground or low reference continuity test result. Terminal Removal Terminal Removal Special Tools * EL-38125-580 - Terminal Release Tool Kit * EL-35616 - Connector Test Adapter Kit For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repair procedures. 1. Find the appropriate connector end view within the connector end view section. The connector end view has the following information: Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7249 * Diagnostic probe tool * Terminal release tool * Terminal/terminated lead part numbers Note: Not using the proper test kit probe may cause damage to the terminal(s) that are probed. 2. Determine if a terminal is damaged. * Locate the diagnostic probe tool from the connector end view. The connector end view describes the color and part number to help the technician find and use the correct tool. * Connect the probe tool to the Digital Multimeter. * Insert the probe tool into the cavity and follow the procedures from the Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter). 3. Disconnect the connector body to perform the repair. 4. Use the following procedure to remove the terminal from the connector body. Note: Several procedures for specific connector bodies are called out in the Wiring Repairs section. * The terminal position assurance (TPA) and connector position assurance (CPA) should be removed before releasing the terminal for the connector body. * Look at the connector end view to locate the cavity of the damaged terminal and find the proper terminal release tool from the terminal release tool kit. Note: Using the incorrect terminal release tool can damage the connector body. * Insert the terminal release tool into the cavity. Note: Some terminals have a lever that must be disengaged before the terminal can be released. 5. Gently pull the wire out of the back of the connector. 6. Repair the terminal by following the Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) procedure. 7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminated Lead Repair Terminated Lead Repair Special Tools * J-38125-8 - Splice Sleeve Crimp Tool Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7250 * J-38125-5 - Ultra Torch For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) procedures. Terminated leads are terminals that are crimped onto wires. The terminated lead can be used throughout the vehicle since it is designed for temperatures up to 150°C. The length of the wire is 450 mm. The DuraSeal splice sleeve has the following 2 critical features: * A special heat shrink tubing that environmentally seals the splice. The shrink tubing contains a sealing adhesive inside the shrink tubing. * A cross hatched (knurled) core crimp that provides the necessary contact integrity for sensitive low energy circuits. 1. Use the connector end view to identify the correct terminated lead. 2. The terminated lead package should include a DuraSeal splice sleeve. If not, use the chart to identify the correct part. 3. Open the harness by removing any tape: Use a sewing seam ripper, or a comparable tool, to cut open the harness, to avoid wire insulation damage. 4. Depending on how many terminals need repairs, cut the terminal and wire back at least 40 mm. Try to keep the harness wire length the same. If more than one terminated lead is required, stagger the lengths by 40 mm. This helps reduce the bundle size of the wire harness. 5. Use the EL-38125-10 - tool in order to position the DuraSeal splice sleeve in the proper color nest of the splice sleeve crimp tool. The crimp tool has four nests, one for each color. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7251 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the J-38125-5 - ultra torch , apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7252 Shift Solenoid: Connector Views Component Connector End Views Control Solenoid Valve Assembly X1 (MYC, MYD or M99) Control Solenoid Valve Assembly X2 (MYC, MYD or M99) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7253 Control Solenoid Valve Assembly X3 (MYC, MYD or M99) 1-2 Shift Solenoid (SS) Valve (M30) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7254 2-3 Shift Solenoid (SS) Valve (M30) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7255 Shift Solenoid (SS) Valve 1 (MW7) Shift Solenoid (SS) Valve 2 (MW7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7256 Shift Solenoid (SS) Valve 3 (MW7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > Control Valve Solenoid Replacement (PCS1 and PCS2) Shift Solenoid: Service and Repair Control Valve Solenoid Replacement (PCS1 and PCS2) Control Valve Solenoid Replacement (PCS1 and PCS2) Removal Procedure 1. Remove the oil pan and transmission internal oil filter. Refer to Oil Pan Replacement (See: Fluid Pan/Service and Repair). 2. Disconnect the internal wiring harness from the solenoid being changed. 3. Remove the 2 bolts that fasten reverse signal pipe (1) to the control valve assembly. Remove the reverse signal pipe. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > Control Valve Solenoid Replacement (PCS1 and PCS2) > Page 7259 Note: * When the pressure control valve retaining bracket (5) is removed, there are 2 sets of accumulators (3) and springs (6) which may fall from the bores. Be sure to catch the accumulators and springs so as to prevent damage to these parts. * The pressure control valve retaining bracket (5) must not be modified. Note that the angle between the 2 bracket surfaces is less than 90 degrees. Replace the bracket if the angle is 90 degrees or more. 4. To remove the pressure control solenoid 1 (PCS1) or PCS2, remove three bolts (4) and the pressure control valve retaining bracket (5). Remove accumulators (3) and springs (6) if they do not fall out when the bracket (5) is removed. 5. Note the position of the solenoid connector and pull the solenoid (1) or (8) out of the bore in the control valve assembly. The O-ring on the solenoid provides the resistance felt during removal. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > Control Valve Solenoid Replacement (PCS1 and PCS2) > Page 7260 1. Obtain the new solenoid (1) or (8). Lubricate new O-ring (2) or (7) with clean transmission fluid. Install the O-ring and push the new solenoid into the control valve body bore with the wiring harness connector in the correct position. 2. Install the 2 accumulators (3) and springs (6) before installing the pressure control valve retaining bracket (5). The valve (3) goes in the bore first with the hollow end facing outward, followed by the spring (6) which goes inside the hollow portion of the valve. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the pressure control valve retaining bracket (5), and install the 3 bolts (4). Tighten the bolts to 12 Nm (108 lb in). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > Control Valve Solenoid Replacement (PCS1 and PCS2) > Page 7261 4. Install the reverse signal pipe (1). Install the 2 bolts that fasten reverse signal pipe to the control valve assembly. Tighten the bolts to 12 Nm (108 lb in). 5. Reconnect the internal wiring harness to the solenoid. 6. Install the oil pan and transmission internal oil filter. Refer to Oil Pan Replacement (See: Fluid Pan/Service and Repair). Note: The FastLearn, adapt, procedure must be performed. This can be done in 1 step using a scan tool. If this procedure is not done, the TCM adaptive values will be at the settings that it learned for the old components and will be in slow adaptive mode. Under these conditions, it will take an unacceptably long time for the adaptive values to converge to levels suitable for the new transmission. 7. Perform the FastLearn procedure. Refer to FastLearn Procedure (See: Testing and Inspection/Programming and Relearning). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > Control Valve Solenoid Replacement (PCS1 and PCS2) > Page 7262 Shift Solenoid: Service and Repair Control Valve Solenoid Replacement (SS1, SS2, SS3, TCC, and MAIN MOD) Control Valve Solenoid Replacement (SS1, SS2, SS3, TCC, and MAIN MOD) Removal Procedure 1. Remove the oil pan and the transmission internal oil filter. Refer to Oil Pan Replacement (See: Fluid Pan/Service and Repair). 2. Disconnect the internal wiring harness from the solenoid being changed. 3. Remove the solenoid retainer (2) for shift solenoid 1 (SS1) (5). Note the position of the solenoid connector and pull the solenoid (5) out of the bore in the control valve assembly (1). The O-rings (3 and 4) provide the resistance felt during removal. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > Control Valve Solenoid Replacement (PCS1 and PCS2) > Page 7263 4. Remove the solenoid retainer (6) for shift solenoid 2 (SS2) (1) or shift solenoid 3 (SS3) (4), whichever is being replaced. 5. Note the position of the solenoid connector and pull the solenoid out of the bore in the control valve assembly. The O-rings (2 and 3) provide the resistance felt during removal. Note: The TCC pressure control solenoid (PCS) retaining bracket must not be modified. Note that the angle between the 2 bracket surfaces is less than 90 degrees. Replace the bracket if the angle is 90 degrees or greater. 6. Remove the TCC PCS retaining bolt and retaining bracket. 7. Remove the TCC PCS (7). Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > Control Valve Solenoid Replacement (PCS1 and PCS2) > Page 7264 1. Obtain a new SS 2 (1), SS 3 (4), TCC PCS (7), or modulated main pressure solenoid. Install O-rings (2 and 3) and lubricate with clean transmission fluid. Push the new solenoid into the control valve assembly (5) with the wiring harness connector in the correct position. 2. Install the solenoid retainer (6). Connect the internal wiring harness to the solenoids replaced. 3. For a new TCC PCS (7), install O-rings and lubricate with clean transmission fluid. Push the new TCC PCS (7) into the control valve assembly with the wiring harness connector in the correct position. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the TCC PCS retainer and bolt. Tighten the bolt to 12 Nm (108 lb in). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > Control Valve Solenoid Replacement (PCS1 and PCS2) > Page 7265 5. For a new SS 1 (5), install O-rings (3 and 4) and lubricate with clean transmission fluid. Push the new SS 1 (5) into the control valve assembly with the wiring harness connector in the correct position. Install the solenoid retainer (2). 6. Install the oil pan and transmission internal oil filter. Refer to Oil Pan Replacement (See: Fluid Pan/Service and Repair). Note: The FastLearn, adapt, procedure must be performed. This can be done in 1 step using a scan tool. If this procedure is not done, the TCM adaptive values will be at the settings that it learned for the old components and will be in slow adaptive mode. Under these conditions, it will take an unacceptably long time for the adaptive values to converge to levels suitable for the new transmission. 7. Perform the FastLearn procedure. Refer to FastLearn Procedure (See: Testing and Inspection/Programming and Relearning). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Torque Converter Clutch Solenoid: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Schematic Symbols Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7270 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7271 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7272 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7273 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7274 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7275 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7276 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7277 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7278 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7279 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7280 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7281 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7282 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7283 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7284 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7285 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7286 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7287 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7288 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7289 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7290 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7291 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7292 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7293 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7294 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7295 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7296 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7297 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7298 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7299 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7300 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7301 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7302 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7303 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7304 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7305 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7306 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7307 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7308 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7309 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7310 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7311 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7312 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7313 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7314 Torque Converter Clutch Solenoid: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed with Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7315 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7316 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Connector Test Adapters) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7317 Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Test Lamp) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Fused Jumper Wires) * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage Drop) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Frequency) * Testing Ground and Low Reference Circuits (See: Testing and Inspection/Component Tests and General Diagnostics/Testing Ground and Low Reference Circuits) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fuses) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Circuit Breakers) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fusible Links) Troubleshooting with a Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Testing for a Short to Voltage Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7318 Testing for a Short to Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure tests for a short to voltage in a circuit. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the Digital Multimeter (DMM) to the V (DC) position. 4. Connect the positive lead of the DMM to one end of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. Turn ON the ignition and operate all accessories. 7. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Special Tools J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure). Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents). Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7319 The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the frequency of a signal. Note: Connecting the Digital Multimeter (DMM) to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Set to Hz on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7320 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the Digital Multimeter (DMM). 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the difference in voltage potential between 2 points. 1. Set the Digital Multimeter (DMM) to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7321 Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Backprobe Note: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7322 (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for Continuity Testing for Continuity Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures verify good continuity in a circuit. With a Digital Multimeter (DMM) 1. Set the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Select the MIN MAX function on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7323 Testing for Electrical Intermittents Testing for Electrical Intermittents Special Tools J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. Note: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions). 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7324 visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing for Terminal Fretting Some intermittent conditions can be caused by wire terminal fretting corrosion. Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can pile up enough at the electrical contact spots that the electrical resistance across the connection increases. Movement between the contacting surfaces as small as 10 to 100 microns can cause fretting. To put this in perspective, a sheet of paper is about 100 microns thick, so fretting motion is small and hard to see. Vibration and thermal expansion/contraction are the main sources that create fretting motion. Since vehicles vibrate and can experience large temperature swings, they are a good source for fretting motion. Tin, copper, nickel, and iron surfaces are all susceptible to fretting corrosion. Fretting corrosion can be difficult to see but it looks like small, dark smudges on the terminals contact surface. To correct a fretting condition disconnect the suspect connector and add Nyogel lubricant 760G (dielectric grease) to both sides of the connector terminals. Then reconnect the connector and wipe away any excess lubricant. This will correct the additional terminal contact resistance due to the terminal fretting corrosion. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7325 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics). * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Ground Distribution Schematics). Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Checking Aftermarket Accessories). * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7326 Note: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures test for a short to ground in a circuit. With a Digital Multimeter (DMM) 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohms position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Danger: High voltage circuits should only be tested using a digital multimeter (DMM) and test leads with at least a CAT III rating, such as the J 39200-A Digital Multimeter. Failure to follow the procedures exactly as written may result in serious injury or death. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Digital Multimeter (DMM) Basic Requirements Service information is validated using digital multimeters that meet or exceed the following requirements. Using a multimeter that does not meet these basic requirements may give inaccurate readings which could lead to an incorrect diagnosis. Display and Settings 1. Four digits displayed 2. Voltage, amperage, resistance, frequency, diode test settings, and min-max function 3. Display positive and negative values Voltage 1. Have at least 10 M ohm input impedance Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7327 2. Test a DC voltage range of 0.1-1000 V. 3. Test an AC voltage range of 0.1-1000 V. Amperage 1. Test a DC amperage range of 0.1µA-10 A. 2. Test an AC amperage range of 0.1µA-10 A. Resistance Test a resistance range of 0.1 ohm-40 Mohm and displays infinite for a value greater than 40 M ohm (O.L. (Over-load)) Frequency Test for a frequency range of 0.5 HZ-199 K HZ Diode Test 1. Apply at least 1 mA when performing the diode bias test 2. Display the break over voltage drop (0-3 V) of a forward biased diode 3. Display infinite (O.L. (Over-load)) when a diode is reverse biased Min-Max Readings 1. Can update at a 1 ms sample rate 2. Saves and displays minimum and maximum values Note: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Probe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors). * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the EL-38125-580 GM Approved Terminal Release Tool Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the EL-38125-580 GM Approved Terminal Release Tool Kit , ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the EL-38125-580 GM Approved Terminal Release Tool Kit label on the inside of the EL-38125-580 GM Approved Terminal Release Tool Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7328 Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/EPC Connectors AFL/EPC Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7329 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 3. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7330 View showing depressing of the lever lock release tab. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7331 6. Release the rear lower half of the wiredress cover. 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7332 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7333 Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Bosch Connectors (ECM) Bosch Connectors (ECM) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7334 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. 2. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7335 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-bladed tool to release the locking tabs and remove the dress cover. 4. The terminal positive assurance (TPA) is located in the front of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7336 5. Use a small flat-blade tool to remove TPA from the connector. 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7337 Note: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7338 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7339 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Terminal Replacement Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7340 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7341 5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Position Assurance Locks) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Terminal Position Assurance Locks) * AFL/EPC Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/AFL/EPC Connectors) * Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (BSK))Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (0.64))Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (2.8 JPT))Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (ECM)) * Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Weather Pack))Delphi Connectors (Push To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Push to Seat))Delphi Connectors Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7342 (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Pull to Seat))Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro-Pack 100W))Delphi Connectors (Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro .64))Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (12-Way)) * FCI Connectors (Lever Lock) (See: General Electrical Diagnostic Procedures/Connector Repairs/FCI Connectors (Lever Lock)) * JST Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/JST Connectors) * Kostal Connectors (Glow Plug Control Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Glow Plug Control Module))Kostal Connectors (Transmission) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Transmission)) * Molex Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Molex Connectors) * Sumitomo Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Sumitomo Connectors) * Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (CM 42-Way))Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Sensor))Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (0.25 Cap))Tyco/AMP Connectors (43-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (43-Way))Tyco/AMP Connectors (Door Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Door Module))Tyco/AMP Connectors (102-Way Inline) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (102-Way Inline))Tyco/AMP Connectors (Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Seat))Tyco/AMP Connectors (SIR) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (SIR)) * Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (2-Way))Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (16-Way)) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7343 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7344 * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7345 * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7346 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7347 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7348 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Push to Seat) Delphi Connectors (Push To Seat) Special Tools J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7349 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs). 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Terminated Lead Repair 1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice sleeves depending on the gauge size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Delphi Connectors (Pull to Seat) Delphi Connectors (Pull To Seat) Special Tools Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7350 J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Note: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7351 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. View of a typical Micro 64 connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7352 Depress the lock and pull the lever over and past the lock. View of the connector when released from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7353 View of another type of Micro 64 connector. Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7354 View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7355 Note: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7356 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7357 Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Note: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7358 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7359 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7360 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7361 1. Cut the wire as close to the terminal as possible. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7362 Terminal Replacement Procedure After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Special Tools J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Note: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals). 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12-Way) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7363 Delphi Connectors (12-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7364 4. Release the lower wire dress cover locking tab. 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7365 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7366 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors (Lever Lock) FCI Connectors (Lever Lock) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7367 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. The release tab is located on the top of the wiredress cover. 3. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7368 6. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7369 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7370 1. While depressing the lock, remove the connector from the component. 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7371 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. 4. View of the TPA when removed from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7372 5. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Glow Plug Control Module) Kostal Connectors (Glow Plug Control Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7373 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7374 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7375 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. Note: The front TPA cannot be removed from the connector. Only move it to the preset position. 6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm). 7. Use a small flat-blade tool to completely remove the rear TPA from the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7376 8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Transmission) Kostal Connectors (Transmission) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7377 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7378 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Terminal Replacement Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7379 After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7380 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7381 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7382 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7383 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7384 3. To assemble the connector, reverse the connector disassembly procedure. Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7385 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7386 7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7387 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7388 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7389 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7390 Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7391 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7392 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7393 6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (102-Way Inline) Tyco/AMP Connectors (102-Way Inline) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7394 View of a typical connector in the assembled position. 1. Pull the locking lever to the 90 degree position from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7395 2. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal. 3. Slide the male connector body out away from the guide plates. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7396 Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 4. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. 5. Using terminal release tool J 38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7397 6. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 7. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7398 8. The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool J-38125-11A or equivalent to release the locking tab and slide the connector off the female body. 9. Move the locking lever 180 degrees from the connected position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7399 10. With the locking lever in the 180 degree position the guide plates can be removed from the connector body. Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 11. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7400 12. Using terminal release tool J 38125-216, lift the terminal plate past the terminals and out of the connector body cavity. 13. Terminal plate will bind slightly on each corner. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7401 14. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 15. Using terminal release tool J 38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7402 16. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 17. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7403 18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever. 19. Slide the male connector body back inward toward the guide plates. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7404 20. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly. 21. Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Seat) Tyco/AMP Connectors (Seat) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7405 Removal Procedure 1. Grasp the locking slide lever and pull outward from the end of the connector. 2. As the slide lever is pulled out the mating connector is lifted from the seated position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7406 Note: TPA is keyed and can only be inserted in one direction. 3. Using terminal release tool J 38125-11A or equivalent, push the TPA tabs into the connector body. 4. Pull the TPA from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7407 5. Using terminal release tool J 38125-11A or equivalent, release the connector wire dress cover locking tab. 6. With the lock tab released, lift the connector wire dress cover from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7408 7. Using terminal release tool J 38125-212, press the prongs into the holes each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 8. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7409 9. Using terminal release tool J 38125-556, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (SIR) Tyco/AMP Connectors (SIR) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7410 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7411 3. Using terminal tool J-38125-11A or equivalent, release the wire dress cover locking tabs. 4. Pivot connector wire dress cover while removing from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7412 5. Using terminal tool J-38125-11A or equivalent, remove the TPA by lifting straight off the connector body. 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals Repairing Connector Terminals Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7413 Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gauge size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7414 2. Disconnect the connector from the component. 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7415 4. Relieve the tension on the nose piece retainers by inserting J 38125-12A into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. 5. Once the nose piece retainers are relaxed, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7416 6. On the opposite side of the nose piece, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7417 8. Insert the J 38125-553 tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7418 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. If the TPA is removed, be sure to reinstall it before reconnecting the connector. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7419 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Special Tools Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7420 J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Note: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7421 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7422 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7423 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7424 1. While depressing the lock, pull the two connector halves apart. Note: The TPA is fragile and may break if not done carefully. 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. 3. View of the male half of the connector with female terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7425 4. View of the female half of the connector with male terminals. 5. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. View of the female half of the connector with male terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7426 7. View of the male half of the connector with female terminals. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7427 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are a one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine if the element in the fuse is broken (2). If not broken (1), also check for continuity using a Digital Multimeter (DMM) or a continuity tester. If the element is broken or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a Digital Multimeter (DMM) at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gauge size. Repairing a Fusible Link Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7428 Flat Wire Repairs The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Special Tools J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool * J 38125-5 Ultra Torch Special Tool The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Note: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation). GMLAN Connector Terminal Repair Note: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) for the appropriate connector repair procedure. GMLAN Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7429 Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7430 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Special Tools J-38125 Terminal Repair Kit Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7431 repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs High Temperature Wiring Repairs Special Tools J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gauge size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7432 splice. Note: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7433 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7434 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the wire insulation has been chafed, or broken, enough to show the conductive portion of the wire, and the wire is not damaged, determine the length of insulation that needs to be repaired. If the repair is less than 280 mm (11 in), cut the wire within the damaged area. Then slide the appropriate heat shrink tubing (listed below) over the wire, and repair the wire by splicing the wires together. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Once the wire is spliced together slide heat shrink tubing over the damaged area and apply heat to seal the repaired wire. If the wire is damaged, or the damaged area is larger than 280 mm (11 in), then replace the damaged wire by splicing in a new section of wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7435 SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Special Tools J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7436 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7437 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7438 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Special Tools J-38125 Terminal Repair Kit Note: Use only DuraSeal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use DuraSeal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use DuraSeal splice sleeves where there are special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7439 * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7440 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7441 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the instructions for Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Staggering the splices by 65 mm (2.5 in) is recommended. Note: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product AL-36FR to replace the damaged mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Flat Wire Repairs) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/GMLAN Wiring Repairs) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Heated Oxygen Sensor Wiring Repairs) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves) * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Twisted or Shielded Cable) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Inline Harness Diodes) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/SIR/SRS Wiring Repairs) US English/Metric Conversion US English/Metric Conversion Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7442 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7443 Testing Ground and Low Reference Circuits Testing Ground and Low Reference Circuits Because a test lamp can light with up to 200 ohm in a ground or low reference circuit they are not recommended to be used for this type of test. A low impedance test lamp can light and indicate the circuit is good when there is as much as 20-30 ohm present, while a high impedance test lamp can light with up to 200 ohm present in the circuit. This is why the Digital Multi-Meter (DMM) is used when validating a ground or low reference circuit continuity. When using the DMM there are many vehicle conditions that can affect the ground and low reference continuity testing. If these conditions are not met, a ground or low reference circuit test can fail on a good circuit. This may cause longer diagnosis time and incorrect component replacement. Any current flow through a ground or low reference circuit, while being tested, will skew the DMM continuity reading, or display a reading higher than when there is no current flowing. Performing a ground or low reference circuit continuity test, in reference to the vehicles battery negative terminal, will have the highest risk of failing a good ground or low reference circuit test than any other ground reference point. The best ground test points would be a control module housing (if the control modules housing is metal and grounded), door jamb striker (if attached to metal), under dash metal frame work, engine block, or body ground studs (other than where the negative battery cable is attached). A typical DMM ground or low reference circuit continuity reading can be as high as 100 ohm with the ignition ON, and drop to 15-25 ohm after the ignition is turned OFF. The reading will drop below 10 ohm after 30-40 seconds, then below 5 ohm after 60 seconds. Once the vehicle completely goes to sleep (generally 3-10 minutes) the reading will drop below 0.3 ohm. The following list of conditions may need to be met to ensure a valid continuity reading on a ground or low reference circuit: * Ignition OFF * Key out of the ignition switch (when not equipped with keyless entry and remote start) * Retained Accessory Power (RAP) OFF (open and close the driver door after ignition OFF) * Battery charger set at a 2 A or less charge rate * Scan tool not communicating with any vehicle control module (in some cases it may need to be disconnected from the DLC) * All entry doors closed * Headlamps OFF (auto headlamps disabled) * Any delay lighting OFF * HVAC after blow OFF * Any accessory that can work when the ignition is OFF * Wait up to 60 seconds (after all other listed conditions are met) Activating the DOOR LOCK function with a key fob can greatly reduce the time to achieve a valid ground or low reference continuity test result. Terminal Removal Terminal Removal Special Tools * EL-38125-580 - Terminal Release Tool Kit * EL-35616 - Connector Test Adapter Kit For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repair procedures. 1. Find the appropriate connector end view within the connector end view section. The connector end view has the following information: Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7444 * Diagnostic probe tool * Terminal release tool * Terminal/terminated lead part numbers Note: Not using the proper test kit probe may cause damage to the terminal(s) that are probed. 2. Determine if a terminal is damaged. * Locate the diagnostic probe tool from the connector end view. The connector end view describes the color and part number to help the technician find and use the correct tool. * Connect the probe tool to the Digital Multimeter. * Insert the probe tool into the cavity and follow the procedures from the Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter). 3. Disconnect the connector body to perform the repair. 4. Use the following procedure to remove the terminal from the connector body. Note: Several procedures for specific connector bodies are called out in the Wiring Repairs section. * The terminal position assurance (TPA) and connector position assurance (CPA) should be removed before releasing the terminal for the connector body. * Look at the connector end view to locate the cavity of the damaged terminal and find the proper terminal release tool from the terminal release tool kit. Note: Using the incorrect terminal release tool can damage the connector body. * Insert the terminal release tool into the cavity. Note: Some terminals have a lever that must be disengaged before the terminal can be released. 5. Gently pull the wire out of the back of the connector. 6. Repair the terminal by following the Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) procedure. 7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminated Lead Repair Terminated Lead Repair Special Tools * J-38125-8 - Splice Sleeve Crimp Tool Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7445 * J-38125-5 - Ultra Torch For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) procedures. Terminated leads are terminals that are crimped onto wires. The terminated lead can be used throughout the vehicle since it is designed for temperatures up to 150°C. The length of the wire is 450 mm. The DuraSeal splice sleeve has the following 2 critical features: * A special heat shrink tubing that environmentally seals the splice. The shrink tubing contains a sealing adhesive inside the shrink tubing. * A cross hatched (knurled) core crimp that provides the necessary contact integrity for sensitive low energy circuits. 1. Use the connector end view to identify the correct terminated lead. 2. The terminated lead package should include a DuraSeal splice sleeve. If not, use the chart to identify the correct part. 3. Open the harness by removing any tape: Use a sewing seam ripper, or a comparable tool, to cut open the harness, to avoid wire insulation damage. 4. Depending on how many terminals need repairs, cut the terminal and wire back at least 40 mm. Try to keep the harness wire length the same. If more than one terminated lead is required, stagger the lengths by 40 mm. This helps reduce the bundle size of the wire harness. 5. Use the EL-38125-10 - tool in order to position the DuraSeal splice sleeve in the proper color nest of the splice sleeve crimp tool. The crimp tool has four nests, one for each color. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7446 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the J-38125-5 - ultra torch , apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7447 Torque Converter Clutch Solenoid: Connector Views Component Connector End Views Torque Converter Clutch (TCC) Pressure Control (PC) Solenoid Valve (MW7) Torque Converter Clutch (TCC) Pulse Width Modulated (PWM) Solenoid Valve (M30) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7448 Torque Converter Clutch (TCC) Solenoid Valve (M30) Wiring Diagram Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > Customer Interest for Case: > 10-07-30-001C > Apr > 11 > A/T Fluid/Oil Leak from Transmission Vent Case: Customer Interest A/T - Fluid/Oil Leak from Transmission Vent TECHNICAL Bulletin No.: 10-07-30-001C Date: April 13, 2011 Subject: Fluid/Oil Leak During Cold Weather from Transmission Vent (Early Models-Replace Transmission Fluid Level Indicator and Install New Transmission Vent Assembly) Models: 2001-2012 Chevrolet Silverado 2500HD-3500HD Series 2001-2012 GMC Sierra 2500HD-3500HD Series Equipped with Allison(R) LCT 1000 Automatic Transmission (RPOs M74, MW7) Supercede: This bulletin is being revised to add the 2012 model year and update information. Please discard Corporate Bulletin Number 10-07-30-001B (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a small red fluid/oil leak during cold weather. Upon further investigation, the technician may find a small fluid leak in the area at the back of the transmission by the vent. Cause This condition may be caused by fluid being discharged out the transmission vent due to a low transmission fluid fill. During extreme cold weather, (approximately -25°C (-15°F or colder), low fluid fill can cause the transmission pump to ingest air which can aerate the fluid and push some fluid out the vent. Correction On 2001 through 2012 models, verify the transmission is full of fluid. Follow the SI fluid checking procedure to PROPERLY check the transmission fluid level using the Hot Check Procedure. Important Ensure that the fluid level is at the top of the HOT band when the transmission fluid temperature is 79°C (175°F). Refer to SI Document ID# 2408059 for the proper fluid level checking procedure. Note Only on 2001-2004 models, replace the transmission fluid indicator (dipstick) with a new vented indicator, P/N 15794381. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > Customer Interest for Case: > 10-07-30-001C > Apr > 11 > A/T Fluid/Oil Leak from Transmission Vent > Page 7457 Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Case: > 10-07-30-001C > Apr > 11 > A/T - Fluid/Oil Leak from Transmission Vent Case: All Technical Service Bulletins A/T - Fluid/Oil Leak from Transmission Vent TECHNICAL Bulletin No.: 10-07-30-001C Date: April 13, 2011 Subject: Fluid/Oil Leak During Cold Weather from Transmission Vent (Early Models-Replace Transmission Fluid Level Indicator and Install New Transmission Vent Assembly) Models: 2001-2012 Chevrolet Silverado 2500HD-3500HD Series 2001-2012 GMC Sierra 2500HD-3500HD Series Equipped with Allison(R) LCT 1000 Automatic Transmission (RPOs M74, MW7) Supercede: This bulletin is being revised to add the 2012 model year and update information. Please discard Corporate Bulletin Number 10-07-30-001B (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a small red fluid/oil leak during cold weather. Upon further investigation, the technician may find a small fluid leak in the area at the back of the transmission by the vent. Cause This condition may be caused by fluid being discharged out the transmission vent due to a low transmission fluid fill. During extreme cold weather, (approximately -25°C (-15°F or colder), low fluid fill can cause the transmission pump to ingest air which can aerate the fluid and push some fluid out the vent. Correction On 2001 through 2012 models, verify the transmission is full of fluid. Follow the SI fluid checking procedure to PROPERLY check the transmission fluid level using the Hot Check Procedure. Important Ensure that the fluid level is at the top of the HOT band when the transmission fluid temperature is 79°C (175°F). Refer to SI Document ID# 2408059 for the proper fluid level checking procedure. Note Only on 2001-2004 models, replace the transmission fluid indicator (dipstick) with a new vented indicator, P/N 15794381. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Case: > 10-07-30-001C > Apr > 11 > A/T - Fluid/Oil Leak from Transmission Vent > Page 7463 Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 10-07-30-008B > Nov > 10 > A/T - Won't Shift Into Overdrive/DTC P0777 or P0735 Clutch: Customer Interest A/T - Won't Shift Into Overdrive/DTC P0777 or P0735 TECHNICAL Bulletin No.: 10-07-30-008B Date: November 10, 2010 Subject: WOT 4-5 Shift Flare or Tie Up with DTC P0733, P0777, P0735 or P2723 Stored, Intermittent Slip in Reverse (Inspect Seals, Replace Piston/Clutch Plates if Damaged) Models: 2006-2011 Chevrolet Silverado 2006-2011 GMC Sierra Equipped with Allison(R) 1000 Automatic Transmission (RPO MW7) Supercede: This bulletin is being revised to add the 2011 model year and additional conditions. Please discard Corporate Bulletin Number 10-07-30-008A (Section 07 - Transmission/Transaxle). Condition Some customers may comment that the transmission won't shift into overdrive, WOT 4-5 shift perceived as either tie-up or flare, intermittent slipping in Reverse or shift inhibited when selecting Reverse. DTC P0777 Pressure Control Solenoid "B" Stuck On or P0735 Incorrect 5th Gear Ratio may be stored. These conditions may not appear until after some mileage and operation, sometimes in the 32,000 to 64,000 km (20,000 to 40,000 mi) range. Cause This condition may be caused by a torn or cut 3rd, 5th and reverse clutch piston bonded seal. Correction Inspect the 3rd, 5th and Reverse clutch piston seals for tears or damage on the ID and OD lips and clutch plates for signs of excessive heat and slipping. Replace the piston and clutch plates if damaged. Refer to 1-2-3-4 and 4-5-6 Clutch Assembly and 3-5 Reverse Clutch Assembly Installation in SI. Refer to the GM Electronic Parts Catalog (EPC) for part numbers. Following the piston replacement, reset the transmission adaptive parameters and run "Fast Learn." Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 10-07-30-008B > Nov > 10 > A/T Won't Shift Into Overdrive/DTC P0777 or P0735 Clutch: All Technical Service Bulletins A/T - Won't Shift Into Overdrive/DTC P0777 or P0735 TECHNICAL Bulletin No.: 10-07-30-008B Date: November 10, 2010 Subject: WOT 4-5 Shift Flare or Tie Up with DTC P0733, P0777, P0735 or P2723 Stored, Intermittent Slip in Reverse (Inspect Seals, Replace Piston/Clutch Plates if Damaged) Models: 2006-2011 Chevrolet Silverado 2006-2011 GMC Sierra Equipped with Allison(R) 1000 Automatic Transmission (RPO MW7) Supercede: This bulletin is being revised to add the 2011 model year and additional conditions. Please discard Corporate Bulletin Number 10-07-30-008A (Section 07 - Transmission/Transaxle). Condition Some customers may comment that the transmission won't shift into overdrive, WOT 4-5 shift perceived as either tie-up or flare, intermittent slipping in Reverse or shift inhibited when selecting Reverse. DTC P0777 Pressure Control Solenoid "B" Stuck On or P0735 Incorrect 5th Gear Ratio may be stored. These conditions may not appear until after some mileage and operation, sometimes in the 32,000 to 64,000 km (20,000 to 40,000 mi) range. Cause This condition may be caused by a torn or cut 3rd, 5th and reverse clutch piston bonded seal. Correction Inspect the 3rd, 5th and Reverse clutch piston seals for tears or damage on the ID and OD lips and clutch plates for signs of excessive heat and slipping. Replace the piston and clutch plates if damaged. Refer to 1-2-3-4 and 4-5-6 Clutch Assembly and 3-5 Reverse Clutch Assembly Installation in SI. Refer to the GM Electronic Parts Catalog (EPC) for part numbers. Following the piston replacement, reset the transmission adaptive parameters and run "Fast Learn." Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps Engine Block Heater: All Technical Service Bulletins Engine - MIL ON P0116/P1400 Set In Very Cold Temps TECHNICAL Bulletin No.: 10-06-04-008A Date: January 24, 2011 Subject: Malfunction Indicator Lamp (MIL) Illuminated at Very Cold Ambient Temperatures When Using Engine Coolant Heater, DTC P0116 and/or P1400 Set (Relocate Engine Coolant Temperature (ECT) Sensor and Engine Coolant Heater Cord) Models: 2006-2007 Buick Rainier 2009 Buick LaCrosse Super, Allure Super (Canada Only) 2006-2010 Cadillac Escalade 2006-2007 Chevrolet Monte Carlo 2006-2009 Chevrolet Impala SS, TrailBlazer 2006-2010 Chevrolet Avalanche, Express, Silverado Tahoe 2006-2009 GMC Envoy 2006-2010 GMC Savana, Sierra, Yukon 2006-2008 Pontiac Grand Prix 2006-2009 Saab 9-7X Equipped with V8 Engine RPO LC9, LH6, LH8, LH9, L76, LS2, LS4, LFA, LZ1, L92, L94, L9H or L20, L96, LMF, LMG, LY2, LY5, LY6 Please Refer to GMVIS Attention: To properly correct this condition, you must follow both of the procedures to relocate the ECT sensor and the engine coolant heater cord. Supercede: This bulletin is being revised to add cast iron block engine RPOs and to update the Warranty Information coverage period. Please discard Corporate Bulletin Number 10-06-04-008 (Section 06 - Engine/Propulsion System). Condition Some customers may comment that the malfunction indicator lamp (MIL) illuminates after starting the vehicle when they were using the engine coolant heater in very cold ambient temperatures. This usually occurs in a range of -23 to -40°C (-10 to -40°F) or colder. The technician may observe on a scan tool DTC P0116 and/or P1400 set as Current or in History. Cause This condition may be caused by the engine control module (ECM) determining that the ignition OFF time requirement has been met at start-up and interpreting the temperature difference between the engine coolant temperature (ECT) sensor and the intake air temperature (IAT) sensor as being outside of a calibrated range. Correction Important DO NOT replace the ECM for this condition. Relocating the ECT Sensor 1. Turn ON the ignition with the engine OFF. 2. Perform the diagnostic system check - vehicle. Refer to Diagnostic System Check - Vehicle in SI. ‹› If DTC P0116 and/or P1400 are set and the customer WAS using the engine coolant heater, proceed to Step 3. ‹› If DTC P0116 and/or P1400 are set and the customer WAS NOT using the engine coolant heater, refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. 3. Turn OFF the ignition. Warning To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 7482 under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator are still hot. 4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle. Refer to Cooling System Draining and Filling in SI. 7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor. 10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J 38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle. 13. Disconnect the wiring harness connector from the ECT sensor (2). 14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT sensor in the hole of the cylinder head where the plug was removed. Tighten Tighten to 20 Nm (15 lb ft). 18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was removed Tighten Tighten to 20 Nm (15 lb ft). Important Leave enough wire attached to the ECT sensor harness connector in order to create manageable splices that are at least 40 mm (1.5 in) away from the other splice. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 7483 20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit. Cut off the ECT sensor harness connector and wiring. 21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured TO or WITHIN an existing protective conduit. Note This step is to set up and verify the length of wiring that is required before cutting. 22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the appropriate length. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. 26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit using tie straps. Important You MUST run the engine at the specified RPM and until it reaches normal operating temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool down in order to top off the coolant level as needed. 28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI. 29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan tool to clear any DTCs. Relocating the Engine Coolant Heater Cord Important For reference, the procedure and graphics that are shown are from a Chevrolet Silverado, but are similar for the other vehicles listed above. 1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit from the engine compartment in order to determine the required extension cord length. 3. Obtain an extension cord with the following features: - 120 volt - 14/3 gauge - 15A capacity - Three prong - Polarized plug and receptacle - Chemical resistant - Grounded terminals - Designed for use in a cold outdoor environment - Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight - Maximum length of 2.5-3 m (8-10 ft) 4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N 12345579 (in Canada, use P/N 10953481) or an equivalent. 6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 7484 7. Wrap electrical tape around the connection as shown. 8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to the engine coolant crossover pipe as shown. 9. Continue to route the extension cord to the exit location desired by the customer as shown. 10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the engine coolant heater cord to the vehicle that were released to provide length. Part Information The extension cord may be obtained at any of the following outlets: - Lowes* - Home Depot* - Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number: CWRSJTOW3C14-10 USA: Cords should bear the UL symbol. Canada: Cords should bear the ULc symbol or CSA approval. *We believe these sources and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from these firms or for any such items that may be available from other sources. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 7485 Warranty Information (excluding Saab Models) For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 7491 under pressure if the radiator cap or the surge tank cap is removed while the engine and radiator are still hot. 4. Remove the surge tank fill cap from the surge tank or the coolant pressure cap from the radiator. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Place a clean drain pan under the radiator drain cock or under the lower radiator hose depending on the vehicle. Refer to Cooling System Draining and Filling in SI. 7. Loosen the radiator drain cock if equipped or use J 38185 clamp pliers and reposition the clamp on the lower radiator hose at the radiator. 8. Remove the end of the lower radiator hose from the radiator. 9. Drain the engine coolant sufficiently below the level of the ECT sensor. 10. Close the radiator drain cock or connect the lower radiator hose at the radiator. 11. Use the J 38185 clamp pliers to place the clamp into the original position on the hose. 12. Lower the vehicle. 13. Disconnect the wiring harness connector from the ECT sensor (2). 14. Remove the ECT sensor (1) from the front of the cylinder head. 15. Remove the corresponding size plug at the rear of the OTHER cylinder head. 16. Coat the threads of the ECT sensor with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 17. Install the ECT sensor in the hole of the cylinder head where the plug was removed. Tighten Tighten to 20 Nm (15 lb ft). 18. Coat the threads of the plug with sealer. Use GM P/N 12346004 (Canadian P/N 10953480) or an equivalent. 19. Install the plug in the hole of the cylinder head where the ECT sensor was removed Tighten Tighten to 20 Nm (15 lb ft). Important Leave enough wire attached to the ECT sensor harness connector in order to create manageable splices that are at least 40 mm (1.5 in) away from the other splice. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 7492 20. Extract a portion of the ECT sensor harness wiring and connector from the protective conduit. Cut off the ECT sensor harness connector and wiring. 21. Determine a routing path for the ECT sensor jumper harness wires so that they can be secured TO or WITHIN an existing protective conduit. Note This step is to set up and verify the length of wiring that is required before cutting. 22. Route the ECT sensor jumper wires and then enclose them in their own protective conduit in order to VERIFY the length that is required. 23. Cut the ECT sensor jumper wires to the appropriate length. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 24. Splice the ECT sensor jumper wires to the ORIGINAL ECT HARNESS LOCATION using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. Note Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splice or connector. 25. Splice the ECT sensor jumper wires to the ECT SENSOR HARNESS CONNECTOR using DuraSeal weatherproof splices. Refer to Splicing Copper Wire Using Splice Sleeves in SI. 26. Connect the ECT sensor harness connector to the ECT sensor. 27. Secure the ECT sensor jumper wires that are in their own protective conduit TO or WITHIN the existing harness conduit using tie straps. Important You MUST run the engine at the specified RPM and until it reaches normal operating temperature and then allow it to idle as indicated in SI. The engine MUST then be allowed to cool down in order to top off the coolant level as needed. 28. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling in SI. 29. Pressure test the cooling system. Refer to Cooling System Leak Testing in SI. 30. Use a scan tool to clear any DTCs. Relocating the Engine Coolant Heater Cord Important For reference, the procedure and graphics that are shown are from a Chevrolet Silverado, but are similar for the other vehicles listed above. 1. Turn OFF the ignition. 2. Ask the customer where they would prefer the extension cord to exit from the engine compartment in order to determine the required extension cord length. 3. Obtain an extension cord with the following features: - 120 volt - 14/3 gauge - 15A capacity - Three prong - Polarized plug and receptacle - Chemical resistant - Grounded terminals - Designed for use in a cold outdoor environment - Outer jacket resistant to deterioration from moisture, abrasion and exposure to sunlight - Maximum length of 2.5-3 m (8-10 ft) 4. Release enough of the clips that retain the engine coolant heater cord to the vehicle to provide the necessary length for repositioning. 5. Apply dielectric grease to the electrical contacts of the heater cord receptacle and the extension cord plug to prevent corrosion. Use GM P/N 12345579 (in Canada, use P/N 10953481) or an equivalent. 6. Connect the heater cord receptacle to the extension cord plug and wipe OFF any excess grease. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 7493 7. Wrap electrical tape around the connection as shown. 8. Route the engine coolant heater cord and extension cord behind the alternator and adjacent to the engine coolant crossover pipe as shown. 9. Continue to route the extension cord to the exit location desired by the customer as shown. 10. Review the routing of the coolant heater cord and extension cord to verify that it does not touch any sharp edges that could damage it. 11. Secure the engine coolant heater cord and the extension cord with tie straps as needed. 12. Resecure any of the original clips that retained the engine coolant heater cord to the vehicle that were released to provide length. Part Information The extension cord may be obtained at any of the following outlets: - Lowes* - Home Depot* - Canada: Acklands-Grainger* (www.acklandsgrainger.com), Catalogue Part Number: CWRSJTOW3C14-10 USA: Cords should bear the UL symbol. Canada: Cords should bear the ULc symbol or CSA approval. *We believe these sources and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from these firms or for any such items that may be available from other sources. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch: > 10-06-04-008A > Jan > 11 > Engine - MIL ON P0116/P1400 Set In Very Cold Temps > Page 7494 Warranty Information (excluding Saab Models) For vehicles repaired under the 5 year / 100,000 mile (160,000 km) emission warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON Control Module: Customer Interest A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 7503 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 7504 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 7505 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON Control Module: All Technical Service Bulletins A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 7511 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 7512 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 7513 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Page 7514 Control Module: Locations Harness Routing Views Engine Chassis Harness Routing - Top Front (Diesel) 1 - Battery - Right 2 - Fuse Holder 3 - X127 4 - X108 5 - X107 6 - X123 (PTO) 7 - Fuse Block Underhood 8 - X109 9 - Battery - Left 10 - Engine Control Module (ECM) 11 - Transmission Control Module (TCM) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Page 7515 Control Module: Diagrams Component Connector End Views Transmission Control Module (TCM) (M30) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Page 7516 Transmission Control Module (TCM) (MW7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Page 7517 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Page 7518 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Technical Service Bulletins > Page 7519 Control Module: Service and Repair Transmission Control Module Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Automatic Transmission Dipstick - Dipstick Tube > Component Information > Technical Service Bulletins > Customer Interest for Automatic Transmission Dipstick - Dipstick Tube: > 10-07-30-001C > Apr > 11 > A/T - Fluid/Oil Leak from Transmission Vent Automatic Transmission Dipstick - Dipstick Tube: Customer Interest A/T - Fluid/Oil Leak from Transmission Vent TECHNICAL Bulletin No.: 10-07-30-001C Date: April 13, 2011 Subject: Fluid/Oil Leak During Cold Weather from Transmission Vent (Early Models-Replace Transmission Fluid Level Indicator and Install New Transmission Vent Assembly) Models: 2001-2012 Chevrolet Silverado 2500HD-3500HD Series 2001-2012 GMC Sierra 2500HD-3500HD Series Equipped with Allison(R) LCT 1000 Automatic Transmission (RPOs M74, MW7) Supercede: This bulletin is being revised to add the 2012 model year and update information. Please discard Corporate Bulletin Number 10-07-30-001B (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a small red fluid/oil leak during cold weather. Upon further investigation, the technician may find a small fluid leak in the area at the back of the transmission by the vent. Cause This condition may be caused by fluid being discharged out the transmission vent due to a low transmission fluid fill. During extreme cold weather, (approximately -25°C (-15°F or colder), low fluid fill can cause the transmission pump to ingest air which can aerate the fluid and push some fluid out the vent. Correction On 2001 through 2012 models, verify the transmission is full of fluid. Follow the SI fluid checking procedure to PROPERLY check the transmission fluid level using the Hot Check Procedure. Important Ensure that the fluid level is at the top of the HOT band when the transmission fluid temperature is 79°C (175°F). Refer to SI Document ID# 2408059 for the proper fluid level checking procedure. Note Only on 2001-2004 models, replace the transmission fluid indicator (dipstick) with a new vented indicator, P/N 15794381. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Automatic Transmission Dipstick - Dipstick Tube > Component Information > Technical Service Bulletins > Customer Interest for Automatic Transmission Dipstick - Dipstick Tube: > 10-07-30-001C > Apr > 11 > A/T - Fluid/Oil Leak from Transmission Vent > Page 7528 Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Automatic Transmission Dipstick - Dipstick Tube > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Automatic Transmission Dipstick - Dipstick Tube: > 10-07-30-001C > Apr > 11 > A/T - Fluid/Oil Leak from Transmission Vent Automatic Transmission Dipstick - Dipstick Tube: All Technical Service Bulletins A/T - Fluid/Oil Leak from Transmission Vent TECHNICAL Bulletin No.: 10-07-30-001C Date: April 13, 2011 Subject: Fluid/Oil Leak During Cold Weather from Transmission Vent (Early Models-Replace Transmission Fluid Level Indicator and Install New Transmission Vent Assembly) Models: 2001-2012 Chevrolet Silverado 2500HD-3500HD Series 2001-2012 GMC Sierra 2500HD-3500HD Series Equipped with Allison(R) LCT 1000 Automatic Transmission (RPOs M74, MW7) Supercede: This bulletin is being revised to add the 2012 model year and update information. Please discard Corporate Bulletin Number 10-07-30-001B (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a small red fluid/oil leak during cold weather. Upon further investigation, the technician may find a small fluid leak in the area at the back of the transmission by the vent. Cause This condition may be caused by fluid being discharged out the transmission vent due to a low transmission fluid fill. During extreme cold weather, (approximately -25°C (-15°F or colder), low fluid fill can cause the transmission pump to ingest air which can aerate the fluid and push some fluid out the vent. Correction On 2001 through 2012 models, verify the transmission is full of fluid. Follow the SI fluid checking procedure to PROPERLY check the transmission fluid level using the Hot Check Procedure. Important Ensure that the fluid level is at the top of the HOT band when the transmission fluid temperature is 79°C (175°F). Refer to SI Document ID# 2408059 for the proper fluid level checking procedure. Note Only on 2001-2004 models, replace the transmission fluid indicator (dipstick) with a new vented indicator, P/N 15794381. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Automatic Transmission Dipstick - Dipstick Tube > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Automatic Transmission Dipstick - Dipstick Tube: > 10-07-30-001C > Apr > 11 > A/T - Fluid/Oil Leak from Transmission Vent > Page 7534 Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - Water Or Coolant Contamination Information Fluid - A/T: Technical Service Bulletins A/T - Water Or Coolant Contamination Information INFORMATION Bulletin No.: 08-07-30-035B Date: November 01, 2010 Subject: Information on Water or Ethylene Glycol in Transmission Fluid Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks with Automatic Transmission Supercede: This bulletin is being revised to update model years. Please discard Corporate Bulletin Number 08-07-30-035A (Section 07 - Transmission/Transaxle). Water or ethylene glycol in automatic transmission fluid (ATF) is harmful to internal transmission components and will have a negative effect on reliability and durability of these parts. Water or ethylene glycol in ATF will also change the friction of the clutches, frequently resulting in shudder during engagement or gear changes, especially during torque converter clutch engagement. Indications of water in the ATF may include: - ATF blowing out of the transmission vent tube. - ATF may appear cloudy or, in cases of extreme contamination, have the appearance of a strawberry milkshake. - Visible water in the oil pan. - A milky white substance inside the pan area. - Spacer plate gaskets that appear to be glued to the valve body face or case. - Spacer plate gaskets that appear to be swollen or wrinkled in areas where they are not compressed. - Rust on internal transmission iron/steel components. If water in the ATF has been found and the source of the water entry has not been identified, or if a leaking in-radiator transmission oil cooler is suspected (with no evidence of cross-contamination in the coolant recovery reservoir), a simple and quick test kit is available that detects the presence of ethylene glycol in ATF. The "Gly-Tek" test kit, available from the Nelco Company, should be obtained and the ATF tested to make an accurate decision on the need for radiator replacement. This can help to prevent customer comebacks if the in-radiator transmission oil cooler is leaking and reduce repair expenses by avoiding radiator replacement if the cooler is not leaking. These test kits can be obtained from: Nelco Company Test kits can be ordered by phone or through the website listed above. Orders are shipped standard delivery time but can be shipped on a next day delivery basis for an extra charge. One test kit will complete 10 individual fluid sample tests. For vehicles repaired under warranty, the cost of the complete test kit plus shipping charges should be divided by 10 and submitted on the warranty claim as a net item. The transmission should be repaired or replaced based on the normal cost comparison procedure. Important If water or coolant is found in the transmission, the following components MUST be replaced. - Replace all of the rubber-type seals. - Replace all of the composition-faced clutch plates and/or bands. - Replace all of the nylon parts. - Replace the torque converter. - Thoroughly clean and rebuild the transmission, using new gaskets and oil filter. Important The following steps must be completed when repairing or replacing. Flush and flow check the transmission oil cooler using J 45096. Refer to Corporate Bulletin Number 02-07-30-052F- Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow. - Thoroughly inspect the engine cooling system and hoses and clean/repair as necessary. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - Water Or Coolant Contamination Information > Page 7539 Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications AUTOMATIC TRANSMISSION FLUID CAPACITY Allison 1000 Automatic Transmission Initial Fill .. .............................................................................................................................................................. .......................... 12.0 liters (12.7 quarts) Refill .................................................................................... ................................................................................................................. 7.0 liters (7.4 quarts) NOTE: All capacities are approximate. When adding, be sure to fill to the approximate level. Recheck fluid level after filling. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 7542 Fluid - A/T: Fluid Type Specifications AUTOMATIC TRANSAXLE FLUID DEXRON-VI Automatic Transmission Fluid. For areas where ambient temperatures are below -40°F (-40°C) use Synthetic Transmission Fluid approved to Allison Transmission specification TES-295 (GM Part No. U.S. 12378515, in Canada 88900701). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 7543 Fluid - A/T: Service and Repair Automatic Transmission Fluid and Filter Replacement Removal Procedure Note: DO NOT drain the fluid if only the transmission external oil filter is being replaced. 1. Remove the drain plug (6) and drain plug seal (5). Drain the transmission fluid into a suitable container. 2. Inspect the drained fluid. Refer to Transmission Fluid Level and Condition Check (See: Testing and Inspection/Component Tests and General Diagnostics/Transmission Fluid Level and Condition Check). Note: Use a standard strap-type filter wrench to remove the transmission external oil filter. 3. Remove the filter (4) by rotating in the counterclockwise direction. 4. Remove the magnet (2) from the filter adapter (1) in the converter housing or from the top of the transmission external oil filter (3). 5. Clean any metal debris from the magnet. Presence of any metal pieces larger than dust may indicate that transmission replacement or overhaul is required. Installation Procedure 1. Install the magnet (2) onto the filter adapter (1) which is in the converter housing. 2. Lubricate the gasket (3) on the transmission external oil filter with transmission fluid. 3. Install, by hand, the transmission external oil filter (4) until the gasket on the filter touches the converter housing. Caution: Turning the transmission external oil filter more than ONE FULL TURN after gasket contact will damage the filter and may cause fluid leakage. 4. Turn the filter ONE FULL TURN ONLY after gasket contact. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Install the drain plug (6) and drain plug seal (5). Tighten the drain plug to 35 Nm (26 lb ft). 6. Refill Transmission with DEXRON(R)VI Automatic Transmission Fluid. Refer to Fluid Capacity Specifications (See: Specifications). Note: DTC P0701 may often set following fluid service. Cycling the ignition clears the code and allows Drive or Reverse range to be attained. 7. Cycle the ignition until Drive or Reverse range is attained. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 7544 Note: Fluid remains in the external circuits and transmission cavities after draining the transmission. 8. Check the transmission fluid level. Refer to Transmission Fluid Level and Condition Check (See: Testing and Inspection/Component Tests and General Diagnostics/Transmission Fluid Level and Condition Check). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > Transmission Fluid Filter Adapter Replacement Fluid Filter - A/T: Service and Repair Transmission Fluid Filter Adapter Replacement Transmission Fluid Filter Adapter Replacement Removal Procedure Note: * DO NOT drain the fluid if only the transmission external oil filter adapter is being replaced. * Use a standard strap-type filter wrench to remove or install the transmission external oil filter. 1. Remove the transmission external oil filter (4) by rotating in the counterclockwise direction. 2. Remove the magnet (2) from the transmission external oil filter adapter (1) in the converter housing or from the filter element. 3. Clean any metal debris from the magnet. Presence of any metal pieces larger than dust may indicate that transmission replacement or overhaul is required. 4. Remove the filter adapter (1) from the converter housing. Installation Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the transmission external oil filter adapter (1). Tighten the adapter to 30 Nm (22 lb ft). 2. Reinstall the magnet (2) onto the filter adapter (1). 3. Lubricate the gasket (3) on the transmission external oil filter with transmission fluid. 4. Install, by hand, the transmission external oil filter (4) until the gasket on the filter touches the converter housing. Caution: Turning the transmission external oil filter more than ONE FULL TURN after gasket contact will damage the filter and may cause fluid leakage. 5. Turn the filter ONE FULL TURN ONLY after gasket contact. Caution: Use only clean and approved transmission fluid. 6. Check the transmission fluid level. Refer to Transmission Fluid Level and Condition Check (See: Testing and Inspection/Component Tests and General Diagnostics/Transmission Fluid Level and Condition Check). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > Transmission Fluid Filter Adapter Replacement > Page 7549 Fluid Filter - A/T: Service and Repair Automatic Transmission Fluid and Filter Replacement Automatic Transmission Fluid and Filter Replacement Removal Procedure Note: DO NOT drain the fluid if only the transmission external oil filter is being replaced. 1. Remove the drain plug (6) and drain plug seal (5). Drain the transmission fluid into a suitable container. 2. Inspect the drained fluid. Refer to Transmission Fluid Level and Condition Check (See: Testing and Inspection/Component Tests and General Diagnostics/Transmission Fluid Level and Condition Check). Note: Use a standard strap-type filter wrench to remove the transmission external oil filter. 3. Remove the filter (4) by rotating in the counterclockwise direction. 4. Remove the magnet (2) from the filter adapter (1) in the converter housing or from the top of the transmission external oil filter (3). 5. Clean any metal debris from the magnet. Presence of any metal pieces larger than dust may indicate that transmission replacement or overhaul is required. Installation Procedure 1. Install the magnet (2) onto the filter adapter (1) which is in the converter housing. 2. Lubricate the gasket (3) on the transmission external oil filter with transmission fluid. 3. Install, by hand, the transmission external oil filter (4) until the gasket on the filter touches the converter housing. Caution: Turning the transmission external oil filter more than ONE FULL TURN after gasket contact will damage the filter and may cause fluid leakage. 4. Turn the filter ONE FULL TURN ONLY after gasket contact. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Install the drain plug (6) and drain plug seal (5). Tighten the drain plug to 35 Nm (26 lb ft). 6. Refill Transmission with DEXRON(R)VI Automatic Transmission Fluid. Refer to Fluid Capacity Specifications (See: Fluid - A/T/Specifications ). Note: DTC P0701 may often set following fluid service. Cycling the ignition clears the code and allows Drive or Reverse range to be attained. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > Transmission Fluid Filter Adapter Replacement > Page 7550 7. Cycle the ignition until Drive or Reverse range is attained. Note: Fluid remains in the external circuits and transmission cavities after draining the transmission. 8. Check the transmission fluid level. Refer to Transmission Fluid Level and Condition Check (See: Testing and Inspection/Component Tests and General Diagnostics/Transmission Fluid Level and Condition Check). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Transmission Fluid Cooler Hose/Pipe Connector Replacement Fluid Line/Hose: Service and Repair Transmission Fluid Cooler Hose/Pipe Connector Replacement Transmission Fluid Cooler Hose/Pipe Connector Replacement Removal Procedure 1. Disconnect the hose from the transmission oil cooler pipe connector being replaced. 2. Remove the transmission oil cooler pipe connectors (1) and (2). Installation Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install new transmission oil cooler pipe connectors (1 and 2). Tighten to 25 Nm (18 lb ft). 2. Connect the hose to the transmission oil cooler pipe connectors. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Transmission Fluid Cooler Hose/Pipe Connector Replacement > Page 7555 Fluid Line/Hose: Service and Repair Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection Removal Procedure Important: Perform the following procedure when removing the retaining rings and cooler lines from the quick connect fittings located on the radiator and/or the transmission. 1. Pull the plastic cap back from the quick connect fitting and down along the cooler line about 5 cm (2 in). 2. Using a bent-tip screwdriver, pull on one of the open ends of the retaining ring in order to rotate the retaining ring around the quick connect fitting until the retaining ring is out of position and can be completely removed. 3. Remove the retaining ring from the quick connect fitting. 4. Discard the retaining ring. 5. Pull the cooler line straight out from the quick connect fitting. Installation Procedure Important: * Do not reuse any of the existing oil lines or oil line fittings if there is excessive corrosion. * Do not reuse any of the existing retaining rings that were removed from the existing quick connect fittings. Install new retaining rings. * Ensure the following procedures are performed when installing the new retaining rings onto the fittings. 1. Install a new retaining ring into the quick connect fitting using the following procedure: Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Transmission Fluid Cooler Hose/Pipe Connector Replacement > Page 7556 2. Hook one of the open ends of the retaining ring in one of the slots in the quick connect fitting. 3. Rotate the retaining ring around the fitting until the retaining ring is positioned with all three ears through the three slots on the fitting. 4. Do not install the new retaining ring onto the fitting by pushing the retaining ring. 5. Ensure that the three retaining ring ears are seen from inside the fitting and that the retaining ring moves freely in the fitting slots. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Transmission Fluid Cooler Hose/Pipe Connector Replacement > Page 7557 6. Install the cooler line into the quick connect fitting. 7. Insert the cooler line end into the quick connect fitting until a click is either heard or felt. 8. Do not use the plastic cap on the cooler line in order to install the cooler line into the fitting. 9. Pull back sharply on the cooler line in order to ensure that the cooler line is fastened into the quick connect fitting. Important: Do not manually depress the retaining clip when installing the plastic cap. 10. Position (snap) the plastic cap onto the fitting. Do not manually depress the retaining ring when installing the plastic cap onto the quick connect fitting. 11. Ensure that the plastic cap is fully seated against the fitting. 12. Ensure that no gap is present between the cap and the fitting. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Transmission Fluid Cooler Hose/Pipe Connector Replacement > Page 7558 13. Ensure that the yellow identification band on the tube is hidden within the quick connect fitting. 14. A hidden yellow identification band indicates proper joint seating. 15. Fill the transmission to the proper level with DEXRON(R) VI transmission fluid. Refer to Transmission Fluid Level and Condition Check (). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Transmission Fluid Cooler Hose/Pipe Connector Replacement > Page 7559 Fluid Line/Hose: Service and Repair Transmission Fluid Cooler Hose/Pipe Replacement Transmission Fluid Cooler Hose/Pipe Replacement Removal Procedure 1. Remove the radiator grille. Refer to Radiator Grille Replacement (Chevrolet) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement)Radiator Grille Replacement (GMC) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement)Radiator Grille Replacement (Chevrolet HD) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement (Chevrolet HD))Radiator Grille Replacement (GMC HD) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement (GMC HD)). 2. Remove the transmission fluid cooler hose from the auxiliary oil cooler (2). Refer to Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection (See: ). 3. Remove the transmission fluid cooler hose from the radiator (1). Refer to Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Transmission Fluid Cooler Hose/Pipe Connector Replacement > Page 7560 Disconnection and Connection (See: ). 4. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 5. Remove the engine protection shield. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement). 6. Remove the cooling lines from the transmission (1). Refer to Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection (See: ). 7. Remove the oil cooling lines from the vehicle. Installation Procedure 1. Install the transmission oil cooler lines to the vehicle. 2. Install the cooling lines to the transmission (1). Refer to Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection (See: ). 3. Install the engine protection shield. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement). 4. Lower the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Transmission Fluid Cooler Hose/Pipe Connector Replacement > Page 7561 5. Install the transmission fluid cooler hose to the radiator (1). Refer to Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection (See: ). 6. Install the transmission fluid cooler hose to the auxiliary oil cooler (1). Refer to Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection (See: ). 7. Install the radiator grille. Refer to Radiator Grille Replacement (Chevrolet) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement)Radiator Grille Replacement (GMC) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement)Radiator Grille Replacement (Chevrolet HD) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement (Chevrolet HD))Radiator Grille Replacement (GMC HD) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement (GMC HD)). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications Fluid Pan: Specifications Oil Pan Bolts ........................................................................................................................................ ........................................................ 27 Nm (20 lb ft) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications > Page 7565 Fluid Pan: Service and Repair Oil Pan Replacement Removal Procedure 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). Note: It would be helpful to record the amount of transmission fluid lost during this procedure. Fluid in good condition, drained into a clean container, may be reused. 2. Remove the drain plug (7) and drain plug seal (6) from the oil pan (5). Allow the fluid to drain into a suitable container. 3. Inspect the drained fluid. Refer to Transmission Fluid Level and Condition Check (See: Testing and Inspection/Component Tests and General Diagnostics/Transmission Fluid Level and Condition Check) 4. Remove 12 bolts (8). Hold the oil pan in position as the last bolt is removed. 5. Remove oil pan (5) and gasket (3). 6. Inspect magnet (4). Excessive metallic particles or large metallic particles may indicate need for overhaul or replacement of the transmission. Note: DO NOT remove the transmission internal oil filter or seal if only replacing the oil pan or oil pan gasket. 7. Remove the transmission internal oil filter (2) by pulling straight down where the suction tube is seated in the transmission case. 8. Remove the transmission internal oil filter seal (1) from the filter or from the seal bore in the transmission case. Discard the old seal. Discard the filter, if the filter is being replaced. Installation Procedure 1. Remove all gasket material from the transmission case. Remove any scratches from the transmission case that would cause a split-line leak. 2. Place a new seal (1) on the tube of the transmission internal oil filter (2), if the filter was removed. Be sure the seal locates against the shoulder on the internal oil filter tube. 3. Push the filter (2) and seal (1) into the seal bore in the transmission case. Position the transmission internal oil filter properly. 4. Install 2 headless guide bolts (9), M8 x 1.25, into opposite corners of the oil pan mounting face on the transmission case. 5. Place a gasket (3) on the oil pan and align the bolt holes. 6. Slide the gasket (3) and oil pan (5) over the guide bolts and hold them in place while installing 2 bolts (8) to hold the parts in place. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 7. Remove the guide bolts. 8. Install the 10 remaining oil pan bolts (8). Tighten the bolts to 27 Nm (20 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications > Page 7566 9. Install the drain plug (7) and drain plug seal (6). Tighten the drain plug to 35 Nm (26 lb ft). 10. Lower the vehicle. Caution: Use only clean and approved transmission fluid. 11. Refill the transmission with DEXRON(R)VI Automatic Transmission Fluid. Refer to Fluid Capacity Specifications (See: Fluid A/T/Specifications). Note: Remember fluid remains in the external circuits and transmission cavities after draining the transmission. 12. Check the transmission fluid level. Refer to Transmission Fluid Level and Condition Check (See: Testing and Inspection/Component Tests and General Diagnostics/Transmission Fluid Level and Condition Check). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations Fluid Pressure Sensor/Switch: Locations Disassembled Views Control Valve Body Assembly 1 - Control Valve Body Assembly 2 - Shift Valve Body Assembly 3 - Separator Plate 4 - Main Valve Body Assembly 5 - Transmission Fluid Pressure (TFP) Switch 6 - Main Valve Body Assembly Bolt, M6 x 10 x 50, Flanged Head (23) 7 - Reverse Signal Pipe 8 - Reverse Signal Pipe Bolt, M6 x 10 x 50, Flanged Head 9 - Retaining Clip 10 - Modulated Main Valve Body 11 - Bolt, M6 x 10 x 65 12 Bolt, M6 x 10 x 50 13 - O-Rings 14 - Modulated Main Pressure (MAIN MOD) Solenoid 15 - 6 Speed Pipe Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 7570 Fluid Pressure Sensor/Switch: Diagrams Component Connector End Views Pressure Switch Manifold (PSM) (MW7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 7571 Fluid Pressure Sensor/Switch: Service and Repair Pressure Switch Manifold Replacement Removal Procedure Note: Individual pressure switches cannot be replaced. When any pressure switch needs replacing, the entire assembly must be replaced. Note: The modulated main pressure (MAIN MOD) solenoid has been removed for clarity. 1. Remove the oil pan and transmission internal oil filter. Refer to Oil Pan Replacement (See: Fluid Pan/Service and Repair). Warning: Refer to Battery Disconnect Warning (See: Starting and Charging/Battery/Service Precautions). 2. Disconnect the internal wiring harness connector from the transmission fluid pressure (TFP) switch (2). 3. Remove six bolts (1). Remove the TFP switch (2). Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 7572 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Place the new TFP manifold assembly (2) in position and install one bolt (1) in a recessed location to hold in position. Start the remaining five bolts (1) in recessed locations and tighten the bolts by hand. Torque the bolts to 12 Nm (108 lb in). 2. Connect the internal wiring harness connector to the TFP switch. 3. Install the oil pan and transmission internal oil filter. Refer to Oil Pan Replacement (See: Fluid Pan/Service and Repair). Note: The FastLearn, adapt, procedure must be performed. This can be done in 1 step using a scan tool. If this procedure is not done, the TCM adaptive values will be at the settings that it learned for the old components and will be in slow adaptive mode. Under these conditions, it will take an unacceptably long time for the adaptive values to converge to levels suitable for the new transmission. 4. Perform the FastLearn procedure. Refer to FastLearn Procedure (See: Testing and Inspection/Programming and Relearning). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft, A/T > Component Information > Technical Service Bulletins > A/T - 2-3 Upshift or 3-2 Downshift Clunk Noise Output Shaft: Technical Service Bulletins A/T - 2-3 Upshift or 3-2 Downshift Clunk Noise INFORMATION Bulletin No.: 01-07-30-042F Date: February 05, 2010 Subject: Information on 2-3 Upshift or 3-2 Downshift Clunk Noise Models: 2010 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2005-2009 Saab 9-7X with 4L60-E, 4L65-E or 4L70-E Automatic Transmission (RPOs M30, M32, M70) Supercede: This bulletin is being revised to add the 2010 model year and 4L70E transmission. Please discard Corporate Bulletin Number 01-07-30-042E (Section 07 - Transmission/Transaxle). Important For 2005 model year fullsize utilities and pickups, refer to Corporate Bulletin 05-07-30-012. Some vehicles may exhibit a clunk noise that can be heard on a 2-3 upshift or a 3-2 downshift. During a 2-3 upshift, the 2-4 band is released and the 3-4 clutch is applied. The timing of this shift can cause a momentary torque reversal of the output shaft that results in a clunk noise. This same torque reversal can also occur on a 3-2 downshift when the 3-4 clutch is released and the 2-4 band applied. This condition may be worse on a 4-wheel drive vehicle due to the additional tolerances in the transfer case. This is a normal condition. No repairs should be attempted. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams Pressure Regulating Solenoid: Diagrams Component Connector End Views Pressure Control (PC) Solenoid Valve (M30) Pressure Control (PC) Solenoid Valve 1 (MW7) Pressure Control (PC) Solenoid Valve 2 (MW7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 7580 Modulated Main Pressure Control (PC) Solenoid Valve (MW7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON Control Module: Customer Interest A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 7590 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 7591 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 7592 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON Control Module: All Technical Service Bulletins A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 7598 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 7599 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 7600 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 7601 Control Module: Locations Harness Routing Views Engine Chassis Harness Routing - Top Front (Diesel) 1 - Battery - Right 2 - Fuse Holder 3 - X127 4 - X108 5 - X107 6 - X123 (PTO) 7 - Fuse Block Underhood 8 - X109 9 - Battery - Left 10 - Engine Control Module (ECM) 11 - Transmission Control Module (TCM) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 7602 Control Module: Diagrams Component Connector End Views Transmission Control Module (TCM) (M30) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 7603 Transmission Control Module (TCM) (MW7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 7604 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 7605 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 7606 Control Module: Service and Repair Transmission Control Module Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Rear Propeller Shaft Seal Replacement Seals and Gaskets: Service and Repair Rear Propeller Shaft Seal Replacement Rear Propeller Shaft Seal Replacement Special Tools * J 24171-A Seal and Dust Shield Remover * J 43782 Rear Seal Installer Removal Procedure 1. Remove the yoke assembly from the transmission. Refer to Differential Drive Pinion Gear Yoke Replacement (See: Differential Assembly/Pinion Flange/Service and Repair/Allison - Automatic Transmission). 2. Obtain J 24171-A and install a 90 degree hook onto the end of the slide-hammer (1). 3. Position the 90 degree hook behind the rear face of the seal's outer case (2). 4. Remove the rear seal using the slide-hammer. 5. Inspect the seal bore for scratches. Remove any scratches in the seal bore using crocus cloth. Installation Procedure Important: Be sure the new seal has blue sealant coating the OD (4). This identifies the seal for use in the 1000 Series transmissions. The blue sealant identification is important because the 1000 Series transmissions have an overdrive ratio in fifth and sixth range and there is a potential for high output shaft speeds and resultant high seal temperature. 1. Align the seal so the seal lip (2) is outward and the face of the steel case (1) will be against the driving face (3) of the tool. Install the new seal onto J 43782 . 2. Slide J 43782 over the output shaft until the seal enters the seal bore. Strike J 43782 with a mallet (1) to drive the seal into the seal bore. The seal is installed correctly when the shoulder of J 43782 squarely contacts the outer surface of the rear cover. 3. Install the yoke assembly onto the transmission. Refer to Differential Drive Pinion Gear Yoke Replacement (See: Differential Assembly/Pinion Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Rear Propeller Shaft Seal Replacement > Page 7611 Flange/Service and Repair/Allison - Automatic Transmission). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Rear Propeller Shaft Seal Replacement > Page 7612 Seals and Gaskets: Service and Repair Manual Shift Shaft Seal Replacement Manual Shift Shaft Seal Replacement Tools Required * J 43911 Manual Shift Shaft Seal Remover * J 43909 Manual Shift Shaft Seal Installer Removal Procedure 1. Be sure that the jackscrew for J 43911 is backed off and will not interfere with installation of the removal tool. Slide the seal remover tool over the manual shift shaft (2) with the threaded end of the tool towards the seal. 2. Rotate the removal tool so that the threads on the end of the tool engage the steel shell (1) of the seal. Use a wrench to be sure that the removal tool is firmly attached to the seal shell. 3. Rotate the jackscrew in the clockwise direction to remove the seal from the bore. Discard the seal that was removed. Installation Procedure 1. Carefully slide a new manual shift shaft seal (1) over the manual shift shaft (2) with the wide face of the steel case facing outward. Position so that the seal is starting to enter the seal bore. 2. Obtain J 43909 and remove the inner sleeve so that the tool will slide over the manual shift shaft. 3. Slide the J 43909 into position so that the end of the tool contacts the seal being installed. Use a mallet to strike the J 43909 and drive the new seal into the seal bore until the seal is seated at the bottom of the bore. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Rear Propeller Shaft Seal Replacement > Page 7613 Seals and Gaskets: Service and Repair Power Take-Off Cover Gasket Replacement Power Take-Off Cover Gasket Replacement Removal Procedure 1. Remove 6 bolts (3). 2. Remove the power take-off (PTO) cover (2) and gasket (1). Discard the used gasket. 3. Ensure the PTO gasket face on the transmission case is free of all foreign material, nicks, and scratches. Installation Procedure 1. Install the new PTO cover gasket (1) and cover (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Start the top-center bolt (3) first. Install the other 5 bolts. Tighten all bolts to 43 Nm (32 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Rear Propeller Shaft Seal Replacement > Page 7614 Seals and Gaskets: Service and Repair Torque Converter Fluid Seal Replacement Torque Converter Fluid Seal Replacement Tools Required * J 24171-A Seal and Dust Shield Remover * J 43772 Torque Converter Seal Installer Removal Procedure 1. Remove the torque converter from the transmission. Refer to Torque Converter Replacement (). 2. Obtain J 24171-A and install the tip (3) with a 90 degree hook onto the end of the slide-hammer (1). 3. Position the 90 degree hook behind the rear face of the seal outer case (2). Remove the torque converter seal using the slide-hammer. 4. Inspect the seal bore for scratches. Remove any scratches in the seal bore using crocus cloth. Installation Procedure 1. Install the new seal (2) onto the J 43772 . Position the seal so the seal lip is outward and the face of the steel case is against the driving face (1) on the tool. 2. Slide J 43772 over the turbine shaft and the stator shaft until the seal starts into the seal bore. Strike the J 43772 with a mallet (1) to drive the seal into the seal bore. The seal is installed correctly when the shoulder of the J 43772 squarely contacts the outer surface of the oil pump. 3. Install the torque converter into the transmission. Refer to Torque Converter Replacement (). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Rear Propeller Shaft Seal Replacement > Page 7615 Seals and Gaskets: Service and Repair Torque Converter Housing Bolt Seal Replacement Torque Converter Housing Bolt Seal Replacement Removal Procedure 1. Remove the torque converter from the transmission. Refer to Torque Converter Replacement (). 2. Remove any of the 10 bolts (1), bolt heads shaded, where leakage at the bolt head is suspected. Note: The bolts (1) have a removable seal under the flanged head. 3. Remove and discard seals from bolts removed. Installation Procedure 1. Install new seals on any removed bolts (1). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install any bolts (1) removed. Tighten bolts to 56 Nm (41 lb ft). 3. Install the torque converter into the transmission. Refer to Torque Converter Replacement (). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations Fluid Pressure Sensor/Switch: Locations Disassembled Views Control Valve Body Assembly 1 - Control Valve Body Assembly 2 - Shift Valve Body Assembly 3 - Separator Plate 4 - Main Valve Body Assembly 5 - Transmission Fluid Pressure (TFP) Switch 6 - Main Valve Body Assembly Bolt, M6 x 10 x 50, Flanged Head (23) 7 - Reverse Signal Pipe 8 - Reverse Signal Pipe Bolt, M6 x 10 x 50, Flanged Head 9 - Retaining Clip 10 - Modulated Main Valve Body 11 - Bolt, M6 x 10 x 65 12 Bolt, M6 x 10 x 50 13 - O-Rings 14 - Modulated Main Pressure (MAIN MOD) Solenoid 15 - 6 Speed Pipe Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 7620 Fluid Pressure Sensor/Switch: Diagrams Component Connector End Views Pressure Switch Manifold (PSM) (MW7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 7621 Fluid Pressure Sensor/Switch: Service and Repair Pressure Switch Manifold Replacement Removal Procedure Note: Individual pressure switches cannot be replaced. When any pressure switch needs replacing, the entire assembly must be replaced. Note: The modulated main pressure (MAIN MOD) solenoid has been removed for clarity. 1. Remove the oil pan and transmission internal oil filter. Refer to Oil Pan Replacement (See: Fluid Pan/Service and Repair). Warning: Refer to Battery Disconnect Warning (See: Starting and Charging/Battery/Service Precautions). 2. Disconnect the internal wiring harness connector from the transmission fluid pressure (TFP) switch (2). 3. Remove six bolts (1). Remove the TFP switch (2). Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 7622 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Place the new TFP manifold assembly (2) in position and install one bolt (1) in a recessed location to hold in position. Start the remaining five bolts (1) in recessed locations and tighten the bolts by hand. Torque the bolts to 12 Nm (108 lb in). 2. Connect the internal wiring harness connector to the TFP switch. 3. Install the oil pan and transmission internal oil filter. Refer to Oil Pan Replacement (See: Fluid Pan/Service and Repair). Note: The FastLearn, adapt, procedure must be performed. This can be done in 1 step using a scan tool. If this procedure is not done, the TCM adaptive values will be at the settings that it learned for the old components and will be in slow adaptive mode. Under these conditions, it will take an unacceptably long time for the adaptive values to converge to levels suitable for the new transmission. 4. Perform the FastLearn procedure. Refer to FastLearn Procedure (See: Testing and Inspection/Programming and Relearning). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON Transmission Mode Switch: Customer Interest A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 7631 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 7632 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 7633 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON Transmission Mode Switch: All Technical Service Bulletins A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 7639 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 7640 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 7641 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > Page 7642 Transmission Mode Switch: Diagrams Component Connector End Views Automatic Transmission Internal Mode Switch (MW7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > Page 7643 Transmission Mode Switch: Service and Repair Transmission Internal Mode Switch Replacement Important: The Internal Mode Switch (IMS) is mounted to the manual shift shaft detent lever as an assembly. The components of the detent lever/IMS assembly cannot be individually serviced. When the IMS needs replacing, the entire assembly must be replaced. Replace the IMS. Refer to Manual Shift Shaft, Detent Lever, and Position Switch Assembly Replacement (See: Transmission Position Switch/Sensor/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams Transmission Position Switch/Sensor: Diagrams Component Connector End Views Park/Neutral Position (PNP) Switch (M30) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 7647 Transmission Position Switch/Sensor: Service and Repair Manual Shift Shaft, Detent Lever, and Position Switch Assembly Replacement Removal Procedure 1. Remove the control valve assembly from the transmission. Refer to Control Valve Body Replacement (See: Valve Body/Service and Repair). Note: The detent lever/IMS retaining bolt contains patch lock material on the threads. Do not reuse the retaining bolt. 2. Remove the detent lever/IMS retaining bolt (1) using a T27 TORX(R) bit and discard the retaining bolt. Caution: DO NOT mar the transmission case surface around the spherical pin when removing or installing the spherical pin. An unmarred surface is required to maintain the seal between the control valve assembly and the transmission case. Caution: DO NOT twist the spherical pin when removing the pin from the transmission case. Damage to the transmission case can occur. 3. Place a protective plate on the transmission case surface around the spherical pin (3). Remove the spherical pin (3) from the transmission case. 4. Slide the manual shift shaft (5) through the detent lever/IMS assembly (4) and through the manual shift shaft seal. 5. Rotate the detent lever/IMS assembly to disengage the park pawl apply assembly (2). Remove the detent lever/IMS assembly (4). Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 7648 1. Place the new detent lever/IMS assembly (4) in position in the transmission case. Rotate the detent lever/IMS assembly to engage the park pawl apply assembly (2). Reinstall the manual shift shaft (5) through the manual shift shaft seal and through the detent lever/IMS assembly (4). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Push the manual shift shaft (5) into the final position in the transmission case. 3. Install the spherical pin (3) into the transmission case that retains the manual shift shaft. 4. Install the detent lever/IMS retaining bolt (1) using a T27 TORX(R) bit. Tighten the bolt (1) to 10 Nm (92 lb in). 5. Install the control valve assembly. Refer to Control Valve Body Replacement (See: Valve Body/Service and Repair). Note: The FastLearn, adapt, procedure must be performed. This can be done in 1 step using a scan tool. If this procedure is not done, the TCM adaptive values will be at the settings that it learned for the old components and will be in slow adaptive mode. Under these conditions, it will take an unacceptably long time for the adaptive values to converge to levels suitable for the new transmission. 6. Perform the FastLearn procedure. Refer to FastLearn Procedure (See: Testing and Inspection/Programming and Relearning). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Component Locations Transmission Speed Sensor: Component Locations Disassembled Views Automatic Transmission Case 1 - Automatic Transmission Case 2 - Transmission Case Locating Pin 3 - Transmission Vent Assembly 4 - Transmission Vent Cap 5 - Transmission Vent 6 - Nameplate Rivet 7 - Nameplate 8 Vehicle Speed Sensor Bolt, M6 x 1.0 x 13 9 - Sensor Shipping Cover 10 - Turbine Speed Sensor 11 - Vehicle Speed Sensor O-Ring 12 - Power Take-Off (PTO) Cover Gasket (2) 13 - PTO Cover (2) 14 - PTO Cover Bolt, M10 x 1.5 x 20, Flanged Head, Coated (12) 16 - Manual Shift Shaft 17 Manual Shift Shaft Seal 18 - Manual Shift Shaft Pin 19 - Manual Shift Shaft Detent Lever/Internal Mode Switch (IMS) Assembly 20 - Park Pawl Assembly 21 - Control Valve Body Locating Pin 22 Detent Lever/IMS Bolt 23 - Connector Shipping Cover 24 - Control Valve Body Assembly 25 Control Valve Body Bolt, M6 x 1.0 x 50, Flanged Head (15) 26 - Manual Shift Shaft Detent Spring 27 - Manual Shift Shaft Detent Spring Bolt M6 x 1.0 x 12. Flanged Head (2) 28 - Transmission Wiring Harness Assembly Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Component Locations > Page 7653 Transmission Speed Sensor: Connector Locations Harness Routing Views Engine Chassis Harness Routing - Rear (Diesel) 1 - X300 2 - G300 3 - Automatic Transmission Turbine Speed Sensor (MW7) 4 - Automatic Transmission (MW7) 5 - Vehicle Speed Sensor (VSS) (MW7) 6 - X124 (PTO) 7 - Power Take Off (PTO) Module (PTO) 8 - X175 (MW7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 7654 Transmission Speed Sensor: Diagrams Component Connector End Views Automatic Transmission Input Shaft Speed (ISS) Sensor (M30) Automatic Transmission Turbine Speed Sensor (MW7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 7655 Output Speed Sensor (OSS) (M99) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 7656 Transmission Speed Sensor: Service and Repair Speed Sensor Replacement Removal Procedure Warning: Refer to Battery Disconnect Warning (See: Starting and Charging/Battery/Service Precautions). 1. Be sure the vehicle ignition is turned off. 2. Disconnect the external wiring harness from the speed sensor. 3. Remove the bolt (1) from the speed sensor and carefully remove the speed sensor (2). Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 7657 Note: Do not rotate the sensor in its retaining bracket. Changing the sensor/bracket orientation may cause improper operation. 1. Install a new a O-ring on the speed sensor (2). Lubricate the O-ring with clean transmission fluid. 2. Install the new speed sensor (2) into the speed sensor bore. Align the hole in the retaining bracket with the bolt hole in the speed sensor boss. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the speed sensor bolt (1). Tighten bolt to 12 Nm (108 lb in). 4. Reconnect the external wiring harness to the speed sensor. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams Transmission Temperature Sensor/Switch: Diagrams Component Connector End Views Automatic Transmission Fluid Temperature (TFT) Sensor (M30) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Service and Repair Shift Interlock Solenoid: Service and Repair Automatic Transmission Shift Lock Control Actuator Replacement Removal Procedure 1. Disable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair). 2. Remove the knee bolster. Refer to Knee Bolster Replacement (With SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (With SLT))Knee Bolster Replacement (Without SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (Without SLT)). 3. Put the shift lever clevis into the neutral position. 4. Disconnect the electrical connector. 5. Using a small screwdriver, pry the automatic transmission shift lock control actuator away from the steering column jacket and the cable shift cam. 6. Remove the shift lock control actuator. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Service and Repair > Page 7665 1. Firmly install the shift lock control actuator onto the steering column jacket and the cable shift cam. 2. Connect the electrical connector. 3. Adjust the shift lock control actuator (with the shift lever clevis in the neutral position) in the following way: 1. Pull out the tab (1) on the adjuster block side (2) of the shift lock control actuator. 2. Press on the adjuster block (2) to compress the internal adjuster spring which disengages the adjuster teeth. Slide the adjuster block (2) as far away from the actuator as possible. 3. Lock the adjuster block (2) in place by pushing in on the tab (1). 4. Inspect the shift lock control actuator for the following items: 1. The shift lock control actuator must lock the shift lever clevis when the shift lever clevis is put into the park position. 2. Depress the brake pedal to move the shift lever out of the park position. 3. The actuator will be energized. 4. Readjust the shift lock control actuator if needed. 5. Install the knee bolster. Refer to Knee Bolster Replacement (With SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (With SLT))Knee Bolster Replacement (Without SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (Without SLT)). 6. Enable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Locations Shift Solenoid: Locations Disassembled Views Main Valve Body Assembly 1 - Main Valve Body Assembly 2 - Retaining Clip 3 - Exhaust Pressure Regulator Valve Spring 4 Exhaust Pressure Regulator Valve 5 - Retaining Clip 6 - Control Relief Spring 7 - Control Relief Valve 8 - Main Valve Body 9 - Locating Pin (4) 10 - Locating Pin 11 - Pressure Control Solenoid 1 (PCS1) Spring 12 - PCS1 Valve 13 - PCS1 Spring 14 - Trim Gain Valve 15 - PCS1 16 - PCS1 O-Ring 17 - PCS2 Spring 18 - PCS2 Valve 19 - Trim Gain Valve 20 - PCS2 21 - PCS2 O-Ring 22 Shift Solenoid (SS) 3 23 - SS3 O-Ring 24 - SS3 O-Ring 25 - SS2 26 - SS2 O-Ring 27 - SS2 O-Ring Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Locations > Page 7669 28 - Torque Converter Clutch Pressure Control Solenoid (TCC PCS) Spring 29 - TCC PCS Valve 31 - TCC PCS 32 - TCC PCS O-Ring 33 - TCC PCS O-Ring 34 - TCC PCS Retaining Bracket 35 SS2 and SS3 Retainers (2) 36 - Accumulator Plug (2) 37 - Accumulator Spring (2) 38 - PCS1 and PCS2 Retaining Bracket Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Shift Solenoid: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Schematic Symbols Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7672 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7673 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7674 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7675 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7676 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7677 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7678 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7679 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7680 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7681 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7682 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7683 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7684 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7685 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7686 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7687 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7688 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7689 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7690 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7691 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7692 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7693 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7694 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7695 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7696 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7697 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7698 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7699 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7700 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7701 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7702 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7703 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7704 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7705 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7706 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7707 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7708 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7709 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7710 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7711 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7712 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7713 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7714 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7715 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7716 Shift Solenoid: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed with Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7717 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7718 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Connector Test Adapters) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7719 Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Test Lamp) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Fused Jumper Wires) * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage Drop) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Frequency) * Testing Ground and Low Reference Circuits (See: Testing and Inspection/Component Tests and General Diagnostics/Testing Ground and Low Reference Circuits) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fuses) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Circuit Breakers) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fusible Links) Troubleshooting with a Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Testing for a Short to Voltage Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7720 Testing for a Short to Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure tests for a short to voltage in a circuit. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the Digital Multimeter (DMM) to the V (DC) position. 4. Connect the positive lead of the DMM to one end of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. Turn ON the ignition and operate all accessories. 7. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Special Tools J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure). Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents). Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7721 The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the frequency of a signal. Note: Connecting the Digital Multimeter (DMM) to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Set to Hz on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7722 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the Digital Multimeter (DMM). 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the difference in voltage potential between 2 points. 1. Set the Digital Multimeter (DMM) to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7723 Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Backprobe Note: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7724 (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for Continuity Testing for Continuity Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures verify good continuity in a circuit. With a Digital Multimeter (DMM) 1. Set the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Select the MIN MAX function on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7725 Testing for Electrical Intermittents Testing for Electrical Intermittents Special Tools J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. Note: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions). 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7726 visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing for Terminal Fretting Some intermittent conditions can be caused by wire terminal fretting corrosion. Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can pile up enough at the electrical contact spots that the electrical resistance across the connection increases. Movement between the contacting surfaces as small as 10 to 100 microns can cause fretting. To put this in perspective, a sheet of paper is about 100 microns thick, so fretting motion is small and hard to see. Vibration and thermal expansion/contraction are the main sources that create fretting motion. Since vehicles vibrate and can experience large temperature swings, they are a good source for fretting motion. Tin, copper, nickel, and iron surfaces are all susceptible to fretting corrosion. Fretting corrosion can be difficult to see but it looks like small, dark smudges on the terminals contact surface. To correct a fretting condition disconnect the suspect connector and add Nyogel lubricant 760G (dielectric grease) to both sides of the connector terminals. Then reconnect the connector and wipe away any excess lubricant. This will correct the additional terminal contact resistance due to the terminal fretting corrosion. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7727 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics). * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Ground Distribution Schematics). Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Checking Aftermarket Accessories). * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7728 Note: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures test for a short to ground in a circuit. With a Digital Multimeter (DMM) 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohms position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Danger: High voltage circuits should only be tested using a digital multimeter (DMM) and test leads with at least a CAT III rating, such as the J 39200-A Digital Multimeter. Failure to follow the procedures exactly as written may result in serious injury or death. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Digital Multimeter (DMM) Basic Requirements Service information is validated using digital multimeters that meet or exceed the following requirements. Using a multimeter that does not meet these basic requirements may give inaccurate readings which could lead to an incorrect diagnosis. Display and Settings 1. Four digits displayed 2. Voltage, amperage, resistance, frequency, diode test settings, and min-max function 3. Display positive and negative values Voltage 1. Have at least 10 M ohm input impedance Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7729 2. Test a DC voltage range of 0.1-1000 V. 3. Test an AC voltage range of 0.1-1000 V. Amperage 1. Test a DC amperage range of 0.1µA-10 A. 2. Test an AC amperage range of 0.1µA-10 A. Resistance Test a resistance range of 0.1 ohm-40 Mohm and displays infinite for a value greater than 40 M ohm (O.L. (Over-load)) Frequency Test for a frequency range of 0.5 HZ-199 K HZ Diode Test 1. Apply at least 1 mA when performing the diode bias test 2. Display the break over voltage drop (0-3 V) of a forward biased diode 3. Display infinite (O.L. (Over-load)) when a diode is reverse biased Min-Max Readings 1. Can update at a 1 ms sample rate 2. Saves and displays minimum and maximum values Note: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Probe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors). * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the EL-38125-580 GM Approved Terminal Release Tool Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the EL-38125-580 GM Approved Terminal Release Tool Kit , ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the EL-38125-580 GM Approved Terminal Release Tool Kit label on the inside of the EL-38125-580 GM Approved Terminal Release Tool Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7730 Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/EPC Connectors AFL/EPC Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7731 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 3. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7732 View showing depressing of the lever lock release tab. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7733 6. Release the rear lower half of the wiredress cover. 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7734 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7735 Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Bosch Connectors (ECM) Bosch Connectors (ECM) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7736 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. 2. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7737 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-bladed tool to release the locking tabs and remove the dress cover. 4. The terminal positive assurance (TPA) is located in the front of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7738 5. Use a small flat-blade tool to remove TPA from the connector. 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7739 Note: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7740 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7741 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Terminal Replacement Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7742 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7743 5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Position Assurance Locks) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Terminal Position Assurance Locks) * AFL/EPC Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/AFL/EPC Connectors) * Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (BSK))Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (0.64))Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (2.8 JPT))Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (ECM)) * Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Weather Pack))Delphi Connectors (Push To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Push to Seat))Delphi Connectors Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7744 (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Pull to Seat))Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro-Pack 100W))Delphi Connectors (Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro .64))Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (12-Way)) * FCI Connectors (Lever Lock) (See: General Electrical Diagnostic Procedures/Connector Repairs/FCI Connectors (Lever Lock)) * JST Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/JST Connectors) * Kostal Connectors (Glow Plug Control Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Glow Plug Control Module))Kostal Connectors (Transmission) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Transmission)) * Molex Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Molex Connectors) * Sumitomo Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Sumitomo Connectors) * Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (CM 42-Way))Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Sensor))Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (0.25 Cap))Tyco/AMP Connectors (43-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (43-Way))Tyco/AMP Connectors (Door Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Door Module))Tyco/AMP Connectors (102-Way Inline) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (102-Way Inline))Tyco/AMP Connectors (Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Seat))Tyco/AMP Connectors (SIR) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (SIR)) * Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (2-Way))Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (16-Way)) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7745 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7746 * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7747 * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7748 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7749 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7750 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Push to Seat) Delphi Connectors (Push To Seat) Special Tools J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7751 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs). 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Terminated Lead Repair 1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice sleeves depending on the gauge size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Delphi Connectors (Pull to Seat) Delphi Connectors (Pull To Seat) Special Tools Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7752 J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Note: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7753 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. View of a typical Micro 64 connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7754 Depress the lock and pull the lever over and past the lock. View of the connector when released from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7755 View of another type of Micro 64 connector. Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7756 View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7757 Note: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7758 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7759 Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Note: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7760 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7761 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7762 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7763 1. Cut the wire as close to the terminal as possible. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7764 Terminal Replacement Procedure After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Special Tools J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Note: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals). 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12-Way) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7765 Delphi Connectors (12-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7766 4. Release the lower wire dress cover locking tab. 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7767 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7768 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors (Lever Lock) FCI Connectors (Lever Lock) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7769 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. The release tab is located on the top of the wiredress cover. 3. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7770 6. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7771 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7772 1. While depressing the lock, remove the connector from the component. 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7773 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. 4. View of the TPA when removed from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7774 5. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Glow Plug Control Module) Kostal Connectors (Glow Plug Control Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7775 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7776 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7777 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. Note: The front TPA cannot be removed from the connector. Only move it to the preset position. 6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm). 7. Use a small flat-blade tool to completely remove the rear TPA from the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7778 8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Transmission) Kostal Connectors (Transmission) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7779 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7780 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Terminal Replacement Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7781 After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7782 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7783 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7784 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7785 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7786 3. To assemble the connector, reverse the connector disassembly procedure. Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7787 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7788 7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7789 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7790 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7791 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7792 Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7793 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7794 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7795 6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (102-Way Inline) Tyco/AMP Connectors (102-Way Inline) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7796 View of a typical connector in the assembled position. 1. Pull the locking lever to the 90 degree position from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7797 2. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal. 3. Slide the male connector body out away from the guide plates. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7798 Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 4. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. 5. Using terminal release tool J 38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7799 6. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 7. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7800 8. The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool J-38125-11A or equivalent to release the locking tab and slide the connector off the female body. 9. Move the locking lever 180 degrees from the connected position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7801 10. With the locking lever in the 180 degree position the guide plates can be removed from the connector body. Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 11. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7802 12. Using terminal release tool J 38125-216, lift the terminal plate past the terminals and out of the connector body cavity. 13. Terminal plate will bind slightly on each corner. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7803 14. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 15. Using terminal release tool J 38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7804 16. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 17. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7805 18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever. 19. Slide the male connector body back inward toward the guide plates. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7806 20. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly. 21. Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Seat) Tyco/AMP Connectors (Seat) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7807 Removal Procedure 1. Grasp the locking slide lever and pull outward from the end of the connector. 2. As the slide lever is pulled out the mating connector is lifted from the seated position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7808 Note: TPA is keyed and can only be inserted in one direction. 3. Using terminal release tool J 38125-11A or equivalent, push the TPA tabs into the connector body. 4. Pull the TPA from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7809 5. Using terminal release tool J 38125-11A or equivalent, release the connector wire dress cover locking tab. 6. With the lock tab released, lift the connector wire dress cover from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7810 7. Using terminal release tool J 38125-212, press the prongs into the holes each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 8. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7811 9. Using terminal release tool J 38125-556, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (SIR) Tyco/AMP Connectors (SIR) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7812 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7813 3. Using terminal tool J-38125-11A or equivalent, release the wire dress cover locking tabs. 4. Pivot connector wire dress cover while removing from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7814 5. Using terminal tool J-38125-11A or equivalent, remove the TPA by lifting straight off the connector body. 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals Repairing Connector Terminals Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7815 Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gauge size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7816 2. Disconnect the connector from the component. 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7817 4. Relieve the tension on the nose piece retainers by inserting J 38125-12A into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. 5. Once the nose piece retainers are relaxed, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7818 6. On the opposite side of the nose piece, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7819 8. Insert the J 38125-553 tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7820 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. If the TPA is removed, be sure to reinstall it before reconnecting the connector. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7821 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Special Tools Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7822 J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Note: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7823 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7824 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7825 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7826 1. While depressing the lock, pull the two connector halves apart. Note: The TPA is fragile and may break if not done carefully. 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. 3. View of the male half of the connector with female terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7827 4. View of the female half of the connector with male terminals. 5. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. View of the female half of the connector with male terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7828 7. View of the male half of the connector with female terminals. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7829 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are a one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine if the element in the fuse is broken (2). If not broken (1), also check for continuity using a Digital Multimeter (DMM) or a continuity tester. If the element is broken or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a Digital Multimeter (DMM) at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gauge size. Repairing a Fusible Link Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7830 Flat Wire Repairs The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Special Tools J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool * J 38125-5 Ultra Torch Special Tool The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Note: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation). GMLAN Connector Terminal Repair Note: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) for the appropriate connector repair procedure. GMLAN Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7831 Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7832 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Special Tools J-38125 Terminal Repair Kit Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7833 repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs High Temperature Wiring Repairs Special Tools J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gauge size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7834 splice. Note: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7835 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7836 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the wire insulation has been chafed, or broken, enough to show the conductive portion of the wire, and the wire is not damaged, determine the length of insulation that needs to be repaired. If the repair is less than 280 mm (11 in), cut the wire within the damaged area. Then slide the appropriate heat shrink tubing (listed below) over the wire, and repair the wire by splicing the wires together. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Once the wire is spliced together slide heat shrink tubing over the damaged area and apply heat to seal the repaired wire. If the wire is damaged, or the damaged area is larger than 280 mm (11 in), then replace the damaged wire by splicing in a new section of wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7837 SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Special Tools J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7838 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7839 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7840 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Special Tools J-38125 Terminal Repair Kit Note: Use only DuraSeal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use DuraSeal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use DuraSeal splice sleeves where there are special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7841 * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7842 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7843 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the instructions for Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Staggering the splices by 65 mm (2.5 in) is recommended. Note: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product AL-36FR to replace the damaged mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Flat Wire Repairs) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/GMLAN Wiring Repairs) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Heated Oxygen Sensor Wiring Repairs) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves) * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Twisted or Shielded Cable) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Inline Harness Diodes) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/SIR/SRS Wiring Repairs) US English/Metric Conversion US English/Metric Conversion Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7844 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7845 Testing Ground and Low Reference Circuits Testing Ground and Low Reference Circuits Because a test lamp can light with up to 200 ohm in a ground or low reference circuit they are not recommended to be used for this type of test. A low impedance test lamp can light and indicate the circuit is good when there is as much as 20-30 ohm present, while a high impedance test lamp can light with up to 200 ohm present in the circuit. This is why the Digital Multi-Meter (DMM) is used when validating a ground or low reference circuit continuity. When using the DMM there are many vehicle conditions that can affect the ground and low reference continuity testing. If these conditions are not met, a ground or low reference circuit test can fail on a good circuit. This may cause longer diagnosis time and incorrect component replacement. Any current flow through a ground or low reference circuit, while being tested, will skew the DMM continuity reading, or display a reading higher than when there is no current flowing. Performing a ground or low reference circuit continuity test, in reference to the vehicles battery negative terminal, will have the highest risk of failing a good ground or low reference circuit test than any other ground reference point. The best ground test points would be a control module housing (if the control modules housing is metal and grounded), door jamb striker (if attached to metal), under dash metal frame work, engine block, or body ground studs (other than where the negative battery cable is attached). A typical DMM ground or low reference circuit continuity reading can be as high as 100 ohm with the ignition ON, and drop to 15-25 ohm after the ignition is turned OFF. The reading will drop below 10 ohm after 30-40 seconds, then below 5 ohm after 60 seconds. Once the vehicle completely goes to sleep (generally 3-10 minutes) the reading will drop below 0.3 ohm. The following list of conditions may need to be met to ensure a valid continuity reading on a ground or low reference circuit: * Ignition OFF * Key out of the ignition switch (when not equipped with keyless entry and remote start) * Retained Accessory Power (RAP) OFF (open and close the driver door after ignition OFF) * Battery charger set at a 2 A or less charge rate * Scan tool not communicating with any vehicle control module (in some cases it may need to be disconnected from the DLC) * All entry doors closed * Headlamps OFF (auto headlamps disabled) * Any delay lighting OFF * HVAC after blow OFF * Any accessory that can work when the ignition is OFF * Wait up to 60 seconds (after all other listed conditions are met) Activating the DOOR LOCK function with a key fob can greatly reduce the time to achieve a valid ground or low reference continuity test result. Terminal Removal Terminal Removal Special Tools * EL-38125-580 - Terminal Release Tool Kit * EL-35616 - Connector Test Adapter Kit For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repair procedures. 1. Find the appropriate connector end view within the connector end view section. The connector end view has the following information: Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7846 * Diagnostic probe tool * Terminal release tool * Terminal/terminated lead part numbers Note: Not using the proper test kit probe may cause damage to the terminal(s) that are probed. 2. Determine if a terminal is damaged. * Locate the diagnostic probe tool from the connector end view. The connector end view describes the color and part number to help the technician find and use the correct tool. * Connect the probe tool to the Digital Multimeter. * Insert the probe tool into the cavity and follow the procedures from the Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter). 3. Disconnect the connector body to perform the repair. 4. Use the following procedure to remove the terminal from the connector body. Note: Several procedures for specific connector bodies are called out in the Wiring Repairs section. * The terminal position assurance (TPA) and connector position assurance (CPA) should be removed before releasing the terminal for the connector body. * Look at the connector end view to locate the cavity of the damaged terminal and find the proper terminal release tool from the terminal release tool kit. Note: Using the incorrect terminal release tool can damage the connector body. * Insert the terminal release tool into the cavity. Note: Some terminals have a lever that must be disengaged before the terminal can be released. 5. Gently pull the wire out of the back of the connector. 6. Repair the terminal by following the Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) procedure. 7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminated Lead Repair Terminated Lead Repair Special Tools * J-38125-8 - Splice Sleeve Crimp Tool Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7847 * J-38125-5 - Ultra Torch For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) procedures. Terminated leads are terminals that are crimped onto wires. The terminated lead can be used throughout the vehicle since it is designed for temperatures up to 150°C. The length of the wire is 450 mm. The DuraSeal splice sleeve has the following 2 critical features: * A special heat shrink tubing that environmentally seals the splice. The shrink tubing contains a sealing adhesive inside the shrink tubing. * A cross hatched (knurled) core crimp that provides the necessary contact integrity for sensitive low energy circuits. 1. Use the connector end view to identify the correct terminated lead. 2. The terminated lead package should include a DuraSeal splice sleeve. If not, use the chart to identify the correct part. 3. Open the harness by removing any tape: Use a sewing seam ripper, or a comparable tool, to cut open the harness, to avoid wire insulation damage. 4. Depending on how many terminals need repairs, cut the terminal and wire back at least 40 mm. Try to keep the harness wire length the same. If more than one terminated lead is required, stagger the lengths by 40 mm. This helps reduce the bundle size of the wire harness. 5. Use the EL-38125-10 - tool in order to position the DuraSeal splice sleeve in the proper color nest of the splice sleeve crimp tool. The crimp tool has four nests, one for each color. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7848 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the J-38125-5 - ultra torch , apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7849 Shift Solenoid: Connector Views Component Connector End Views Control Solenoid Valve Assembly X1 (MYC, MYD or M99) Control Solenoid Valve Assembly X2 (MYC, MYD or M99) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7850 Control Solenoid Valve Assembly X3 (MYC, MYD or M99) 1-2 Shift Solenoid (SS) Valve (M30) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7851 2-3 Shift Solenoid (SS) Valve (M30) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7852 Shift Solenoid (SS) Valve 1 (MW7) Shift Solenoid (SS) Valve 2 (MW7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7853 Shift Solenoid (SS) Valve 3 (MW7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Service and Repair > Control Valve Solenoid Replacement (PCS1 and PCS2) Shift Solenoid: Service and Repair Control Valve Solenoid Replacement (PCS1 and PCS2) Control Valve Solenoid Replacement (PCS1 and PCS2) Removal Procedure 1. Remove the oil pan and transmission internal oil filter. Refer to Oil Pan Replacement (See: Fluid Pan/Service and Repair). 2. Disconnect the internal wiring harness from the solenoid being changed. 3. Remove the 2 bolts that fasten reverse signal pipe (1) to the control valve assembly. Remove the reverse signal pipe. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Service and Repair > Control Valve Solenoid Replacement (PCS1 and PCS2) > Page 7856 Note: * When the pressure control valve retaining bracket (5) is removed, there are 2 sets of accumulators (3) and springs (6) which may fall from the bores. Be sure to catch the accumulators and springs so as to prevent damage to these parts. * The pressure control valve retaining bracket (5) must not be modified. Note that the angle between the 2 bracket surfaces is less than 90 degrees. Replace the bracket if the angle is 90 degrees or more. 4. To remove the pressure control solenoid 1 (PCS1) or PCS2, remove three bolts (4) and the pressure control valve retaining bracket (5). Remove accumulators (3) and springs (6) if they do not fall out when the bracket (5) is removed. 5. Note the position of the solenoid connector and pull the solenoid (1) or (8) out of the bore in the control valve assembly. The O-ring on the solenoid provides the resistance felt during removal. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Service and Repair > Control Valve Solenoid Replacement (PCS1 and PCS2) > Page 7857 1. Obtain the new solenoid (1) or (8). Lubricate new O-ring (2) or (7) with clean transmission fluid. Install the O-ring and push the new solenoid into the control valve body bore with the wiring harness connector in the correct position. 2. Install the 2 accumulators (3) and springs (6) before installing the pressure control valve retaining bracket (5). The valve (3) goes in the bore first with the hollow end facing outward, followed by the spring (6) which goes inside the hollow portion of the valve. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the pressure control valve retaining bracket (5), and install the 3 bolts (4). Tighten the bolts to 12 Nm (108 lb in). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Service and Repair > Control Valve Solenoid Replacement (PCS1 and PCS2) > Page 7858 4. Install the reverse signal pipe (1). Install the 2 bolts that fasten reverse signal pipe to the control valve assembly. Tighten the bolts to 12 Nm (108 lb in). 5. Reconnect the internal wiring harness to the solenoid. 6. Install the oil pan and transmission internal oil filter. Refer to Oil Pan Replacement (See: Fluid Pan/Service and Repair). Note: The FastLearn, adapt, procedure must be performed. This can be done in 1 step using a scan tool. If this procedure is not done, the TCM adaptive values will be at the settings that it learned for the old components and will be in slow adaptive mode. Under these conditions, it will take an unacceptably long time for the adaptive values to converge to levels suitable for the new transmission. 7. Perform the FastLearn procedure. Refer to FastLearn Procedure (See: Testing and Inspection/Programming and Relearning). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Service and Repair > Control Valve Solenoid Replacement (PCS1 and PCS2) > Page 7859 Shift Solenoid: Service and Repair Control Valve Solenoid Replacement (SS1, SS2, SS3, TCC, and MAIN MOD) Control Valve Solenoid Replacement (SS1, SS2, SS3, TCC, and MAIN MOD) Removal Procedure 1. Remove the oil pan and the transmission internal oil filter. Refer to Oil Pan Replacement (See: Fluid Pan/Service and Repair). 2. Disconnect the internal wiring harness from the solenoid being changed. 3. Remove the solenoid retainer (2) for shift solenoid 1 (SS1) (5). Note the position of the solenoid connector and pull the solenoid (5) out of the bore in the control valve assembly (1). The O-rings (3 and 4) provide the resistance felt during removal. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Service and Repair > Control Valve Solenoid Replacement (PCS1 and PCS2) > Page 7860 4. Remove the solenoid retainer (6) for shift solenoid 2 (SS2) (1) or shift solenoid 3 (SS3) (4), whichever is being replaced. 5. Note the position of the solenoid connector and pull the solenoid out of the bore in the control valve assembly. The O-rings (2 and 3) provide the resistance felt during removal. Note: The TCC pressure control solenoid (PCS) retaining bracket must not be modified. Note that the angle between the 2 bracket surfaces is less than 90 degrees. Replace the bracket if the angle is 90 degrees or greater. 6. Remove the TCC PCS retaining bolt and retaining bracket. 7. Remove the TCC PCS (7). Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Service and Repair > Control Valve Solenoid Replacement (PCS1 and PCS2) > Page 7861 1. Obtain a new SS 2 (1), SS 3 (4), TCC PCS (7), or modulated main pressure solenoid. Install O-rings (2 and 3) and lubricate with clean transmission fluid. Push the new solenoid into the control valve assembly (5) with the wiring harness connector in the correct position. 2. Install the solenoid retainer (6). Connect the internal wiring harness to the solenoids replaced. 3. For a new TCC PCS (7), install O-rings and lubricate with clean transmission fluid. Push the new TCC PCS (7) into the control valve assembly with the wiring harness connector in the correct position. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the TCC PCS retainer and bolt. Tighten the bolt to 12 Nm (108 lb in). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Service and Repair > Control Valve Solenoid Replacement (PCS1 and PCS2) > Page 7862 5. For a new SS 1 (5), install O-rings (3 and 4) and lubricate with clean transmission fluid. Push the new SS 1 (5) into the control valve assembly with the wiring harness connector in the correct position. Install the solenoid retainer (2). 6. Install the oil pan and transmission internal oil filter. Refer to Oil Pan Replacement (See: Fluid Pan/Service and Repair). Note: The FastLearn, adapt, procedure must be performed. This can be done in 1 step using a scan tool. If this procedure is not done, the TCM adaptive values will be at the settings that it learned for the old components and will be in slow adaptive mode. Under these conditions, it will take an unacceptably long time for the adaptive values to converge to levels suitable for the new transmission. 7. Perform the FastLearn procedure. Refer to FastLearn Procedure (See: Testing and Inspection/Programming and Relearning). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Diagrams Shifter A/T: Diagrams Component Connector End Views Automatic Transmission Shift Lever (M30, MYC, MYD, M99 or MW7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Diagrams > Page 7866 Shifter A/T: Service and Repair Shift Lever Replacement Removal Procedure 1. Remove the steering column shroud. Refer to Steering Column Shroud Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Column Shroud Replacement). 2. Roll back the shift lever seal on the shift lever until the shift lever bolt is exposed. 3. Disconnect any electrical connectors as needed. 4. Remove the shift lever bolt (2). 5. Remove the shift lever (1). Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Diagrams > Page 7867 1. Install the shift lever (1). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the shift lever bolt (2) and tighten to 20 Nm (15 lb ft). 3. Connect all electrical connectors. 4. Position the shift lever seal. 5. Install the steering column shroud. Refer to Steering Column Shroud Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Column Shroud Replacement). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > Customer Interest for Shift Cable: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON Shift Cable: Customer Interest A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > Customer Interest for Shift Cable: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 7877 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > Customer Interest for Shift Cable: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 7878 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > Customer Interest for Shift Cable: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 7879 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Cable: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON Shift Cable: All Technical Service Bulletins A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Cable: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 7885 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Cable: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 7886 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Cable: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 7887 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > Page 7888 Shift Cable: Adjustments Range Selector Lever Cable Adjustment 1. Ensure that the steering column shift lever is in the park (P) position. 2. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 3. Ensure that the transmission manual shaft lever is in the park (P) position. 4. Grasp the shift cable shifter end (1) in the left hand and the shift cable transmission end (2) in the right hand. 5. Align the outside diameter of the transmission end (2) with the inside diameter of the shifter end (1). 6. Push the end of the transmission cable (3) inside the shifter end until the blue spring (2) on the transmission end (3) is fully compressed, this will engage the inner wire and lock both wires together. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > Page 7889 Important: DO NOT hold the transmission end (1) during this operation, this will result in a mis-adjusted cable. 7. Release the transmission end (3) and allow the spring (2) to tension/adjust the cable system. 8. Pull the white cover (5) on the shifter end (1) back. 9. Push the natural colored lock button (4) down to engage the locking teeth on the transmission end (3). 10. Release the white cover (1). 11. Verify the white cover (1) conceals the natural colored lock (2). 12. If the white cover (1) does not conceal the natural colored lock (2), the shift cable must be re-adjusted. Refer to cable re-adjustment below. 13. Lower the vehicle. 14. Test the transmission for proper shift operation. 15. If all of the gear positions cannot be achieved, the shift cable must be re-adjusted. Refer to cable re-adjustment below. Cable Re-Adjustment Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > Page 7890 1. Place the steering column shift lever back into the park (P) position. 2. Raise the vehicle. 3. Ensure that the transmission manual shaft lever is in the park (P) position. 4. Pull the white cover (1) back to expose the natural colored lock (2). Under the lock (2), insert a flat bladed screwdriver under the lock ramp located at the top of the lock. The lock will pop up, and the transmission end will move slightly away from the shifter end. 5. Push the end of the transmission end (3) inside the shifter end (1) until the blue spring (2) on the transmission end (3) is fully compressed, this will engage the inner wire and lock both wires together. Important: DO NOT hold the transmission end (1) during this operation, this will result in a mis-adjusted cable. 6. Release the transmission end (3) and allow the spring (2) to tension/adjust the cable system. 7. Pull the white cover (5) on the shifter end (1) back. 8. Push the natural colored lock button (4) down to engage the locking teeth on the transmission end (3). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > Page 7891 9. Release the white cover (1). 10. Verify the white cover (1) conceals the natural colored lock (2). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > Page 7892 Shift Cable: Service and Repair Range Selector Lever Cable Replacement Removal Procedure Warning The automatic transaxle range selector cable is made out of two cable sections. After initial connection never separate the two metal couplings from one another. Integrity of the connection of the two metal couplings will be lost if separation of the two metal couplings occurs. When servicing the transaxle remove the cable at the automatic transaxle range selector lever and at the automatic transaxle range selector cable bracket. If either section of the cable needs to be replaced, replace both of the cable sections. Loss of connection integrity of the two metal couplings can cause loss of transaxle shift control which could result in personal injury. 1. Position the steering column shift lever to the park position. 2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 3. Remove the range selector cable heat shield bolts. 4. Remove the range selector cable heat shield. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > Page 7893 5. Ensure the transmission manual shaft is positioned in mechanical park. 6. Remove the range selector cable end from the transmission range selector lever stud. 7. Remove the retainer securing the range selector cable to the bracket. 8. Depress the tangs and remove the cable from the range selector cable bracket. 9. Remove the cable clips from the floor panel reinforcement. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > Page 7894 10. Remove the cable clips (2) from the transfer case, if equipped. 11. Lower the vehicle. 12. Ensure that the steering column shift lever is still in the park position. 13. Pull back the carpet and insulation around the driver's area. 14. Remove the instrument panel knee bolster. Refer to Knee Bolster Replacement (With SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (With SLT))Knee Bolster Replacement (Without SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (Without SLT)). 15. Remove the retainer securing the cable to the steering column. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > Page 7895 16. Remove the cable end from the steering column ball stud. 17. Depress the tangs and remove the cable from the steering column bracket. Note: Avoid unnecessary twisting/bending of the range selector cable when removing the cable from the support. 18. Remove the range selector cable from the support. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > Page 7896 19. Remove the cable grommet from the floor panel. 20. Remove the cable from the vehicle. Installation Procedure 1. Install the cable to the vehicle. 2. Install the cable grommet to the floor panel. Note: Avoid unnecessary twisting/bending of the range selector cable when installing the cable to the support. 3. Install the range selector cable to the support. 4. Ensure that the transmission manual shaft lever is in the mechanical park position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > Page 7897 5. Install the cable to the steering column bracket. 6. Ensure the tangs fully seat (snap) into the steering column bracket. 7. Install the cable end to the steering column ball stud. 8. Install the retainer securing the cable to the steering column. 9. Position the carpet and insulation around the driver's area. 10. Install the instrument panel knee bolster. Refer to Knee Bolster Replacement (With SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (With SLT))Knee Bolster Replacement (Without SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (Without SLT)). 11. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > Page 7898 12. Install the cable clips (2) to the transfer case, if equipped. 13. Install the cable clips to the floor panel reinforcement. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > Page 7899 14. Ensure the transmission manual shaft is positioned in mechanical park. 15. Install the range selector cable to the range selector cable bracket. 16. Install the retainer securing the range selector cable to the bracket. 17. Install the range selector cable end to the transmission range selector lever stud. 18. Install the range selector cable heat shield. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Note: Install bolts by hand then mechanically tighten the front bolt first and the rear bolt last. Failure to tighten the bolts in the specified order will result in misalignment of the heat shield. 19. Install the range selector cable heat shield bolts. * Tighten the front bolt to 25 Nm (18 lb ft). * Tighten the rear bolt to 25 Nm (18 lb ft). 20. Lower the vehicle. 21. Test the transmission for proper shift operation. 22. If all of the gear positions cannot be achieved, adjust the cable. Refer to Range Selector Lever Cable Adjustment (See: Adjustments). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Service and Repair Torque Converter: Service and Repair Torque Converter Replacement Special Tools * J 21366 Converter Holding Strap * J 46409 Torque Converter Lifting Handles * J 44723 Transmission/Stand Adaptor Plate Removal Procedure 1. Remove the transmission from the vehicle. Refer to Transmission Replacement (See: Service and Repair). 2. Install J 21366 to restrain the torque converter. 3. Install J 44723 . Refer to Holding Fixture Installation (See: Service and Repair/Overhaul/1. Holding Fixture Installation). 4. Position the transmission vertically with the torque converter end up. 5. Remove J 21366 torque converter retaining bracket. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Service and Repair > Page 7903 Note: The distance from the torque converter mounting lugs to the transmission mounting face is an important measurement. It is required to check correct reassembly of the torque converter. 6. Measure from the mounting lugs to the transmission mounting face. 7. Install J 46409 180 degrees apart into 2 lugs on the front of the torque converter. Warning Avoid personal injury or property damage when removing or installing the torque converter by seeking an assistant to help lift the torque converter. 8. Lift the torque converter free of the transmission and place it on the work table. 9. Remove the lifting handles. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Service and Repair > Page 7904 1. Lubricate the converter pump hub OD and the torque converter seal with clean transmission fluid. 2. Install J 46409 180 degrees apart into 2 lugs on the front of the torque converter. Warning Avoid personal injury or property damage when removing or installing the torque converter by seeking an assistant to help lift the torque converter. 3. Lift the torque converter into the transmission. 4. Spin the torque converter to engage the turbine shaft splines in the torque converter hub, the stator shaft splines in the stator race and to engage the drive flats on the converter pump hub with the oil pump drive gear. 5. The torque converter is correctly installed when the distance from the lugs to the mounting face is the same as when measured before removing the torque converter. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Service and Repair > Page 7905 6. Install J 21366 . 7. Reinstall the transmission into the vehicle. Refer to Transmission Replacement (See: Service and Repair). Note: The FastLearn (adapt) procedure must be performed. This can be done in one step using a scan tool. If this procedure is not done, the TCM 's adaptive values will be at the settings that it learned for the old components. and will be in slow adaptive mode. Under these conditions, it would take an unacceptably long time for the adaptive values to converge to levels suitable for the new transmission. 8. Perform the FastLearn procedure. Refer to FastLearn Procedure (See: Testing and Inspection/Programming and Relearning). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Torque Converter Clutch Solenoid: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Schematic Symbols Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7910 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7911 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7912 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7913 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7914 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7915 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7916 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7917 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7918 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7919 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7920 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7921 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7922 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7923 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7924 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7925 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7926 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7927 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7928 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7929 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7930 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7931 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7932 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7933 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7934 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7935 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7936 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7937 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7938 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7939 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7940 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7941 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7942 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7943 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7944 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7945 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7946 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7947 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7948 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7949 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7950 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7951 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7952 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7953 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7954 Torque Converter Clutch Solenoid: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed with Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7955 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7956 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Connector Test Adapters) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7957 Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Test Lamp) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Fused Jumper Wires) * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage Drop) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Frequency) * Testing Ground and Low Reference Circuits (See: Testing and Inspection/Component Tests and General Diagnostics/Testing Ground and Low Reference Circuits) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fuses) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Circuit Breakers) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fusible Links) Troubleshooting with a Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Testing for a Short to Voltage Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7958 Testing for a Short to Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure tests for a short to voltage in a circuit. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the Digital Multimeter (DMM) to the V (DC) position. 4. Connect the positive lead of the DMM to one end of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. Turn ON the ignition and operate all accessories. 7. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Special Tools J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure). Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents). Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7959 The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the frequency of a signal. Note: Connecting the Digital Multimeter (DMM) to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Set to Hz on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7960 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the Digital Multimeter (DMM). 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the difference in voltage potential between 2 points. 1. Set the Digital Multimeter (DMM) to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7961 Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Backprobe Note: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7962 (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for Continuity Testing for Continuity Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures verify good continuity in a circuit. With a Digital Multimeter (DMM) 1. Set the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Select the MIN MAX function on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7963 Testing for Electrical Intermittents Testing for Electrical Intermittents Special Tools J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. Note: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions). 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7964 visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing for Terminal Fretting Some intermittent conditions can be caused by wire terminal fretting corrosion. Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can pile up enough at the electrical contact spots that the electrical resistance across the connection increases. Movement between the contacting surfaces as small as 10 to 100 microns can cause fretting. To put this in perspective, a sheet of paper is about 100 microns thick, so fretting motion is small and hard to see. Vibration and thermal expansion/contraction are the main sources that create fretting motion. Since vehicles vibrate and can experience large temperature swings, they are a good source for fretting motion. Tin, copper, nickel, and iron surfaces are all susceptible to fretting corrosion. Fretting corrosion can be difficult to see but it looks like small, dark smudges on the terminals contact surface. To correct a fretting condition disconnect the suspect connector and add Nyogel lubricant 760G (dielectric grease) to both sides of the connector terminals. Then reconnect the connector and wipe away any excess lubricant. This will correct the additional terminal contact resistance due to the terminal fretting corrosion. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7965 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics). * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Ground Distribution Schematics). Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Checking Aftermarket Accessories). * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7966 Note: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures test for a short to ground in a circuit. With a Digital Multimeter (DMM) 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohms position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Danger: High voltage circuits should only be tested using a digital multimeter (DMM) and test leads with at least a CAT III rating, such as the J 39200-A Digital Multimeter. Failure to follow the procedures exactly as written may result in serious injury or death. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Digital Multimeter (DMM) Basic Requirements Service information is validated using digital multimeters that meet or exceed the following requirements. Using a multimeter that does not meet these basic requirements may give inaccurate readings which could lead to an incorrect diagnosis. Display and Settings 1. Four digits displayed 2. Voltage, amperage, resistance, frequency, diode test settings, and min-max function 3. Display positive and negative values Voltage 1. Have at least 10 M ohm input impedance Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7967 2. Test a DC voltage range of 0.1-1000 V. 3. Test an AC voltage range of 0.1-1000 V. Amperage 1. Test a DC amperage range of 0.1µA-10 A. 2. Test an AC amperage range of 0.1µA-10 A. Resistance Test a resistance range of 0.1 ohm-40 Mohm and displays infinite for a value greater than 40 M ohm (O.L. (Over-load)) Frequency Test for a frequency range of 0.5 HZ-199 K HZ Diode Test 1. Apply at least 1 mA when performing the diode bias test 2. Display the break over voltage drop (0-3 V) of a forward biased diode 3. Display infinite (O.L. (Over-load)) when a diode is reverse biased Min-Max Readings 1. Can update at a 1 ms sample rate 2. Saves and displays minimum and maximum values Note: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Probe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors). * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the EL-38125-580 GM Approved Terminal Release Tool Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the EL-38125-580 GM Approved Terminal Release Tool Kit , ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the EL-38125-580 GM Approved Terminal Release Tool Kit label on the inside of the EL-38125-580 GM Approved Terminal Release Tool Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7968 Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/EPC Connectors AFL/EPC Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7969 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 3. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7970 View showing depressing of the lever lock release tab. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7971 6. Release the rear lower half of the wiredress cover. 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7972 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7973 Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Bosch Connectors (ECM) Bosch Connectors (ECM) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7974 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. 2. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7975 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-bladed tool to release the locking tabs and remove the dress cover. 4. The terminal positive assurance (TPA) is located in the front of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7976 5. Use a small flat-blade tool to remove TPA from the connector. 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7977 Note: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7978 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7979 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Terminal Replacement Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7980 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7981 5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Position Assurance Locks) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Terminal Position Assurance Locks) * AFL/EPC Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/AFL/EPC Connectors) * Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (BSK))Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (0.64))Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (2.8 JPT))Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (ECM)) * Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Weather Pack))Delphi Connectors (Push To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Push to Seat))Delphi Connectors Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7982 (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Pull to Seat))Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro-Pack 100W))Delphi Connectors (Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro .64))Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (12-Way)) * FCI Connectors (Lever Lock) (See: General Electrical Diagnostic Procedures/Connector Repairs/FCI Connectors (Lever Lock)) * JST Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/JST Connectors) * Kostal Connectors (Glow Plug Control Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Glow Plug Control Module))Kostal Connectors (Transmission) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Transmission)) * Molex Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Molex Connectors) * Sumitomo Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Sumitomo Connectors) * Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (CM 42-Way))Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Sensor))Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (0.25 Cap))Tyco/AMP Connectors (43-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (43-Way))Tyco/AMP Connectors (Door Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Door Module))Tyco/AMP Connectors (102-Way Inline) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (102-Way Inline))Tyco/AMP Connectors (Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Seat))Tyco/AMP Connectors (SIR) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (SIR)) * Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (2-Way))Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (16-Way)) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7983 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7984 * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7985 * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7986 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7987 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7988 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Push to Seat) Delphi Connectors (Push To Seat) Special Tools J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7989 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs). 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Terminated Lead Repair 1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice sleeves depending on the gauge size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Delphi Connectors (Pull to Seat) Delphi Connectors (Pull To Seat) Special Tools Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7990 J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Note: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7991 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. View of a typical Micro 64 connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7992 Depress the lock and pull the lever over and past the lock. View of the connector when released from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7993 View of another type of Micro 64 connector. Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7994 View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7995 Note: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7996 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7997 Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Note: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7998 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 7999 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8000 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8001 1. Cut the wire as close to the terminal as possible. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8002 Terminal Replacement Procedure After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Special Tools J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Note: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals). 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12-Way) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8003 Delphi Connectors (12-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8004 4. Release the lower wire dress cover locking tab. 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8005 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8006 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors (Lever Lock) FCI Connectors (Lever Lock) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8007 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. The release tab is located on the top of the wiredress cover. 3. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8008 6. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8009 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8010 1. While depressing the lock, remove the connector from the component. 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8011 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. 4. View of the TPA when removed from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8012 5. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Glow Plug Control Module) Kostal Connectors (Glow Plug Control Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8013 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8014 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8015 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. Note: The front TPA cannot be removed from the connector. Only move it to the preset position. 6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm). 7. Use a small flat-blade tool to completely remove the rear TPA from the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8016 8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Transmission) Kostal Connectors (Transmission) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8017 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8018 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Terminal Replacement Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8019 After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8020 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8021 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8022 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8023 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8024 3. To assemble the connector, reverse the connector disassembly procedure. Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8025 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8026 7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8027 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8028 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8029 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8030 Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8031 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8032 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8033 6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (102-Way Inline) Tyco/AMP Connectors (102-Way Inline) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8034 View of a typical connector in the assembled position. 1. Pull the locking lever to the 90 degree position from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8035 2. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal. 3. Slide the male connector body out away from the guide plates. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8036 Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 4. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. 5. Using terminal release tool J 38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8037 6. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 7. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8038 8. The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool J-38125-11A or equivalent to release the locking tab and slide the connector off the female body. 9. Move the locking lever 180 degrees from the connected position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8039 10. With the locking lever in the 180 degree position the guide plates can be removed from the connector body. Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 11. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8040 12. Using terminal release tool J 38125-216, lift the terminal plate past the terminals and out of the connector body cavity. 13. Terminal plate will bind slightly on each corner. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8041 14. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 15. Using terminal release tool J 38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8042 16. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 17. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8043 18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever. 19. Slide the male connector body back inward toward the guide plates. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8044 20. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly. 21. Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Seat) Tyco/AMP Connectors (Seat) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8045 Removal Procedure 1. Grasp the locking slide lever and pull outward from the end of the connector. 2. As the slide lever is pulled out the mating connector is lifted from the seated position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8046 Note: TPA is keyed and can only be inserted in one direction. 3. Using terminal release tool J 38125-11A or equivalent, push the TPA tabs into the connector body. 4. Pull the TPA from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8047 5. Using terminal release tool J 38125-11A or equivalent, release the connector wire dress cover locking tab. 6. With the lock tab released, lift the connector wire dress cover from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8048 7. Using terminal release tool J 38125-212, press the prongs into the holes each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 8. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8049 9. Using terminal release tool J 38125-556, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (SIR) Tyco/AMP Connectors (SIR) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8050 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8051 3. Using terminal tool J-38125-11A or equivalent, release the wire dress cover locking tabs. 4. Pivot connector wire dress cover while removing from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8052 5. Using terminal tool J-38125-11A or equivalent, remove the TPA by lifting straight off the connector body. 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals Repairing Connector Terminals Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8053 Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gauge size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8054 2. Disconnect the connector from the component. 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8055 4. Relieve the tension on the nose piece retainers by inserting J 38125-12A into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. 5. Once the nose piece retainers are relaxed, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8056 6. On the opposite side of the nose piece, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8057 8. Insert the J 38125-553 tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8058 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. If the TPA is removed, be sure to reinstall it before reconnecting the connector. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8059 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Special Tools Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8060 J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Note: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8061 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8062 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8063 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8064 1. While depressing the lock, pull the two connector halves apart. Note: The TPA is fragile and may break if not done carefully. 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. 3. View of the male half of the connector with female terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8065 4. View of the female half of the connector with male terminals. 5. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. View of the female half of the connector with male terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8066 7. View of the male half of the connector with female terminals. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8067 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are a one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine if the element in the fuse is broken (2). If not broken (1), also check for continuity using a Digital Multimeter (DMM) or a continuity tester. If the element is broken or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a Digital Multimeter (DMM) at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gauge size. Repairing a Fusible Link Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8068 Flat Wire Repairs The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Special Tools J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool * J 38125-5 Ultra Torch Special Tool The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Note: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation). GMLAN Connector Terminal Repair Note: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) for the appropriate connector repair procedure. GMLAN Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8069 Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8070 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Special Tools J-38125 Terminal Repair Kit Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8071 repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs High Temperature Wiring Repairs Special Tools J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gauge size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8072 splice. Note: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8073 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8074 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the wire insulation has been chafed, or broken, enough to show the conductive portion of the wire, and the wire is not damaged, determine the length of insulation that needs to be repaired. If the repair is less than 280 mm (11 in), cut the wire within the damaged area. Then slide the appropriate heat shrink tubing (listed below) over the wire, and repair the wire by splicing the wires together. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Once the wire is spliced together slide heat shrink tubing over the damaged area and apply heat to seal the repaired wire. If the wire is damaged, or the damaged area is larger than 280 mm (11 in), then replace the damaged wire by splicing in a new section of wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8075 SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Special Tools J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8076 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8077 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8078 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Special Tools J-38125 Terminal Repair Kit Note: Use only DuraSeal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use DuraSeal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use DuraSeal splice sleeves where there are special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8079 * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8080 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8081 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the instructions for Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Staggering the splices by 65 mm (2.5 in) is recommended. Note: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product AL-36FR to replace the damaged mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Flat Wire Repairs) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/GMLAN Wiring Repairs) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Heated Oxygen Sensor Wiring Repairs) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves) * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Twisted or Shielded Cable) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Inline Harness Diodes) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/SIR/SRS Wiring Repairs) US English/Metric Conversion US English/Metric Conversion Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8082 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8083 Testing Ground and Low Reference Circuits Testing Ground and Low Reference Circuits Because a test lamp can light with up to 200 ohm in a ground or low reference circuit they are not recommended to be used for this type of test. A low impedance test lamp can light and indicate the circuit is good when there is as much as 20-30 ohm present, while a high impedance test lamp can light with up to 200 ohm present in the circuit. This is why the Digital Multi-Meter (DMM) is used when validating a ground or low reference circuit continuity. When using the DMM there are many vehicle conditions that can affect the ground and low reference continuity testing. If these conditions are not met, a ground or low reference circuit test can fail on a good circuit. This may cause longer diagnosis time and incorrect component replacement. Any current flow through a ground or low reference circuit, while being tested, will skew the DMM continuity reading, or display a reading higher than when there is no current flowing. Performing a ground or low reference circuit continuity test, in reference to the vehicles battery negative terminal, will have the highest risk of failing a good ground or low reference circuit test than any other ground reference point. The best ground test points would be a control module housing (if the control modules housing is metal and grounded), door jamb striker (if attached to metal), under dash metal frame work, engine block, or body ground studs (other than where the negative battery cable is attached). A typical DMM ground or low reference circuit continuity reading can be as high as 100 ohm with the ignition ON, and drop to 15-25 ohm after the ignition is turned OFF. The reading will drop below 10 ohm after 30-40 seconds, then below 5 ohm after 60 seconds. Once the vehicle completely goes to sleep (generally 3-10 minutes) the reading will drop below 0.3 ohm. The following list of conditions may need to be met to ensure a valid continuity reading on a ground or low reference circuit: * Ignition OFF * Key out of the ignition switch (when not equipped with keyless entry and remote start) * Retained Accessory Power (RAP) OFF (open and close the driver door after ignition OFF) * Battery charger set at a 2 A or less charge rate * Scan tool not communicating with any vehicle control module (in some cases it may need to be disconnected from the DLC) * All entry doors closed * Headlamps OFF (auto headlamps disabled) * Any delay lighting OFF * HVAC after blow OFF * Any accessory that can work when the ignition is OFF * Wait up to 60 seconds (after all other listed conditions are met) Activating the DOOR LOCK function with a key fob can greatly reduce the time to achieve a valid ground or low reference continuity test result. Terminal Removal Terminal Removal Special Tools * EL-38125-580 - Terminal Release Tool Kit * EL-35616 - Connector Test Adapter Kit For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repair procedures. 1. Find the appropriate connector end view within the connector end view section. The connector end view has the following information: Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8084 * Diagnostic probe tool * Terminal release tool * Terminal/terminated lead part numbers Note: Not using the proper test kit probe may cause damage to the terminal(s) that are probed. 2. Determine if a terminal is damaged. * Locate the diagnostic probe tool from the connector end view. The connector end view describes the color and part number to help the technician find and use the correct tool. * Connect the probe tool to the Digital Multimeter. * Insert the probe tool into the cavity and follow the procedures from the Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter). 3. Disconnect the connector body to perform the repair. 4. Use the following procedure to remove the terminal from the connector body. Note: Several procedures for specific connector bodies are called out in the Wiring Repairs section. * The terminal position assurance (TPA) and connector position assurance (CPA) should be removed before releasing the terminal for the connector body. * Look at the connector end view to locate the cavity of the damaged terminal and find the proper terminal release tool from the terminal release tool kit. Note: Using the incorrect terminal release tool can damage the connector body. * Insert the terminal release tool into the cavity. Note: Some terminals have a lever that must be disengaged before the terminal can be released. 5. Gently pull the wire out of the back of the connector. 6. Repair the terminal by following the Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) procedure. 7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminated Lead Repair Terminated Lead Repair Special Tools * J-38125-8 - Splice Sleeve Crimp Tool Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8085 * J-38125-5 - Ultra Torch For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) procedures. Terminated leads are terminals that are crimped onto wires. The terminated lead can be used throughout the vehicle since it is designed for temperatures up to 150°C. The length of the wire is 450 mm. The DuraSeal splice sleeve has the following 2 critical features: * A special heat shrink tubing that environmentally seals the splice. The shrink tubing contains a sealing adhesive inside the shrink tubing. * A cross hatched (knurled) core crimp that provides the necessary contact integrity for sensitive low energy circuits. 1. Use the connector end view to identify the correct terminated lead. 2. The terminated lead package should include a DuraSeal splice sleeve. If not, use the chart to identify the correct part. 3. Open the harness by removing any tape: Use a sewing seam ripper, or a comparable tool, to cut open the harness, to avoid wire insulation damage. 4. Depending on how many terminals need repairs, cut the terminal and wire back at least 40 mm. Try to keep the harness wire length the same. If more than one terminated lead is required, stagger the lengths by 40 mm. This helps reduce the bundle size of the wire harness. 5. Use the EL-38125-10 - tool in order to position the DuraSeal splice sleeve in the proper color nest of the splice sleeve crimp tool. The crimp tool has four nests, one for each color. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8086 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the J-38125-5 - ultra torch , apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8087 Torque Converter Clutch Solenoid: Connector Views Component Connector End Views Torque Converter Clutch (TCC) Pressure Control (PC) Solenoid Valve (MW7) Torque Converter Clutch (TCC) Pulse Width Modulated (PWM) Solenoid Valve (M30) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8088 Torque Converter Clutch (TCC) Solenoid Valve (M30) Wiring Diagram Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush Transmission Cooler: Technical Service Bulletins A/T - Fluid Oil Cooler Flush INFORMATION Bulletin No.: 02-07-30-052G Date: March 02, 2011 Subject: Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow(R) Models: 2011 and Prior Passenger Cars and Light Duty Trucks 2003-2010 HUMMER H2 2006-2010 HUMMER H3 with Automatic Transmission/Transaxle including Allison(R) Transmissions Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 02-07-30-052F (Section 07 - Transmission/Transaxle). Important All labor operations that include removal of the transmission from the vehicle include labor time to flush the transmission oil cooler system. The J 45096 transmission oil cooling system flush and flow test tool replaces current tool J 35944-A. J 45096 is a self-contained unit utilizing a 12-volt flow meter, shop air supply and DEXRON(R) VI automatic transmission fluid (ATF). In the flush mode, transmission fluid is cycled through the transmission oil cooling system. High-pressure air is automatically injected into the fluid stream adding agitation to the ATF oil to enhance the removal of contaminated ATF oil and debris. In the flow mode, an electronic flow meter is used to measure the flow capability of the ATF oil cooling system. A digital display indicates the ATF oil flow rate in gallons per minute (GPM) along with the amount of ATF oil in the supply vessel, supply vessel ATF oil temperature, machine cycles and the operating mode. The supply oil vessel has 30 L (32 qt) capacity and the waste oil vessel has 32 L (34 qt) capacity. The waste oil vessel is constructed of a translucent composite material that allows the user to easily identify the oil level. The waste oil vessel can accommodate vacuum evacuation and gravity draining. In the code mode, a random, encrypted code is generated that can be used for verification of flow test results. Current essential cooler line adapters are used to connect the J 45096 to the automatic transmission oil cooler lines that allows J 45096 to adapt to General Motors passenger cars and light duty trucks, current and past models (except the Pontiac Vibe, Wave and Chevrolet Aveo). The tool may be adapted for use on the Pontiac Vibe, Wave and Chevrolet Aveo by dealership personnel with a barbed hose connector and rubber hose obtained locally. The Vibe's/Wave's/Aveo's transmission has a transmission oil requirement which is slightly different than DEXRON(R) VI ATF. However, flushing the cooler with DEXRON(R) VI automatic transmission fluid is an acceptable service procedure. Very little fluid remains in the cooler after the flush procedure and the residual DEXRON(R) VI ATF in the cooler is compatible with the Vibe's/Wave's/Aveo's transmission fluid. Notice Insufficient oil flow through the ATF oil cooling system will cause premature transmission failure. The required minimum ATF oil flow rate reading is directly related to the supply oil temperature. Refer to the flow rate reference chart for the oil flow rate specification based on the temperature of the ATF in the supply vessel. Helpful Hints for Maintaining the Temperature at or above 18°C (65°F) Important - The temperature of the supply vessel oil must be 18°C (65°F) or greater for J 45096 to operate. It is recommended to store the J 45096 in an area of the dealership where the room temperature remains at or above 18°C (65°F) when not in use. - Do not attempt to increase the fluid temperature in the Transflow(R) machine with an engine oil dipstick, or any other immersion type heater. The Transflow(R) machine has a check valve in the supply reservoir. Inserting a heater will damage the check valve and the subsequent repair expense would be the dealer's responsibility. - A heater blanket, P/N J-45096-10, is available for the Transflow(R) transmission cooling system flushing tool. This heater fastens around the Transflow(R) internal supply vessel and runs on 110 volts AC. The heater will warm the ATF in the supply vessel to at least 18°C (65° F) and has a thermostat to hold a constant temperature. Store the Transmission Cooling System Service Tool, J 45096, Transflow(R) machine in a room where the temperature is maintained at or above 18°C (65°F). Keep the ATF level in the reservoir low when the Transmission Cooling System Service Tool, J 45096, Transflow(R), is not in use. Store several gallons of oil in an area where the temperature is maintained at or above 18°C (65°F). Fill the reservoir of the J 45096 as needed before using the machine on Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush > Page 8093 each repair. With the ATF in a tightly sealed container, place the container in a tub of hot water for a period of time. Then pour the ATF into the reservoir. This method works best with a low fluid level in the reservoir. Place the Transflow(R) machine in the direct sunlight with the cabinet door open to expose the reservoir to the rays of the warm sun. Flush / Flow Test Procedure Important All labor operations that include removal of the transmission from the vehicle and require the transmission oil pan or transmission side cover to be removed include labor time to flush the transmission oil cooler system. Refer to SI for Automatic Transmission Oil Cooler Flushing and Flow Test J 45096 for the appropriate procedure. Important The J 45096 can be used to flush the transmission oil cooler system on an Allison equipped vehicle, but the flow meter should not be utilized. Refer to SI for Automatic Transmission Oil Cooler Flushing and Flow Test J 45096 for the appropriate flow check procedure. Machine Displays After completion of the flush and flow test, the following information is to be recorded on the repair order. This information is displayed on the Transmission Cooling System Service Tool, J 45096, Transflow(R) machine when the dial is in the code position. - Tested flow rate (displayed in Gallons Per Minute (GPM) - Temperature (displayed is degrees Fahrenheit) - Cycle number (a number) - Seven digit Alpha/Numeric flow code (i.e. A10DFB2) Warranty Information Important All labor operations that include removal of the transmission from the vehicle include labor time to flush the transmission oil cooler system. Performing a transmission oil cooling system flush and flow test will use between 4.7-7.5 L (5-8 qts) of DEXRON(R)VI transmission fluid. The amount Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush > Page 8094 of transmission fluid (ATF), (DEXRON(R)VI) (fluid) that is to be charged for the flush portion of the repair should not exceed the allowable charge for 7.5 L (2 gal) of fluid. This expense should be shown in the Parts Section of the warranty claim document. The Seven digit Alpha/Numeric flow code, i.e. A10DFB2, "MUST" be written on the job card and placed in the comments section of the warranty claim. Any repair that requires the technician to contact the Product Quality Center (PQC) must also include the seven digit flow code. The agent will request the seven digit flow code and add the information to the PQC case prior to providing authorization for the warranty claim. The Seven digit Alpha/Numeric flow code, i.e. A10DFB2, "MUST" be written on the job card, entered in the warranty claim labor operation Flush Code additional field (when available) and placed in the comments section of the warranty claim. Any repair that requires the technician to contact the Product Quality Center (PQC) must also include the seven digit flow code. The agent will request the seven digit flow code and add the information to the PQC case prior to providing authorization for the warranty claim. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush > Page 8095 Transmission Cooler: Technical Service Bulletins A/T - Water Or Coolant Contamination Information INFORMATION Bulletin No.: 08-07-30-035B Date: November 01, 2010 Subject: Information on Water or Ethylene Glycol in Transmission Fluid Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks with Automatic Transmission Supercede: This bulletin is being revised to update model years. Please discard Corporate Bulletin Number 08-07-30-035A (Section 07 - Transmission/Transaxle). Water or ethylene glycol in automatic transmission fluid (ATF) is harmful to internal transmission components and will have a negative effect on reliability and durability of these parts. Water or ethylene glycol in ATF will also change the friction of the clutches, frequently resulting in shudder during engagement or gear changes, especially during torque converter clutch engagement. Indications of water in the ATF may include: - ATF blowing out of the transmission vent tube. - ATF may appear cloudy or, in cases of extreme contamination, have the appearance of a strawberry milkshake. - Visible water in the oil pan. - A milky white substance inside the pan area. - Spacer plate gaskets that appear to be glued to the valve body face or case. - Spacer plate gaskets that appear to be swollen or wrinkled in areas where they are not compressed. - Rust on internal transmission iron/steel components. If water in the ATF has been found and the source of the water entry has not been identified, or if a leaking in-radiator transmission oil cooler is suspected (with no evidence of cross-contamination in the coolant recovery reservoir), a simple and quick test kit is available that detects the presence of ethylene glycol in ATF. The "Gly-Tek" test kit, available from the Nelco Company, should be obtained and the ATF tested to make an accurate decision on the need for radiator replacement. This can help to prevent customer comebacks if the in-radiator transmission oil cooler is leaking and reduce repair expenses by avoiding radiator replacement if the cooler is not leaking. These test kits can be obtained from: Nelco Company Test kits can be ordered by phone or through the website listed above. Orders are shipped standard delivery time but can be shipped on a next day delivery basis for an extra charge. One test kit will complete 10 individual fluid sample tests. For vehicles repaired under warranty, the cost of the complete test kit plus shipping charges should be divided by 10 and submitted on the warranty claim as a net item. The transmission should be repaired or replaced based on the normal cost comparison procedure. Important If water or coolant is found in the transmission, the following components MUST be replaced. - Replace all of the rubber-type seals. - Replace all of the composition-faced clutch plates and/or bands. - Replace all of the nylon parts. - Replace the torque converter. - Thoroughly clean and rebuild the transmission, using new gaskets and oil filter. Important The following steps must be completed when repairing or replacing. Flush and flow check the transmission oil cooler using J 45096. Refer to Corporate Bulletin Number 02-07-30-052F- Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow. - Thoroughly inspect the engine cooling system and hoses and clean/repair as necessary. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush > Page 8096 Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Transmission Fluid Auxiliary Cooler Replacement Transmission Cooler: Service and Repair Transmission Fluid Auxiliary Cooler Replacement Transmission Fluid Auxiliary Cooler Replacement (LMM Diesel) Removal Procedure 1. Remove the radiator grille. Refer to Radiator Grille Replacement (Chevrolet) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement)Radiator Grille Replacement (GMC) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement)Radiator Grille Replacement (Chevrolet HD) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement (Chevrolet HD))Radiator Grille Replacement (GMC HD) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement (GMC HD)). 2. Place a drain pan under the vehicle. 3. Disconnect the transmission oil cooler lines from the auxiliary cooler. Refer to Transmission Fluid Cooler Hose/Pipe Replacement (See: Fluid Line/Hose/Service and Repair). 4. Remove the auxiliary oil cooler bolts (1). 5. Remove the auxiliary oil cooler from the vehicle (2). Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Transmission Fluid Auxiliary Cooler Replacement > Page 8099 1. Install the auxiliary oil cooler to the vehicle (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the auxiliary oil cooler bolts (1). Tighten the bolts to 12 Nm (106 lb in). 3. Connect the transmission oil cooler lines to the auxiliary cooler. Refer to Transmission Fluid Cooler Hose/Pipe Replacement (See: Fluid Line/Hose/Service and Repair). 4. Install the radiator grille. Refer to Radiator Grille Replacement (Chevrolet) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement)Radiator Grille Replacement (GMC) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement)Radiator Grille Replacement (Chevrolet HD) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement (Chevrolet HD))Radiator Grille Replacement (GMC HD) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement (GMC HD)). 5. Check and add transmission fluid as necessary. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Transmission Fluid Auxiliary Cooler Replacement > Page 8100 Transmission Cooler: Service and Repair Transmission Fluid Auxiliary Cooler Replacement (Gas) Transmission Fluid Auxiliary Cooler Replacement (Gas) Removal Procedure 1. Remove the radiator grille. Refer to Radiator Grille Replacement (Chevrolet) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement)Radiator Grille Replacement (GMC) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement)Radiator Grille Replacement (Chevrolet HD) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement (Chevrolet HD))Radiator Grille Replacement (GMC HD) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement (GMC HD)). 2. Place a drain pan under the vehicle. 3. Disconnect the transmission oil cooler lines from the auxiliary cooler. Refer to Transmission Fluid Cooler Hose/Pipe Replacement (See: Fluid Line/Hose/Service and Repair). 4. Remove the auxiliary oil cooler bolts (1) and push pins (2). 5. Remove the auxiliary oil cooler from the vehicle. Installation Procedure 1. Install the auxiliary oil cooler to the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the bolts (1) and the push pins (2) that retain the auxiliary oil cooler to the radiator brace. Tighten the bolts to 12 Nm (106 lb in). 3. Connect the transmission oil cooler lines to the auxiliary cooler. Refer to Transmission Fluid Cooler Hose/Pipe Replacement (See: Fluid Line/Hose/Service and Repair). 4. Install the radiator grille. Refer to Radiator Grille Replacement (Chevrolet) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement)Radiator Grille Replacement (GMC) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement)Radiator Grille Replacement (Chevrolet HD) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement (Chevrolet HD))Radiator Grille Replacement (GMC HD) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement (GMC HD)). 5. Check and add transmission fluid as necessary. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON Transmission Mode Switch: Customer Interest A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 8109 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 8110 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 8111 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON Transmission Mode Switch: All Technical Service Bulletins A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 8117 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 8118 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 8119 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > Page 8120 Transmission Mode Switch: Diagrams Component Connector End Views Automatic Transmission Internal Mode Switch (MW7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > Page 8121 Transmission Mode Switch: Service and Repair Transmission Internal Mode Switch Replacement Important: The Internal Mode Switch (IMS) is mounted to the manual shift shaft detent lever as an assembly. The components of the detent lever/IMS assembly cannot be individually serviced. When the IMS needs replacing, the entire assembly must be replaced. Replace the IMS. Refer to Manual Shift Shaft, Detent Lever, and Position Switch Assembly Replacement (See: Sensors and Switches - A/T/Transmission Position Switch/Sensor/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair Transmission Mount: Service and Repair Transmission Mount Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Support the transmission with a transmission jack. 3. Remove the transmission mount to the transmission support retaining nut or nuts. 4. Raise the transmission to take the weight off of the mount. 5. Remove the transmission mount to the transmission or transfer case adapter mounting bolts (1). 6. Raise the transmission just enough to remove the transmission mount. 7. Remove the transmission mount from the vehicle. Installation Procedure 1. Install the transmission mount to the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the transmission mount to the transmission or transfer case adapter mounting bolts (1). Tighten the bolts to 50 Nm (37 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > Page 8125 3. Lower the transmission. 4. Install the transmission mount to the transmission support retaining nut or nuts. Tighten the nut or nuts to 50 Nm (37 lb ft). 5. Remove the transmission jack. 6. Lower the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams Transmission Position Switch/Sensor: Diagrams Component Connector End Views Park/Neutral Position (PNP) Switch (M30) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 8129 Transmission Position Switch/Sensor: Service and Repair Manual Shift Shaft, Detent Lever, and Position Switch Assembly Replacement Removal Procedure 1. Remove the control valve assembly from the transmission. Refer to Control Valve Body Replacement (See: Valve Body/Service and Repair). Note: The detent lever/IMS retaining bolt contains patch lock material on the threads. Do not reuse the retaining bolt. 2. Remove the detent lever/IMS retaining bolt (1) using a T27 TORX(R) bit and discard the retaining bolt. Caution: DO NOT mar the transmission case surface around the spherical pin when removing or installing the spherical pin. An unmarred surface is required to maintain the seal between the control valve assembly and the transmission case. Caution: DO NOT twist the spherical pin when removing the pin from the transmission case. Damage to the transmission case can occur. 3. Place a protective plate on the transmission case surface around the spherical pin (3). Remove the spherical pin (3) from the transmission case. 4. Slide the manual shift shaft (5) through the detent lever/IMS assembly (4) and through the manual shift shaft seal. 5. Rotate the detent lever/IMS assembly to disengage the park pawl apply assembly (2). Remove the detent lever/IMS assembly (4). Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 8130 1. Place the new detent lever/IMS assembly (4) in position in the transmission case. Rotate the detent lever/IMS assembly to engage the park pawl apply assembly (2). Reinstall the manual shift shaft (5) through the manual shift shaft seal and through the detent lever/IMS assembly (4). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Push the manual shift shaft (5) into the final position in the transmission case. 3. Install the spherical pin (3) into the transmission case that retains the manual shift shaft. 4. Install the detent lever/IMS retaining bolt (1) using a T27 TORX(R) bit. Tighten the bolt (1) to 10 Nm (92 lb in). 5. Install the control valve assembly. Refer to Control Valve Body Replacement (See: Valve Body/Service and Repair). Note: The FastLearn, adapt, procedure must be performed. This can be done in 1 step using a scan tool. If this procedure is not done, the TCM adaptive values will be at the settings that it learned for the old components and will be in slow adaptive mode. Under these conditions, it will take an unacceptably long time for the adaptive values to converge to levels suitable for the new transmission. 6. Perform the FastLearn procedure. Refer to FastLearn Procedure (See: Testing and Inspection/Programming and Relearning). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Pressure Test Port, A/T > Component Information > Service and Repair Transmission Pressure Test Port: Service and Repair Automatic Transmission Fluid Pressure Test Hole Plug Replacement Removal Procedure 1. Remove the pressure tap plug (2) and O-ring (1) on the bottom of the converter housing near the transmission external oil filter. 2. Remove the O-ring from the plug and discard it. Installation Procedure 1. Install a new O-ring (1) on the pressure tap plug (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the plug and O-ring into the converter housing. Tighten the plug to 12 Nm (108 lb in). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Component Locations Transmission Speed Sensor: Component Locations Disassembled Views Automatic Transmission Case 1 - Automatic Transmission Case 2 - Transmission Case Locating Pin 3 - Transmission Vent Assembly 4 - Transmission Vent Cap 5 - Transmission Vent 6 - Nameplate Rivet 7 - Nameplate 8 Vehicle Speed Sensor Bolt, M6 x 1.0 x 13 9 - Sensor Shipping Cover 10 - Turbine Speed Sensor 11 - Vehicle Speed Sensor O-Ring 12 - Power Take-Off (PTO) Cover Gasket (2) 13 - PTO Cover (2) 14 - PTO Cover Bolt, M10 x 1.5 x 20, Flanged Head, Coated (12) 16 - Manual Shift Shaft 17 Manual Shift Shaft Seal 18 - Manual Shift Shaft Pin 19 - Manual Shift Shaft Detent Lever/Internal Mode Switch (IMS) Assembly 20 - Park Pawl Assembly 21 - Control Valve Body Locating Pin 22 Detent Lever/IMS Bolt 23 - Connector Shipping Cover 24 - Control Valve Body Assembly 25 Control Valve Body Bolt, M6 x 1.0 x 50, Flanged Head (15) 26 - Manual Shift Shaft Detent Spring 27 - Manual Shift Shaft Detent Spring Bolt M6 x 1.0 x 12. Flanged Head (2) 28 - Transmission Wiring Harness Assembly Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Component Locations > Page 8138 Transmission Speed Sensor: Connector Locations Harness Routing Views Engine Chassis Harness Routing - Rear (Diesel) 1 - X300 2 - G300 3 - Automatic Transmission Turbine Speed Sensor (MW7) 4 - Automatic Transmission (MW7) 5 - Vehicle Speed Sensor (VSS) (MW7) 6 - X124 (PTO) 7 - Power Take Off (PTO) Module (PTO) 8 - X175 (MW7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Page 8139 Transmission Speed Sensor: Diagrams Component Connector End Views Automatic Transmission Input Shaft Speed (ISS) Sensor (M30) Automatic Transmission Turbine Speed Sensor (MW7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Page 8140 Output Speed Sensor (OSS) (M99) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Page 8141 Transmission Speed Sensor: Service and Repair Speed Sensor Replacement Removal Procedure Warning: Refer to Battery Disconnect Warning (See: Starting and Charging/Battery/Service Precautions). 1. Be sure the vehicle ignition is turned off. 2. Disconnect the external wiring harness from the speed sensor. 3. Remove the bolt (1) from the speed sensor and carefully remove the speed sensor (2). Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Page 8142 Note: Do not rotate the sensor in its retaining bracket. Changing the sensor/bracket orientation may cause improper operation. 1. Install a new a O-ring on the speed sensor (2). Lubricate the O-ring with clean transmission fluid. 2. Install the new speed sensor (2) into the speed sensor bore. Align the hole in the retaining bracket with the bolt hole in the speed sensor boss. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the speed sensor bolt (1). Tighten bolt to 12 Nm (108 lb in). 4. Reconnect the external wiring harness to the speed sensor. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams Transmission Temperature Sensor/Switch: Diagrams Component Connector End Views Automatic Transmission Fluid Temperature (TFT) Sensor (M30) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > A/T - Control Valve/Solenoid Cleaning Information Valve Body: Technical Service Bulletins A/T - Control Valve/Solenoid Cleaning Information INFORMATION Bulletin No.: 07-07-30-006B Date: March 02, 2010 Subject: Information on Control Solenoid Valve and Transmission Control Solenoid Module Assembly Cleaning Procedure for Rear Wheel Drive Six-Speed HYDRA-MATIC(R) Automatic Transmissions when MIL/DTCs Set Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 Equipped with Six Speed HYDRA-MATIC(R) 6L50, 6L80 or 6L90 Automatic Transmission (RPOs MYB, MYC, MYD) Supercede: This bulletin is being updated to add models and model years and to advise technicians that the control solenoid valve assembly cleaning procedure is no longer valid. Please discard Corporate Bulletin Number 07-07-30-006A (Section 07 - Transmission/Transaxle). The control solenoid (w/body and TCM) valve assembly cleaning procedure has been determined to be ineffective. This procedure will be removed from the scan tool and will be no longer available for use. Reference to this procedure will be removed from SI diagnostics and labor operation K9450 will be removed from the Labor Time Guide. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 8150 Valve Body: Service and Repair Control Valve Body Replacement Special Tools * J 44247 Internal Wiring Harness Installer * J 44257 Main Wiring Harness Connector Remover Removal Procedure Warning: Refer to Battery Disconnect Warning (See: Starting and Charging/Battery/Service Precautions). 1. Disconnect the external wiring harness from the transmission main connector. Use J 44257 if the connector is not easily accessible. 2. Remove the oil pan and transmission internal oil filter. Refer to Oil Pan Replacement (See: Fluid Pan/Service and Repair). Note: The transmission main connector is actually one end of the internal harness that protrudes through the transmission case. 3. Place a 30 mm (1 3/16 in) 12-point deep socket or box-end (2) over the connector (1). 4. Push inward on the socket or wrench to release the retainer feet that attach the connector (1) to the transmission case. 5. Remove the wrench. Push inward on the electrical connector to separate it from the transmission case. This allows the internal wiring harness to remain with the control valve assembly when removed. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 8151 6. Remove the 2 detent spring bolts (3). Remove the detent spring assembly (2). 7. Disconnect the internal wiring harness from the detent lever/IMS assembly. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 8152 Note: As the control valve assembly is removed, be careful not to lose the manual selector valve pin or allow the manual selector valve to slide out of the control valve assembly. 8. Remove 10 of the 11 bolts at locations marked (1) and 4 bolts at locations marked (2). Support the control valve assembly, about 10 pounds, and remove the last bolt marked (1). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 8153 9. Lower the control valve assembly (1) to clear the locating pins (2) in the transmission case. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 8154 10. Move the control valve assembly (4) sideways to disengage pin (1) in the manual selector valve (2) from the slot in detent lever (3). Remove the control valve assembly (4). Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 8155 1. Move the control valve assembly (4) into position under the transmission case. Engage the pin (1) in the manual selector valve (2) into the slot in the detent lever (3). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 8156 2. Align control valve assembly (1) with the locating pins (2) in the transmission case. Seat the control valve assembly against the transmission case and hold the position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 8157 3. Install one bolt marked (1) to hold the control valve assembly in place. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Reinstall the remaining 10 bolts marked (1) and 4 bolts marked (2) that fasten the control valve assembly to the transmission case. Tighten the bolts to 12 Nm (108 lb in). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 8158 5. Push the transmission main connector outward through the hole in the transmission case until the retaining feet on the connector are nearing the locked position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 8159 6. Use the J 44247 to complete the seating of the retaining feet that lock the connector (1) into the transmission case. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 8160 7. Install the detent spring assembly (2) onto the control valve assembly. Confirm that the roller of the detent spring assembly rests on the detent lever (1). 8. Attach the IMS connector on the internal harness to the IMS. 9. Install 2 detent spring bolts (3). Tighten the bolts to 12 Nm (108 lb in). 10. Install the oil pan and transmission internal oil filter. Refer to Oil Pan Replacement (See: Fluid Pan/Service and Repair). 11. Connect the external wiring harness to the transmission main connector. Note: The FastLearn, adapt, procedure must be performed. This can be done in 1 step using a scan tool. If this procedure is not done, the TCM adaptive values will be at the settings that it learned for the old components and will be in slow adaptive mode. Under these conditions, it will take an unacceptably long time for the adaptive values to converge to levels suitable for the new transmission. 12. Perform the FastLearn procedure. Refer to FastLearn Procedure (See: Testing and Inspection/Programming and Relearning). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > Customer Interest for Wiring Harness: > 08-07-30-021E > Jun > 10 > Electrical - Electrical Malfunction/Multiple DTCs Technical Service Bulletin # 08-07-30-021E Date: 100607 Electrical - Electrical Malfunction/Multiple DTCs TECHNICAL Bulletin No.: 08-07-30-021E Date: June 07, 2010 Subject: Loss of High Speed GMLAN Communications, Intermittent No Crank, IP Gage Fluctuation, Intermittent Door Lock Cycling, Intermittent Chime Operation, Various IP Warning Lamps Illuminated, Transmission May Not Shift, Communication DTCs U0073, U0100, U0101, U0102, U0109, U0121 or U0140 Set (Repair Backed Out Terminal in Transmission Harness Connector, Repair Open or Shorted GM High Speed LAN Circuits, Open or Shorted Data Link Resistor, Correct Corrosion or Poor Connections in Various Control Module Connectors) Models: 2007-2010 Cadillac Escalade Models, XLR 2009-2010 Cadillac Escalade Hybrid 2007-2010 Chevrolet Avalanche, Corvette, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Silverado Hybrid, Tahoe Hybrid 2007-2010 GMC Sierra, Yukon Models 2008-2010 GMC Sierra Hybrid, Yukon Hybrid 2008-2009 HUMMER H2 Equipped With 6 Speed 6L80 (RPO MYC) or 6L90 (RPO MYD) or Hybrid Two Mode 2ML70 Automatic Transmission Please Refer to GMVIS Supercede: This bulletin is being revised to update the Parts and Warranty Information. Please discard Corporate Bulletin Number 08-07-30-021D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on any of the following conditions: - Instrument panel cluster (IPC) warning lamps may illuminate. - The transmission may not shift or defaults to 2nd gear. - The door locks may cycle by themselves. - The engine may not crank intermittently. - A driver information center (DIC) message is displayed. - The IPC gages may fluctuate. - Applying the brakes may cause the IPC to become erratic and the chimes to operate simultaneously. Depending on the vehicle, technicians may find one or more of the following High Speed GMLAN Communications DTCs set as Current or History: - U0073: Control Module Communications Bus OFF - U0100: Lost Communication With ECM/PCM - U0101: Lost Communication With TCM - U0102: Lost Communication With Transfer Case Control Module - U0109: Lost Communication With Fuel Pump Control Module - U0121: Lost Communication With ABS Control Module - U0140: Lost Communication With Body Control Module (BCM) Cause These conditions may be caused by, but not limited to, any of the following: - The terminal(s) for the High Speed GMLAN Serial Data Bus has backed out of the 16-way electrical connector to the automatic transmission. - The terminal position assurance (TPA) lock in the transmission 16-way electrical connector is not fully seated. - The High Speed GMLAN Serial Data Bus circuits are open or shorted to ground. - Corrosion in various control module connectors. - Intermittent or poor connections in the inline connectors containing the High Speed GMLAN Serial Data Bus circuits. - The data link resistor is open or shorted. - Water intrusion in various control module connectors. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > Customer Interest for Wiring Harness: > 08-07-30-021E > Jun > 10 > Electrical - Electrical Malfunction/Multiple DTCs > Page 8169 Parts Information Warranty Information For transmission electrical repairs please note in the technicians comments field on the repair order which terminal number(s) were repaired or replaced. Also if a male terminal is bent (transmission side of connector), then indicate the bent terminal number on the repair order. For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > Customer Interest for Wiring Harness: > 08-07-30-021E > Jun > 10 > Electrical - Electrical Malfunction/Multiple DTCs > Page 8170 Procedures to Diagnose/Chafed Wiring Harness at Trans Case Information for the Procedures to Diagnose and Repair the Above Conditions 1. Perform the Diagnostic System Check-Vehicle to begin your diagnosis of these conditions. 2. Perform a thorough visual inspection of the vehicle. 3. Depending on the vehicle, some of the procedures may not be applicable. 4. The following procedure is the only one applicable to the Corvette and XLR. Chafed Wiring Harness at Transmission Case Retaining Clip and Inspection of the 16-way Electrical Connector for Backed Out Terminals 1. Turn OFF the ignition and all accessories. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 4. Locate the 16-way electrical connector on the right side of the automatic transmission as shown. 5. Inspect for a pinched/cut wiring harness where it is attached at the transmission by a metal attachment clip as shown. Inspect any of these harness clips that you may observe as needed. If the wiring is damaged, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures in SI. 6. Protect the harness by covering the sharp edge with butyl tape or a suitable material. Secure the harness as needed. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > Customer Interest for Wiring Harness: > 08-07-30-021E > Jun > 10 > Electrical - Electrical Malfunction/Multiple DTCs > Page 8171 7. Before disconnecting the 16-way connector, inspect for any backed out terminals (2) as shown. Fully seated terminals (1) are shown for comparison. 1. If a backed out terminal (2) is found, identify the terminal(s) on the repair order. 2. Look at the connector in order to identify the number of the cavity with the backed out terminal. Refer to Wiring Systems and Power Management > Component Locator > Master Electrical Component List in SI. 8. Use the following procedure to disconnect the 16-way electrical connector: 1. For 2ML70 Only: Disconnect the 24-way electrical connector. 2. Release and hold the slide lock on the wiring harness connector. 3. Rotate the connector lever and remove the connector from the component. 9. Repair or replace the terminal(s) as necessary using the following procedure: Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > Customer Interest for Wiring Harness: > 08-07-30-021E > Jun > 10 > Electrical - Electrical Malfunction/Multiple DTCs > Page 8172 1. Locate the terminal position assurance (TPA) as shown. Note The TPA cannot be removed from the connector while there are terminals present in the connector body. 2. Use a small flat blade tool to push the TPA until it bottoms out. 3. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Use the J-38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Note If the female terminal(s) must be replaced, it is part number 22124472200. It is located in Yazaki tray number 12 in the J-38125 Terminal Repair Kit. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > Customer Interest for Wiring Harness: > 08-07-30-021E > Jun > 10 > Electrical - Electrical Malfunction/Multiple DTCs > Page 8173 5. Repair or replace the terminal(s) as needed. Refer to the instructions in the J-38125 manual. 10. If the wiring is damaged, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures in SI. 11. Slide the new terminal(s) into the correct cavity at the back of the connector until it locks in place. The new terminal(s) should be even with the other terminal(s). 12. Ensure that each terminal is locked in place by gently pulling on the wire. Note The male terminal(s) cannot be repaired as they are an integral part of the transmission control module (TCM). 13. Inspect for bent or misaligned terminal(s) in the transmission half of the electrical connector. ‹› If they are bent, use a suitable tool and apply gentle pressure to straighten them. Indicate on the repair order the terminal number of the male terminal that was bent. ‹› If they are damaged, refer to Control Solenoid Valve and Transmission Control Module Assembly Replacement in SI. 14. Prior to installing the transmission connector, perform the following steps to ensure that the TPA lock is fully seated. Locate the TPA lock in the reassembled transmission connector. Refer to the arrow in the illustration above, which points to a TPA lock. This one is in an unseated position. Using a small flat blade tool, push to seat the TPA until it bottoms out. Verify the TPA is fully seated. - If the TPA is off-center in the check window as shown, then it is only partially seated. Note the large gap at the arrow. Reseat the TPA lock and ensure that it is fully seated. - If the TPA lock is centered in the window as shown, then it is fully seated. The gaps shown by the arrows should be even on both sides. 15. Install the transmission 16-way electrical connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > Customer Interest for Wiring Harness: > 08-07-30-021E > Jun > 10 > Electrical - Electrical Malfunction/Multiple DTCs > Page 8174 16. Lower the vehicle. 17. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 18. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Inspection of Fuse Block Inspection of Fuse Block - I/P (Left Side) for Loose Connector X1 1. Turn OFF the ignition and all accessories. 2. Disconnect the negative battery cable. Refer to Battery Disconnect Caution and Battery Negative Cable Disconnection and Connection in SI. 3. Remove the left side fuse block as shown. 4. Inspect connector X1 (1) on the back of the fuse block for a loose connection as shown. Secure the connector as needed. 5. Install the left side fuse block. 6. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 7. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Chafed IP Wiring Harness Near Park Brake Pedal Assembly Chafed IP Wiring Harness Near Park Brake Pedal Assembly The above condition may cause one or more of the following fuses to open: - 60A - MBEC1 (#72) (Underhood) - 30A - AMP (#40) (Underhood) - 15A - RDO (#41) (Underhood) - 10A - IPC (#46) (Underhood) - 15A - AIRBAG BATT (#51) (Underhood) - 10A - DSM (Left side of IP) Five Areas of Potential Contact Have Been Identified Five areas of potential contact have been identified: Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > Customer Interest for Wiring Harness: > 08-07-30-021E > Jun > 10 > Electrical - Electrical Malfunction/Multiple DTCs > Page 8175 - The IP wiring branch to C202 may have been routed outboard of the junction block (left IP) and the retaining clip (1) off the branch may not have been fully seated. Possible point of contact (2). - The IP wiring branch to C202 may have been pushed up and forward into the park brake assembly and the retaining clip off the branch may not have been fully seated. Possible points of contact (1, 2). - The IP wiring branch to C202 may have never been secured into place as the gray retaining clip (1) off the branch was never seated. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > Customer Interest for Wiring Harness: > 08-07-30-021E > Jun > 10 > Electrical - Electrical Malfunction/Multiple DTCs > Page 8176 - The IP harness may be in hard contact with the top rear edge (1) of the park brake assembly. - When releasing the park brake pedal, the moving part (1) at the end of the park brake release cable may be coming into hard contact with the IP harness. If a condition is suspected/found with one of the circuits running to C1 or C2 of the junction block or to the inline IP-to-body connector (C202) or at any of these areas of concern then remove the front driver side door sill plate, driver side body hinge pillar trim panel, left IP outer trim cover and perform the following steps: 1. Turn OFF the ignition and all accessories. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 3. Visually inspect the IP harness for damage at the park brake pedal assembly. Refer to potential damage points shown in the photos at the side and rear of the park brake assembly. Note that damage may be hidden from view. The harness may be turned away from you, or covered by electrical tape. 4. Operate the park brake release lever. Observe the moving part at the end of the park brake release cable as it may contact and damage the IP harness. Inspect the IP harness at this point. Note that the damage may be hidden from view by electrical tape. If the wiring is damaged, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures in SI. 5. If the harness is still in contact with a sharp edge or point of the park brake assembly, route it away from the contact point and secure it with tie straps. 6. Protect the harness by covering the sharp edge with butyl tape or a suitable material. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > Customer Interest for Wiring Harness: > 08-07-30-021E > Jun > 10 > Electrical - Electrical Malfunction/Multiple DTCs > Page 8177 7. Inspect how the IP branch to C202 is routed. Reroute the harness as necessary to match the correct routing in the photo as shown. In order to route the IP harness branch correctly (behind the junction block-left I/P), remove the cover from the junction block-left I/P, unseat the junction block from the bracket. 8. Disconnect C202. Route the harness such that it lies between the "goalposts" of the junction block bracket. Seat the junction block to the bracket (harness will now be under the junction block). 9. Secure the harness by seating the grey offset retaining clip to the dashmat (or brown "buddy clip" if present - usually on SUV's only). Reconnect C202. 10. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 11. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Chafed IP Wiring Harness at Left Side Junction Block Mounting Bracket 1. Turn OFF the ignition and all accessories. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 3. Remove the left side junction block. Refer to Instrument Panel Electrical Center or Junction Block Replacement - Left Side in SI. 4. Inspect for chafed/shorted wiring at the mounting bracket. If the wiring is damaged, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures in SI. 5. Protect the harness by covering the sharp edge with butyl tape or a suitable material. Secure the harness as needed. 6. Replace the left side junction block. Refer to Instrument Panel Electrical Center or Junction Block Replacement - Left Side in SI. 7. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 8. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Chafed Wiring Harness at Adjustable Pedals Motor 1. Turn OFF the ignition and all accessories. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 3. Inspect the wiring harness for chafed/shorted wiring at the adjustable pedals motor as shown. 4. If the wiring is damaged, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures in SI. 5. Protect the harness by covering the sharp edge with butyl tape or a suitable material. Secure the harness as needed. 6. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 7. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Chafed Wiring Harness at Transmission 1. Turn OFF the ignition and all accessories. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 3. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 4. Support the transmission with a transmission jack. 5. Remove the transmission support crossmember. Refer to Transmission Support Crossmember Replacement in SI. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > Customer Interest for Wiring Harness: > 08-07-30-021E > Jun > 10 > Electrical - Electrical Malfunction/Multiple DTCs > Page 8178 6. Lower the transmission sufficiently to provide access to the engine wiring harness where it routes from the engine intake manifold to the transmission bell housing as shown. 7. Release the wiring harness conduit from the retainers that secure it to the transmission and/or transfer case. Note IT WILL be necessary to extract the wiring harness from the protective conduit if chafing IS NOT observed on exposed wiring. 8. Examine the harness for wiring that may be exposed outside of the conduit. Inspect ALL areas for chafing as shown. If chafing is not observed on exposed wiring then extract the wiring from the protective conduit and inspect ALL areas for chafing. ‹› If chafing or damage is found, repair the wiring. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures > Wiring Repairs in SI. 9. Protect the wiring harness by covering the sharp edge with butyl tape or a suitable material. Secure the wiring harness conduit as needed. 10. Raise the transmission as needed to install the transmission support crossmember. Refer to Transmission Support Crossmember Replacement in SI. 11. Lower the vehicle. 12. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 13. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Chafed Wiring Harness at Engine Intake Manifold 1. Turn OFF the ignition and all accessories. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 3. Remove the upper intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement in SI. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > Customer Interest for Wiring Harness: > 08-07-30-021E > Jun > 10 > Electrical - Electrical Malfunction/Multiple DTCs > Page 8179 4. Release the wiring harness conduit from the retainers that secure it to the rear of the engine and at the top of the transmission bell housing. Note The engine intake manifold is shown removed to provide clarity. 5. Pull the wiring harness up gently at the rear of the engine (1) and inspect the wiring harness for chafed/shorted wiring (2). If chafing is not observed on exposed wiring then extract the wiring from the protective conduit and inspect ALL areas for chafing. ‹› If chafing (1) or damage is found, repair the wiring. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures > Wiring Repairs in SI. 6. Protect the wiring harness by covering the sharp edge with butyl tape or a suitable material. Secure the wiring harness conduit as needed. 7. Install the upper intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement in SI. 8. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 9. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Chafed Wiring Harness at Chassis Body Mounts Left Side Frame Rail 1. Turn OFF the ignition and all accessories. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > Customer Interest for Wiring Harness: > 08-07-30-021E > Jun > 10 > Electrical - Electrical Malfunction/Multiple DTCs > Page 8180 4. Inspect the wiring harness along the left side frame rail at the body mounts for chafed/shorted wiring as shown. 5. If the wiring is damaged, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures > Wiring Repairs in SI. 6. Protect the harness by covering the sharp edge with butyl tape or a suitable material. Secure the harness as needed. 7. Lower the vehicle. 8. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 9. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Chafed Wiring Harness Near Data Link Resistor Chafed Wiring Harness Near Data Link Resistor Causing Intermittent No/Crank and/or Scan Tool Does Not Communicate with High Speed GMLAN Device 1. Turn OFF the ignition and all accessories. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 4. Typical location of a data link resistor (3) mounted on the chassis. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > Customer Interest for Wiring Harness: > 08-07-30-021E > Jun > 10 > Electrical - Electrical Malfunction/Multiple DTCs > Page 8181 5. Inspect the wiring harness near the data link resistor, between the truck box and frame for chafed/shorted wiring as shown. Refer to Wiring Systems and Power Management > Component Locator > Master Electrical Component List > Data Link Resistor in SI. If the wiring is damaged, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures > Wiring Repairs in SI. 6. Disconnect the electrical connector from the data link resistor. 7. Test the resistor for 110-130ohm. ‹› If not within the specified range, replace the data link resistor. ‹› If within the specified range, refer to Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. 8. Connect the electrical connector to the data link resistor. Secure the resistor as needed. 9. Protect the harness by covering the sharp edge with butyl tape or a suitable material. Secure the harness as needed. 10. Lower the vehicle. 11. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 12. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Inspection of Engine Harness Inspection of Engine Harness Connector X109 for Backed Out or Bent Terminals and Poor Connections 1. Turn OFF the ignition and all accessories. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 3. Locate the X109 connector. Refer to Wiring Systems and Power Management > Component Locator > Master Electrical Component List > X109 in SI. 4. Before disconnecting, verify the connector is fully seated together even though the lever is locked down as shown. If the connector is not fully seated, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures > Connector Repairs in SI. 5. Inspect the connector for the following conditions: - Backed out terminals - Bent pins - Corrosion - Poor terminal fit (use the correct test probe) ‹› If a condition is found, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures in SI. AND ‹› If corrosion is found, proceed to the section of the bulletin titled: Repairing Fretting Corrosion to complete the repair. 6. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 7. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Inspection of Engine Harness Connector X115 for Backed Out or Bent Terminals and Poor Connections 1. Turn OFF the ignition and all accessories. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > Customer Interest for Wiring Harness: > 08-07-30-021E > Jun > 10 > Electrical - Electrical Malfunction/Multiple DTCs > Page 8182 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 3. Locate the X115 connector. Refer to Wiring Systems and Power Management > Component Locator > Master Electrical Component List > X115 in SI. 4. Inspect the connector for the following conditions: - Backed out terminals - Bent pins - Corrosion - Poor terminal fit (use the correct test probe) ‹› If a condition is found, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures in SI. AND ‹› If corrosion is found, proceed to the section of the bulletin titled: Repairing Fretting Corrosion to complete the repair. 5. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 6. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Hybrid Models Chafed Wiring Harness Locations/Inspections Hybrid Models (HP2) Chafed Wiring Harness Locations and Inspection of Engine Harness Connector X150 for Backed Out Terminals and Poor Connections at Ground Locations G102 and G300 1. Turn OFF the ignition and all accessories. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 3. Locate the X150 connector. Refer to Wiring Systems and Power Management > Component Locator > Master Electrical Component List > X150 in SI. 4. Inspect the connector for the following conditions: - Backed out terminals - Bent pins - Corrosion - Poor terminal fit (use the correct test probe) ‹› If a condition is found, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures in SI. AND ‹› If corrosion is found, proceed to the section of the bulletin titled: Repairing Fretting Corrosion to complete the connector repair. 5. Inspect for a misrouted/chafed harness rubbing on the cooling fins of the Transmission Auxiliary Fluid Pump Control Module as shown. If the wiring is damaged, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures in SI. 6. Inspect for a chafed harness caused by a mispositioned retaining clip as shown. The chafing condition usually occurs when the tab of the clip is aligned with a slot in the conduit. If the wiring is damaged, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures in SI. 7. Locate ground connections G102 and G300. Refer to Wiring Systems and Power Management > Component Locator > Master Electrical Component List > G102 and G300 in SI. 8. Inspect G102 and G300 for a clean and tight connection. Undercoating has been found between the eyelet and the frame resulting in a poor connection. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > Customer Interest for Wiring Harness: > 08-07-30-021E > Jun > 10 > Electrical - Electrical Malfunction/Multiple DTCs > Page 8183 If a condition is found, clean the area and repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures in SI. 9. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 10. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Lost Communication With DTC's Set Lost Communication with Various Control Modules and DTCs Set DTC Descriptors Note Depending on the vehicle there may be other DTCs set by other modules. - DTC U0073 Control Module Communication Bus A Off - DTC U0100 Lost Communication with Engine/Powertrain Control Module (ECM/PCM) - DTC U0101 Lost Communication with Transmission Control Module (TCM) - DTC U0102 Lost Communication with Transfer Case Control Module - DTC U0121 Lost Communication with Electronic Brake Control Module (EBCM) - DTC U0140 Lost Communication with Body Control Module (BCM) 1. Connect a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). If any DTC(s) are set, refer to the list above or the Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. Turn OFF the ignition and all accessories. 3. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 4. Disconnect the connector(s) at the affected module. 5. Inspect the connector(s) for the following conditions: - Backed out terminals - Bent pins - Corrosion - Poor terminal fit (use the correct test probe) - Water intrusion ‹› If a condition is found, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures in SI AND ‹› If corrosion or water intrusion is found, proceed to the section of the bulletin titled: Repairing Fretting Corrosion to complete the repair. 6. Reconnect the connector(s) at the affected modules. 7. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Repairing Fretting Corrosion Repairing Fretting Corrosion Note Fretting corrosion looks like little dark smudges on the electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. 1. If any water intrusion is present in the connector, use pressure regulated compressed air to dry it out. 2. DO NOT apply an excessive amount of dielectric lubricant as shown, to the connectors as hydrolock may result when attempting to mate the connectors. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > Customer Interest for Wiring Harness: > 08-07-30-021E > Jun > 10 > Electrical - Electrical Malfunction/Multiple DTCs > Page 8184 Important Use ONLY a clean nylon brush that is DEDICATED to the repair of this specific condition. With a one-inch nylon bristle brush, apply dielectric lubricant P/N 12377900 (in Canada, 10953529 to both the module/component side and the harness side of the affected connector(s). 3. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 4. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 08-07-30-021E > Jun > 10 > Electrical - Electrical Malfunction/Multiple DTCs Technical Service Bulletin # 08-07-30-021E Date: 100607 Electrical - Electrical Malfunction/Multiple DTCs TECHNICAL Bulletin No.: 08-07-30-021E Date: June 07, 2010 Subject: Loss of High Speed GMLAN Communications, Intermittent No Crank, IP Gage Fluctuation, Intermittent Door Lock Cycling, Intermittent Chime Operation, Various IP Warning Lamps Illuminated, Transmission May Not Shift, Communication DTCs U0073, U0100, U0101, U0102, U0109, U0121 or U0140 Set (Repair Backed Out Terminal in Transmission Harness Connector, Repair Open or Shorted GM High Speed LAN Circuits, Open or Shorted Data Link Resistor, Correct Corrosion or Poor Connections in Various Control Module Connectors) Models: 2007-2010 Cadillac Escalade Models, XLR 2009-2010 Cadillac Escalade Hybrid 2007-2010 Chevrolet Avalanche, Corvette, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Silverado Hybrid, Tahoe Hybrid 2007-2010 GMC Sierra, Yukon Models 2008-2010 GMC Sierra Hybrid, Yukon Hybrid 2008-2009 HUMMER H2 Equipped With 6 Speed 6L80 (RPO MYC) or 6L90 (RPO MYD) or Hybrid Two Mode 2ML70 Automatic Transmission Please Refer to GMVIS Supercede: This bulletin is being revised to update the Parts and Warranty Information. Please discard Corporate Bulletin Number 08-07-30-021D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on any of the following conditions: - Instrument panel cluster (IPC) warning lamps may illuminate. - The transmission may not shift or defaults to 2nd gear. - The door locks may cycle by themselves. - The engine may not crank intermittently. - A driver information center (DIC) message is displayed. - The IPC gages may fluctuate. - Applying the brakes may cause the IPC to become erratic and the chimes to operate simultaneously. Depending on the vehicle, technicians may find one or more of the following High Speed GMLAN Communications DTCs set as Current or History: - U0073: Control Module Communications Bus OFF - U0100: Lost Communication With ECM/PCM - U0101: Lost Communication With TCM - U0102: Lost Communication With Transfer Case Control Module - U0109: Lost Communication With Fuel Pump Control Module - U0121: Lost Communication With ABS Control Module - U0140: Lost Communication With Body Control Module (BCM) Cause These conditions may be caused by, but not limited to, any of the following: - The terminal(s) for the High Speed GMLAN Serial Data Bus has backed out of the 16-way electrical connector to the automatic transmission. - The terminal position assurance (TPA) lock in the transmission 16-way electrical connector is not fully seated. - The High Speed GMLAN Serial Data Bus circuits are open or shorted to ground. - Corrosion in various control module connectors. - Intermittent or poor connections in the inline connectors containing the High Speed GMLAN Serial Data Bus circuits. - The data link resistor is open or shorted. - Water intrusion in various control module connectors. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 08-07-30-021E > Jun > 10 > Electrical - Electrical Malfunction/Multiple DTCs > Page 8190 Parts Information Warranty Information For transmission electrical repairs please note in the technicians comments field on the repair order which terminal number(s) were repaired or replaced. Also if a male terminal is bent (transmission side of connector), then indicate the bent terminal number on the repair order. For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 08-07-30-021E > Jun > 10 > Electrical - Electrical Malfunction/Multiple DTCs > Page 8191 Procedures to Diagnose/Chafed Wiring Harness at Trans Case Information for the Procedures to Diagnose and Repair the Above Conditions 1. Perform the Diagnostic System Check-Vehicle to begin your diagnosis of these conditions. 2. Perform a thorough visual inspection of the vehicle. 3. Depending on the vehicle, some of the procedures may not be applicable. 4. The following procedure is the only one applicable to the Corvette and XLR. Chafed Wiring Harness at Transmission Case Retaining Clip and Inspection of the 16-way Electrical Connector for Backed Out Terminals 1. Turn OFF the ignition and all accessories. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 4. Locate the 16-way electrical connector on the right side of the automatic transmission as shown. 5. Inspect for a pinched/cut wiring harness where it is attached at the transmission by a metal attachment clip as shown. Inspect any of these harness clips that you may observe as needed. If the wiring is damaged, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures in SI. 6. Protect the harness by covering the sharp edge with butyl tape or a suitable material. Secure the harness as needed. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 08-07-30-021E > Jun > 10 > Electrical - Electrical Malfunction/Multiple DTCs > Page 8192 7. Before disconnecting the 16-way connector, inspect for any backed out terminals (2) as shown. Fully seated terminals (1) are shown for comparison. 1. If a backed out terminal (2) is found, identify the terminal(s) on the repair order. 2. Look at the connector in order to identify the number of the cavity with the backed out terminal. Refer to Wiring Systems and Power Management > Component Locator > Master Electrical Component List in SI. 8. Use the following procedure to disconnect the 16-way electrical connector: 1. For 2ML70 Only: Disconnect the 24-way electrical connector. 2. Release and hold the slide lock on the wiring harness connector. 3. Rotate the connector lever and remove the connector from the component. 9. Repair or replace the terminal(s) as necessary using the following procedure: Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 08-07-30-021E > Jun > 10 > Electrical - Electrical Malfunction/Multiple DTCs > Page 8193 1. Locate the terminal position assurance (TPA) as shown. Note The TPA cannot be removed from the connector while there are terminals present in the connector body. 2. Use a small flat blade tool to push the TPA until it bottoms out. 3. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Use the J-38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Note If the female terminal(s) must be replaced, it is part number 22124472200. It is located in Yazaki tray number 12 in the J-38125 Terminal Repair Kit. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 08-07-30-021E > Jun > 10 > Electrical - Electrical Malfunction/Multiple DTCs > Page 8194 5. Repair or replace the terminal(s) as needed. Refer to the instructions in the J-38125 manual. 10. If the wiring is damaged, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures in SI. 11. Slide the new terminal(s) into the correct cavity at the back of the connector until it locks in place. The new terminal(s) should be even with the other terminal(s). 12. Ensure that each terminal is locked in place by gently pulling on the wire. Note The male terminal(s) cannot be repaired as they are an integral part of the transmission control module (TCM). 13. Inspect for bent or misaligned terminal(s) in the transmission half of the electrical connector. ‹› If they are bent, use a suitable tool and apply gentle pressure to straighten them. Indicate on the repair order the terminal number of the male terminal that was bent. ‹› If they are damaged, refer to Control Solenoid Valve and Transmission Control Module Assembly Replacement in SI. 14. Prior to installing the transmission connector, perform the following steps to ensure that the TPA lock is fully seated. Locate the TPA lock in the reassembled transmission connector. Refer to the arrow in the illustration above, which points to a TPA lock. This one is in an unseated position. Using a small flat blade tool, push to seat the TPA until it bottoms out. Verify the TPA is fully seated. - If the TPA is off-center in the check window as shown, then it is only partially seated. Note the large gap at the arrow. Reseat the TPA lock and ensure that it is fully seated. - If the TPA lock is centered in the window as shown, then it is fully seated. The gaps shown by the arrows should be even on both sides. 15. Install the transmission 16-way electrical connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 08-07-30-021E > Jun > 10 > Electrical - Electrical Malfunction/Multiple DTCs > Page 8195 16. Lower the vehicle. 17. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 18. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Inspection of Fuse Block Inspection of Fuse Block - I/P (Left Side) for Loose Connector X1 1. Turn OFF the ignition and all accessories. 2. Disconnect the negative battery cable. Refer to Battery Disconnect Caution and Battery Negative Cable Disconnection and Connection in SI. 3. Remove the left side fuse block as shown. 4. Inspect connector X1 (1) on the back of the fuse block for a loose connection as shown. Secure the connector as needed. 5. Install the left side fuse block. 6. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 7. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Chafed IP Wiring Harness Near Park Brake Pedal Assembly Chafed IP Wiring Harness Near Park Brake Pedal Assembly The above condition may cause one or more of the following fuses to open: - 60A - MBEC1 (#72) (Underhood) - 30A - AMP (#40) (Underhood) - 15A - RDO (#41) (Underhood) - 10A - IPC (#46) (Underhood) - 15A - AIRBAG BATT (#51) (Underhood) - 10A - DSM (Left side of IP) Five Areas of Potential Contact Have Been Identified Five areas of potential contact have been identified: Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 08-07-30-021E > Jun > 10 > Electrical - Electrical Malfunction/Multiple DTCs > Page 8196 - The IP wiring branch to C202 may have been routed outboard of the junction block (left IP) and the retaining clip (1) off the branch may not have been fully seated. Possible point of contact (2). - The IP wiring branch to C202 may have been pushed up and forward into the park brake assembly and the retaining clip off the branch may not have been fully seated. Possible points of contact (1, 2). - The IP wiring branch to C202 may have never been secured into place as the gray retaining clip (1) off the branch was never seated. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 08-07-30-021E > Jun > 10 > Electrical - Electrical Malfunction/Multiple DTCs > Page 8197 - The IP harness may be in hard contact with the top rear edge (1) of the park brake assembly. - When releasing the park brake pedal, the moving part (1) at the end of the park brake release cable may be coming into hard contact with the IP harness. If a condition is suspected/found with one of the circuits running to C1 or C2 of the junction block or to the inline IP-to-body connector (C202) or at any of these areas of concern then remove the front driver side door sill plate, driver side body hinge pillar trim panel, left IP outer trim cover and perform the following steps: 1. Turn OFF the ignition and all accessories. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 3. Visually inspect the IP harness for damage at the park brake pedal assembly. Refer to potential damage points shown in the photos at the side and rear of the park brake assembly. Note that damage may be hidden from view. The harness may be turned away from you, or covered by electrical tape. 4. Operate the park brake release lever. Observe the moving part at the end of the park brake release cable as it may contact and damage the IP harness. Inspect the IP harness at this point. Note that the damage may be hidden from view by electrical tape. If the wiring is damaged, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures in SI. 5. If the harness is still in contact with a sharp edge or point of the park brake assembly, route it away from the contact point and secure it with tie straps. 6. Protect the harness by covering the sharp edge with butyl tape or a suitable material. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 08-07-30-021E > Jun > 10 > Electrical - Electrical Malfunction/Multiple DTCs > Page 8198 7. Inspect how the IP branch to C202 is routed. Reroute the harness as necessary to match the correct routing in the photo as shown. In order to route the IP harness branch correctly (behind the junction block-left I/P), remove the cover from the junction block-left I/P, unseat the junction block from the bracket. 8. Disconnect C202. Route the harness such that it lies between the "goalposts" of the junction block bracket. Seat the junction block to the bracket (harness will now be under the junction block). 9. Secure the harness by seating the grey offset retaining clip to the dashmat (or brown "buddy clip" if present - usually on SUV's only). Reconnect C202. 10. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 11. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Chafed IP Wiring Harness at Left Side Junction Block Mounting Bracket 1. Turn OFF the ignition and all accessories. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 3. Remove the left side junction block. Refer to Instrument Panel Electrical Center or Junction Block Replacement - Left Side in SI. 4. Inspect for chafed/shorted wiring at the mounting bracket. If the wiring is damaged, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures in SI. 5. Protect the harness by covering the sharp edge with butyl tape or a suitable material. Secure the harness as needed. 6. Replace the left side junction block. Refer to Instrument Panel Electrical Center or Junction Block Replacement - Left Side in SI. 7. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 8. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Chafed Wiring Harness at Adjustable Pedals Motor 1. Turn OFF the ignition and all accessories. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 3. Inspect the wiring harness for chafed/shorted wiring at the adjustable pedals motor as shown. 4. If the wiring is damaged, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures in SI. 5. Protect the harness by covering the sharp edge with butyl tape or a suitable material. Secure the harness as needed. 6. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 7. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Chafed Wiring Harness at Transmission 1. Turn OFF the ignition and all accessories. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 3. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 4. Support the transmission with a transmission jack. 5. Remove the transmission support crossmember. Refer to Transmission Support Crossmember Replacement in SI. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 08-07-30-021E > Jun > 10 > Electrical - Electrical Malfunction/Multiple DTCs > Page 8199 6. Lower the transmission sufficiently to provide access to the engine wiring harness where it routes from the engine intake manifold to the transmission bell housing as shown. 7. Release the wiring harness conduit from the retainers that secure it to the transmission and/or transfer case. Note IT WILL be necessary to extract the wiring harness from the protective conduit if chafing IS NOT observed on exposed wiring. 8. Examine the harness for wiring that may be exposed outside of the conduit. Inspect ALL areas for chafing as shown. If chafing is not observed on exposed wiring then extract the wiring from the protective conduit and inspect ALL areas for chafing. ‹› If chafing or damage is found, repair the wiring. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures > Wiring Repairs in SI. 9. Protect the wiring harness by covering the sharp edge with butyl tape or a suitable material. Secure the wiring harness conduit as needed. 10. Raise the transmission as needed to install the transmission support crossmember. Refer to Transmission Support Crossmember Replacement in SI. 11. Lower the vehicle. 12. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 13. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Chafed Wiring Harness at Engine Intake Manifold 1. Turn OFF the ignition and all accessories. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 3. Remove the upper intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement in SI. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 08-07-30-021E > Jun > 10 > Electrical - Electrical Malfunction/Multiple DTCs > Page 8200 4. Release the wiring harness conduit from the retainers that secure it to the rear of the engine and at the top of the transmission bell housing. Note The engine intake manifold is shown removed to provide clarity. 5. Pull the wiring harness up gently at the rear of the engine (1) and inspect the wiring harness for chafed/shorted wiring (2). If chafing is not observed on exposed wiring then extract the wiring from the protective conduit and inspect ALL areas for chafing. ‹› If chafing (1) or damage is found, repair the wiring. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures > Wiring Repairs in SI. 6. Protect the wiring harness by covering the sharp edge with butyl tape or a suitable material. Secure the wiring harness conduit as needed. 7. Install the upper intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement in SI. 8. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 9. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Chafed Wiring Harness at Chassis Body Mounts Left Side Frame Rail 1. Turn OFF the ignition and all accessories. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 08-07-30-021E > Jun > 10 > Electrical - Electrical Malfunction/Multiple DTCs > Page 8201 4. Inspect the wiring harness along the left side frame rail at the body mounts for chafed/shorted wiring as shown. 5. If the wiring is damaged, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures > Wiring Repairs in SI. 6. Protect the harness by covering the sharp edge with butyl tape or a suitable material. Secure the harness as needed. 7. Lower the vehicle. 8. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 9. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Chafed Wiring Harness Near Data Link Resistor Chafed Wiring Harness Near Data Link Resistor Causing Intermittent No/Crank and/or Scan Tool Does Not Communicate with High Speed GMLAN Device 1. Turn OFF the ignition and all accessories. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 4. Typical location of a data link resistor (3) mounted on the chassis. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 08-07-30-021E > Jun > 10 > Electrical - Electrical Malfunction/Multiple DTCs > Page 8202 5. Inspect the wiring harness near the data link resistor, between the truck box and frame for chafed/shorted wiring as shown. Refer to Wiring Systems and Power Management > Component Locator > Master Electrical Component List > Data Link Resistor in SI. If the wiring is damaged, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures > Wiring Repairs in SI. 6. Disconnect the electrical connector from the data link resistor. 7. Test the resistor for 110-130ohm. ‹› If not within the specified range, replace the data link resistor. ‹› If within the specified range, refer to Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. 8. Connect the electrical connector to the data link resistor. Secure the resistor as needed. 9. Protect the harness by covering the sharp edge with butyl tape or a suitable material. Secure the harness as needed. 10. Lower the vehicle. 11. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 12. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Inspection of Engine Harness Inspection of Engine Harness Connector X109 for Backed Out or Bent Terminals and Poor Connections 1. Turn OFF the ignition and all accessories. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 3. Locate the X109 connector. Refer to Wiring Systems and Power Management > Component Locator > Master Electrical Component List > X109 in SI. 4. Before disconnecting, verify the connector is fully seated together even though the lever is locked down as shown. If the connector is not fully seated, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures > Connector Repairs in SI. 5. Inspect the connector for the following conditions: - Backed out terminals - Bent pins - Corrosion - Poor terminal fit (use the correct test probe) ‹› If a condition is found, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures in SI. AND ‹› If corrosion is found, proceed to the section of the bulletin titled: Repairing Fretting Corrosion to complete the repair. 6. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 7. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Inspection of Engine Harness Connector X115 for Backed Out or Bent Terminals and Poor Connections 1. Turn OFF the ignition and all accessories. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 08-07-30-021E > Jun > 10 > Electrical - Electrical Malfunction/Multiple DTCs > Page 8203 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 3. Locate the X115 connector. Refer to Wiring Systems and Power Management > Component Locator > Master Electrical Component List > X115 in SI. 4. Inspect the connector for the following conditions: - Backed out terminals - Bent pins - Corrosion - Poor terminal fit (use the correct test probe) ‹› If a condition is found, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures in SI. AND ‹› If corrosion is found, proceed to the section of the bulletin titled: Repairing Fretting Corrosion to complete the repair. 5. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 6. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Hybrid Models Chafed Wiring Harness Locations/Inspections Hybrid Models (HP2) Chafed Wiring Harness Locations and Inspection of Engine Harness Connector X150 for Backed Out Terminals and Poor Connections at Ground Locations G102 and G300 1. Turn OFF the ignition and all accessories. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 3. Locate the X150 connector. Refer to Wiring Systems and Power Management > Component Locator > Master Electrical Component List > X150 in SI. 4. Inspect the connector for the following conditions: - Backed out terminals - Bent pins - Corrosion - Poor terminal fit (use the correct test probe) ‹› If a condition is found, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures in SI. AND ‹› If corrosion is found, proceed to the section of the bulletin titled: Repairing Fretting Corrosion to complete the connector repair. 5. Inspect for a misrouted/chafed harness rubbing on the cooling fins of the Transmission Auxiliary Fluid Pump Control Module as shown. If the wiring is damaged, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures in SI. 6. Inspect for a chafed harness caused by a mispositioned retaining clip as shown. The chafing condition usually occurs when the tab of the clip is aligned with a slot in the conduit. If the wiring is damaged, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures in SI. 7. Locate ground connections G102 and G300. Refer to Wiring Systems and Power Management > Component Locator > Master Electrical Component List > G102 and G300 in SI. 8. Inspect G102 and G300 for a clean and tight connection. Undercoating has been found between the eyelet and the frame resulting in a poor connection. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 08-07-30-021E > Jun > 10 > Electrical - Electrical Malfunction/Multiple DTCs > Page 8204 If a condition is found, clean the area and repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures in SI. 9. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 10. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Lost Communication With DTC's Set Lost Communication with Various Control Modules and DTCs Set DTC Descriptors Note Depending on the vehicle there may be other DTCs set by other modules. - DTC U0073 Control Module Communication Bus A Off - DTC U0100 Lost Communication with Engine/Powertrain Control Module (ECM/PCM) - DTC U0101 Lost Communication with Transmission Control Module (TCM) - DTC U0102 Lost Communication with Transfer Case Control Module - DTC U0121 Lost Communication with Electronic Brake Control Module (EBCM) - DTC U0140 Lost Communication with Body Control Module (BCM) 1. Connect a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). If any DTC(s) are set, refer to the list above or the Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. Turn OFF the ignition and all accessories. 3. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 4. Disconnect the connector(s) at the affected module. 5. Inspect the connector(s) for the following conditions: - Backed out terminals - Bent pins - Corrosion - Poor terminal fit (use the correct test probe) - Water intrusion ‹› If a condition is found, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures in SI AND ‹› If corrosion or water intrusion is found, proceed to the section of the bulletin titled: Repairing Fretting Corrosion to complete the repair. 6. Reconnect the connector(s) at the affected modules. 7. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Repairing Fretting Corrosion Repairing Fretting Corrosion Note Fretting corrosion looks like little dark smudges on the electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. 1. If any water intrusion is present in the connector, use pressure regulated compressed air to dry it out. 2. DO NOT apply an excessive amount of dielectric lubricant as shown, to the connectors as hydrolock may result when attempting to mate the connectors. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 08-07-30-021E > Jun > 10 > Electrical - Electrical Malfunction/Multiple DTCs > Page 8205 Important Use ONLY a clean nylon brush that is DEDICATED to the repair of this specific condition. With a one-inch nylon bristle brush, apply dielectric lubricant P/N 12377900 (in Canada, 10953529 to both the module/component side and the harness side of the affected connector(s). 3. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 4. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > Page 8206 Wiring Harness: Locations Disassembled Views Automatic Transmission Case 1 - Automatic Transmission Case 2 - Transmission Case Locating Pin 3 - Transmission Vent Assembly 4 - Transmission Vent Cap 5 - Transmission Vent 6 - Nameplate Rivet 7 - Nameplate 8 Vehicle Speed Sensor Bolt, M6 x 1.0 x 13 9 - Sensor Shipping Cover 10 - Turbine Speed Sensor 11 - Vehicle Speed Sensor O-Ring 12 - Power Take-Off (PTO) Cover Gasket (2) 13 - PTO Cover (2) 14 - PTO Cover Bolt, M10 x 1.5 x 20, Flanged Head, Coated (12) 16 - Manual Shift Shaft 17 Manual Shift Shaft Seal 18 - Manual Shift Shaft Pin 19 - Manual Shift Shaft Detent Lever/Internal Mode Switch (IMS) Assembly 20 - Park Pawl Assembly 21 - Control Valve Body Locating Pin 22 Detent Lever/IMS Bolt 23 - Connector Shipping Cover 24 - Control Valve Body Assembly 25 Control Valve Body Bolt, M6 x 1.0 x 50, Flanged Head (15) 26 - Manual Shift Shaft Detent Spring 27 - Manual Shift Shaft Detent Spring Bolt M6 x 1.0 x 12. Flanged Head (2) 28 - Transmission Wiring Harness Assembly Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > Page 8207 Wiring Harness: Service and Repair Wiring Harness Replacement Special Tools * J 44247 Internal Wiring Harness Installer * J 44257 Main Wiring Harness Connector Remover Removal Procedure Warning: Refer to Battery Disconnect Warning (See: Starting and Charging/Battery/Service Precautions). 1. Remove the oil pan and transmission internal oil filter. Refer to Oil Pan Replacement (See: Fluid Pan/Service and Repair). 2. Disconnect the external wiring harness from the main transmission connector. Use J 44257 , if connector is not easily accessible. Note: The main transmission connector is actually one end of the internal wiring harness that protrudes through the transmission case. 3. Place a 30 mm or 1 3/16 inch 12-point deep socket or box-end wrench (2) over the main transmission connector (1). 4. Push inward on the socket or wrench to release the retaining feet that attach the connector (1) to the transmission case. 5. Remove the wrench. Push inward on the electrical connector to separate from the transmission case. 6. Disconnect the internal wiring harness connectors (1) from the solenoids, the internal mode switch (IMS), and from the transmission fluid pressure (TFP) switch. Note: The solenoid retainers for shift solenoid 3 (SS3) and shift solenoid 2 (SS2) also retain tabs on the wiring harness U-channel. The solenoids will remain in position even after the solenoid retainers are removed. 7. Remove the solenoid retainers (2) for SS3 and SS2. 8. Remove the internal wiring harness from the transmission. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > Page 8208 1. Align the tabs on the new wiring harness (10) U-channel with the solenoid retainer slots for SS3 (3) and SS2 (2) on the control valve assembly. Install the solenoid retainers (12) for the SS3 (3) and SS2 (2) solenoids. Note: The internal wiring harness connectors should be in the correct position for installation because of their pre-assembled position in the U-channel. 2. Attach the internal wiring harness (10) connectors to the solenoids, the IMS, and the TFP switch. * Connector (8) goes to SS1 (5) * Connector (9) goes to the TFP switch (7) * Connector (11) goes to the MAIN MOD solenoid (19) * Connector (13) goes to the IMS * Connector (14) goes to the TCC PCS (1) * Connector (15) goes to SS2 (2) * Connector (16) goes to SS3 (3) * Connector (17) goes to PCS1 (4) * Connector (18) goes to PCS2 (6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > Page 8209 3. Push the main transmission connector outward through hole in the transmission case until the retaining feet on the connector are near the locked position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > Page 8210 4. Use J 44247 to seat the retaining feet on transmission connector (1). 5. Install the oil pan and transmission internal oil filter. Refer to Oil Pan Replacement (See: Fluid Pan/Service and Repair). 6. Connect the external wiring harness to the main transmission connector. Note: The FastLearn, adapt, procedure must be performed. This can be done in 1 step using a scan tool. If this procedure is not done, the TCM adaptive values will be at the settings that it learned for the old components and will be in slow adaptive mode. Under these conditions, it will take an unacceptably long time for the adaptive values to converge to levels suitable for the new transmission. 7. Perform the FastLearn procedure. Refer to FastLearn Procedure (See: Testing and Inspection/Programming and Relearning). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Service and Repair Clutch Disc: Service and Repair Clutch Assembly Replacement Special Tools J 5824-A Clutch Alignment Tool Removal Procedure 1. Remove the transmission. Refer to Transmission Replacement (See: Manual Transmission/Transaxle/Service and Repair/Removal and Replacement/Tremec 5-Speed (TZ0) - Manual Transmission/Transmission Replacement). 2. Remove the clutch pressure plate bolts. Note: Dowel pins are used to align the flywheel and pressure plate. When removing the pressure plate check to see if the dowel pins are rusted into the pressure plate, if so remove, clean, and reinstall the dowel pins into the correct location(s) on the flywheel. 3. Remove the clutch pressure plate and disc from the dowel pins. Installation Procedure 1. If equipped with a 4.8L or 6.0L engine, install the clutch pressure plate and driven plate to the dowel pins. 2. Install J 5824-A in order to align the clutch. 3. Install the clutch pressure plate bolts finger tight. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Service and Repair > Page 8215 4. If equipped with a 4.8L or 6.0L engine, tighten the clutch pressure plate bolts in the sequence shown. Tighten the bolts to 70 Nm (52 lb ft). 5. Remove the J 5824-A . 6. Install the transmission. Refer to Transmission Replacement (See: Manual Transmission/Transaxle/Service and Repair/Removal and Replacement/Tremec 5-Speed (TZ0) - Manual Transmission/Transmission Replacement). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Fluid > Component Information > Specifications Clutch Fluid: Specifications HYDRAULIC CLUTCH FLUID GM Part No. U.S. 12345347, in Canada 10953517) or equivalent DOT-3 brake fluid. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Service and Repair Clutch Master Cylinder: Service and Repair Clutch Master Cylinder Replacement Removal Procedure 1. Disconnect the clutch pedal position switch electrical connector (1). 2. Push the clutch pedal in and squeeze the pushrod bushing tabs in, in order to release the pushrod bushing from the clutch pedal. 3. Disconnect the clutch actuator cylinder to clutch master cylinder quick connect fitting. 4. Remove the clutch master cylinder clip from the brake pressure module valve pipe. 5. Rotate the clutch master cylinder 45 degrees clockwise to the unlocked position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Service and Repair > Page 8223 6. Remove the clutch master cylinder. Installation Procedure 1. Install the clutch master cylinder. 2. Push in and rotate the clutch master cylinder 45 degrees counterclockwise to the locked position. 3. Disconnect the clutch actuator cylinder to clutch master cylinder quick connect fitting. 4. Install the clutch master cylinder clip to the brake pressure module valve pipe. 5. Apply light pressure to the clutch pedal to couple the pushrod socket to the clutch pedal. 6. Connect the clutch pedal position switch electrical connector (1). 7. Pump the clutch pedal 3 time prior to starting the vehicle to ensure connection is complete. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Service and Repair > Clutch Actuator Cylinder Replacement (TZ0) Clutch Slave Cylinder: Service and Repair Clutch Actuator Cylinder Replacement (TZ0) Clutch Actuator Cylinder Replacement (TZ0) Removal Procedure 1. Disconnect the clutch pedal position switch electrical connector (1). 2. Push the clutch pedal in and squeeze the pushrod bushing tabs in, in order to release the pushrod bushing from the clutch pedal. 3. Disconnect the clutch actuator cylinder to clutch master cylinder quick connect fitting. 4. Remove the clutch master cylinder clip from the brake pressure module valve pipe. 5. Rotate the clutch master cylinder 45 degrees clockwise to the unlocked position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Service and Repair > Clutch Actuator Cylinder Replacement (TZ0) > Page 8228 6. Remove the clutch master cylinder. Installation Procedure 1. Install the clutch master cylinder. 2. Push in and rotate the clutch master cylinder 45 degrees counterclockwise to the locked position. 3. Disconnect the clutch actuator cylinder to clutch master cylinder quick connect fitting. 4. Install the clutch master cylinder clip to the brake pressure module valve pipe. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Service and Repair > Clutch Actuator Cylinder Replacement (TZ0) > Page 8229 5. Apply light pressure to the clutch pedal to couple the pushrod socket to the clutch pedal. 6. Connect the clutch pedal position switch electrical connector (1). 7. Pump the clutch pedal 3 time prior to starting the vehicle to ensure connection is complete. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Service and Repair > Clutch Actuator Cylinder Replacement (TZ0) > Page 8230 Clutch Slave Cylinder: Service and Repair Clutch Actuator Cylinder Replacement (M96) Clutch Actuator Cylinder Replacement (M96) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Service and Repair Clutch Pedal Assembly: Service and Repair Clutch Pedal Replacement Removal Procedure 1. Move the instrument panel to the service position. Refer to Instrument Panel Service Positioning (with SLT) (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Service Positioning (with SLT))Instrument Panel Service Positioning (without SLT) (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Service Positioning (without SLT)). 2. Disconnect the clutch pedal engine start switch electrical connector (1). 3. Remove the clutch master cylinder. Refer to Clutch Master Cylinder Replacement (See: Clutch Hydraulic System/Clutch Master Cylinder/Service and Repair). 4. Remove the clutch pedal to clutch pedal bracket bolt. 5. Remove the clutch pedal to brake module bolts. 6. Remove the clutch pedal sub-assembly. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Service and Repair > Page 8234 1. Install the clutch pedal sub-assembly. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the clutch pedal to brake module bolts. Tighten the bolts to 50 Nm (37 lb ft). 3. Install the clutch pedal to clutch pedal bracket bolt. Tighten the bolt to 36 Nm (27 lb ft). 4. Remove the clutch master cylinder. Refer to Clutch Master Cylinder Replacement (See: Clutch Hydraulic System/Clutch Master Cylinder/Service and Repair). 5. Connect the clutch pedal engine start switch electrical connector (1). 6. Install the instrument panel. Refer to Instrument Panel Service Positioning (with SLT) (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Service Positioning (with SLT))Instrument Panel Service Positioning (without SLT) (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Service Positioning (without SLT)). Warning Replacement or reprogramming of the ECM, or replacement of the clutch pedal position sensor (CPPS) or clutch pedal requires that a CPPS learn procedure be performed. Failure to perform the CPPS learn procedure may result in personal injury or damage to the vehicle or its components if the vehicle is in gear and the starter motor is accidentally engaged. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Service and Repair > Page 8235 7. Perform the clutch pedal position sensor learn procedure. Refer to Clutch Pedal Position Sensor Learn (See: Testing and Inspection/Programming and Relearning/Clutch Pedal Position Sensor Learn/Tremec 5-Speed (TZ0) - Manual Transmission) or Clutch Pedal Position Sensor Learn (See: Manual Transmission/Transaxle/Testing and Inspection/Component Tests and General Diagnostics). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Position Sensor / Switch > Component Information > Testing and Inspection Clutch Pedal Position Sensor / Switch: Testing and Inspection Clutch Pedal Position Sensor Learn Important: The clutch pedal position (CPP) sensor learn procedure is required when the following service procedures have been performed regardless of whether DTC P080A is set: * An engine control module (ECM) replacement * A CPP sensor replacement * Any repairs which affect the CPP sensor relationship 1. Install a scan tool. 2. Monitor the ECM for DTCs with a scan tool. If other DTCs are set, except DTC P080A, refer to Diagnostic Trouble Code (DTC) List - Vehicle ( See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle) for the applicable DTC that set. 3. With a scan tool, select Clutch Pedal Position Learn under Module Setup in Manual Transmission, and perform the following instructions displayed on the scan tool screen. Important: The CPP sensor learn procedure cannot be performed more than once per ignition cycle. The clutch pedal needs to be fully depressed and held steady throughout this procedure in order to perform a correct learning. 4. The scan tool will display under CPP Learn Status: Not Learned, In Process, Complete, Fail Low Volt, Fail - High Volt, or Fail Moving. The scan tool will display under CPP Learn Status Complete if the process was successful. 5. If the scan tool indicates that DTC P080A ran and passed this ignition the CPP sensor learn procedure is complete. If the scan tool indicates DTC P080A failed or did not run this ignition, refer to DTC P080A (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P080A/Tremec 5-Speed (TZ0) - Manual Transmission). If any other DTC is set, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle) for the applicable DTC. 6. Turn OFF the ignition for 30 seconds after the learn procedure has successfully completed in order to store the CPP sensor variation values in ECM history. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Position Sensor / Switch > Component Information > Testing and Inspection > Page 8239 Clutch Pedal Position Sensor / Switch: Service and Repair Clutch Pedal Engine Start Switch Replacement Removal Procedure 1. Disconnect the clutch pedal position switch electrical connector (1). 2. Remove the plastic retainer (1) tabs from the clutch pedal position switch (2). 3. Remove the clutch pedal position switch (2) from the pushrod. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Position Sensor / Switch > Component Information > Testing and Inspection > Page 8240 1. Install the clutch pedal position switch (2) to the pushrod. 2. Install the plastic retainer (1) tabs to the clutch pedal position switch (2). 3. Connect the clutch pedal position switch electrical connector (1). Warning Replacement or reprogramming of the ECM, or replacement of the clutch pedal position sensor (CPPS) or clutch pedal requires that a CPPS learn procedure be performed. Failure to perform the CPPS learn procedure may result in personal injury or damage to the vehicle or its components if the vehicle is in gear and the starter motor is accidentally engaged. 4. Perform the clutch pedal position sensor learn procedure. Refer to DTC P080A (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P080A/Tremec 5-Speed (TZ0) - Manual Transmission) or Clutch Pedal Position Sensor Learn (See: Manual Transmission/Transaxle/Testing and Inspection/Component Tests and General Diagnostics). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Release Bearing, M/T > Component Information > Service and Repair Clutch Release Bearing: Service and Repair Release Bearing Replacement Removal Procedure 1. Remove the transmission. Refer to Transmission Replacement (See: Manual Transmission/Transaxle/Service and Repair/Removal and Replacement/Tremec 5-Speed (TZ0) - Manual Transmission/Transmission Replacement). 2. Remove the clutch release bearing. * Rotate the bearing in either direction. * The compression spring load will push the release bearing off the end of the clutch actuator bearing. Installation Procedure Important: DO NOT use cleaners or chemicals to clean the quill and DO NOT grease the quill. 1. Using a clean dry cloth, clean the exposed area of the actuator cylinder quill. 2. Install the NEW clutch release bearing to the clutch actuator cylinder. * Firmly push the clutch release bearing into place. * The release bearing will snap over the retainer tab and will be self-retained to the actuator cylinder. 3. Install the transmission. Refer to Transmission Replacement (See: Manual Transmission/Transaxle/Service and Repair/Removal and Replacement/Tremec 5-Speed (TZ0) - Manual Transmission/Transmission Replacement). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pilot Bearing > Component Information > Service and Repair Pilot Bearing: Service and Repair Clutch Pilot Bearing Replacement Special Tools * J 43276 Clutch Pilot Bearing Remover * J 38836 Bushing Installer/Clutch Arbor Removal Procedure Caution: When using the J 43276 Clutch Pilot Bearing Remover, always secure the J 43276-1 Clutch Pilot Bearing Remover tool body using a wrench. Do not allow the J 43276-1 tool body to rotate. Failing to do so causes damage to the J 43276-1 tool body. Note: The flywheel spacer (if applicable) must be removed prior to clutch pilot bearing removal. 1. Remove the clutch assembly. Refer to Clutch Assembly Replacement (See: Service and Repair). 2. Using J 43276 perform the following in order to remove the clutch pilot bearing: 1. Install the J 43276-1 into the clutch pilot bearing. 2. Using a wrench, secure the J 43276-1. 3. Insert the J 43276-2 into the J 43276-1. 4. Rotate the J 43276-2 clockwise into the J 43276-1 until the clutch pilot bearing is completely removed from the crankshaft. 5. Rotate the J 43276-2 counterclockwise to remove the J 43276-2 from the J 43276-1. 6. Remove the J 43276-1 from the tool body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pilot Bearing > Component Information > Service and Repair > Page 8247 3. Discard the old clutch pilot bearing. Installation Procedure Note: The flywheel spacer (if applicable) must be removed prior to pilot bearing installation. 1. Install a 5/8 inch washer (1) onto the J 38836 or equivalent. 2. Install a NEW clutch pilot bearing (2) onto the tool. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pilot Bearing > Component Information > Service and Repair > Page 8248 3. Install the NEW clutch pilot bearing into the crankshaft using J 38836 . 4. Inspect the clutch pilot bearing for proper installation. 5. Install the clutch assembly. Refer to Clutch Assembly Replacement (See: Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Specifications Pressure Plate: Specifications Fastener Tightening Specifications Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Specifications > Page 8252 Pressure Plate: Service and Repair Clutch Assembly Replacement Special Tools J 5824-A Clutch Alignment Tool Removal Procedure 1. Remove the transmission. Refer to Transmission Replacement (See: Manual Transmission/Transaxle/Service and Repair/Removal and Replacement/Tremec 5-Speed (TZ0) - Manual Transmission/Transmission Replacement). 2. Remove the clutch pressure plate bolts. Note: Dowel pins are used to align the flywheel and pressure plate. When removing the pressure plate check to see if the dowel pins are rusted into the pressure plate, if so remove, clean, and reinstall the dowel pins into the correct location(s) on the flywheel. 3. Remove the clutch pressure plate and disc from the dowel pins. Installation Procedure 1. If equipped with a 4.8L or 6.0L engine, install the clutch pressure plate and driven plate to the dowel pins. 2. Install J 5824-A in order to align the clutch. 3. Install the clutch pressure plate bolts finger tight. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Specifications > Page 8253 4. If equipped with a 4.8L or 6.0L engine, tighten the clutch pressure plate bolts in the sequence shown. Tighten the bolts to 70 Nm (52 lb ft). 5. Remove the J 5824-A . 6. Install the transmission. Refer to Transmission Replacement (See: Manual Transmission/Transaxle/Service and Repair/Removal and Replacement/Tremec 5-Speed (TZ0) - Manual Transmission/Transmission Replacement). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Component Information > Technical Service Bulletins > A/T Controls - Snapshot Data Upload Information Continuously Variable Transmission/Transaxle: Technical Service Bulletins A/T Controls Snapshot Data Upload Information INFORMATION Bulletin No.: 07-07-30-010B Date: June 19, 2009 Subject: Procedure to Take Snapshot Data with a Tech 2(R) and Upload Data to a Computer Using TIS Software Models: 2004-2010 Passenger Cars and Light Duty Truck (Including Saturn; excluding Astra models) 2004-2010 HUMMER H2, H3 2004-2009 Saab 9-7X Supercede: This bulletin is being revised to update the Sending a Snapshot to GM TAC section and add the 2010 model year. Please discard Corporate Bulletin Number 07-07-30-010A (Section 07 - Transmission/Transaxle). Important Global Diagnostic System (GDS) will take the place of the Tech 2(R) on certain vehicles when communicating and diagnosing vehicle on-board electrical systems. This new diagnostic tool platform and software will be required for use with all GM Global Architecture (Global A) vehicles beginning with the 2010 Chevrolet Camaro, followed later by the Buick Allure/LaCrosse, Chevrolet Equinox, Cadillac SRX and the GMC Terrain. These vehicles will no longer permit Tech 2(R) communication for diagnostic purposes. For further information, refer to Corporate Bulletin Number 09-00-89-019 (Introduction of New Global Diagnostic System (GDS)). This procedure is intended to show the user how to take snapshot data with a Tech 2(R) and upload it to a computer. The procedure is written for an automatic transmission data snapshot on a Saturn AURA, but is similar for all applications. This procedure is written with the assumption the user has a basic understanding of how to use a Tech 2(R) already. Capturing a Snapshot of the Vehicle Data Stream 1. Connect the Tech 2(R) to the vehicle Data Link Connector (DLC) as shown above. Use a CANdi module as required. 2. Power up the Tech 2(R) and press the ENTER key at the start-up screen. 3. From the Main Menu select F0: Diagnostics. 4. Enter all vehicle information as requested on the scan tool's display. Bolded selections are vehicle specific. - Select "2007" - Select "Passenger Car (F0)" - Select "Saturn" Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Component Information > Technical Service Bulletins > A/T Controls - Snapshot Data Upload Information > Page 8258 - Select "Z" - Select "Aura" - Select "Powertrain" - Select "3.6L LY7" - Select "Transmission" - Select "Transmission Data" 5. From the application menu, select F3: Snapshot. - Choose trigger type and trigger point, as described above. - It is preferred to trigger on "Any Code" (F1) - If multiple codes are setting, select "Single Code" and enter the code you are trying to capture on the next screen. - Select "Center (F5)" for the trigger point. This allows the requester/viewer of the data to see the events before and after the code sets. 6. Press the Record Snapshot soft key. The Tech 2(R) screen will display the parameters it is going to record for live viewing. - When the fault occurs, the Tech 2(R) will automatically start recording if the preferred settings (F1 and F5) are selected. - If manual trigger is selected during the setup procedure, you will have to hit the "Trigger" soft key to actually record data. Otherwise, it will automatically start recording when a DTC is set. - Allow the Tech 2(R) to record the data. Please note that a Tech 2(R) can record a maximum of 1 minute of data (30 seconds before and 30 seconds after the trigger point if center trigger is selected). Important The Tech(R)2 can only record two snapshots prior to uploading to a computer. If a third snapshot is requested, the first snapshot will be overwritten. 7. When the snap shot data has been recorded, exit to the Main Menu, then power down and disconnect the Tech 2(R) from the vehicle. Uploading and Sending a Snapshot via TIS2WEB Figure 8 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Component Information > Technical Service Bulletins > A/T Controls - Snapshot Data Upload Information > Page 8259 Figure 9 1. Once TIS2WEB is launched and you're at the main screen, select Snapshot, indicated with a arrow in Figure 8. 2. Select the Upload from Handheld button to launch the device selection screen just like the TIS 2000 procedure described above. Figure 10 3. Select the top button, "Upload from Handheld" which will launch the screen displayed in Figure 10. Make sure the Tech 2(R) is connected to the computer and plugged in. Select Tech 2(R) under Device and select OK. The screen of your Tech 2(R) should start blinking and a line will start scrolling across the screen indicating it is communicating with your computer. Figure 11 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Component Information > Technical Service Bulletins > A/T Controls - Snapshot Data Upload Information > Page 8260 4. Once communication is established and you select the file you want to upload, you will see a screen similar to below. You can email the file directly from TIS2WEB by going to the Snapshot drop down menu and selecting "Send to e-mail" as shown in Figure 11. Figure 12 5. After selecting Send to e-mail, a dialog box like the one shown in Figure 12 will be displayed. Fill in the information as requested and then click send. Include the VIN in the subject line. 6. After all the information is entered, hit the send button. After sending the file, you will receive a confirmation box letting you know the e-mail was sent successfully. 7. It is recommended to now save the file to your computer using the same procedure as if you were using TIS 2000 in case your recipient doesn't receive your email with the snapshot data. Important Sending the file via e-mail through TIS2WEB does NOT save the file locally and there is no way to access your sent mail in TIS2WEB like a regular e-mail program. Sending a Snapshot to GM TAC Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Component Information > Technical Service Bulletins > A/T Controls - Snapshot Data Upload Information > Page 8261 During your call with GM TAC on a current case, you may be advised to send a copy of the Tech 2(R) or VDR Snapshot Data to the TAC e-mail box. U.S. Dealers - send to e-mail box [email protected] Canadian Dealers - send to e-mail box [email protected] Please complete the following: - Be sure to review the procedures listed above for uploading and sending a Snapshot via TIS2WEB. - If you are using a VDR to capture Snapshot Data, information can be accessed in the Techlink Website in the articles (December 2002, December 2003, July 2004 and January 2006). - Please be sure to identify the snapshot by placing the TAC Case Number, the last eight digits of the VIN and the type of data (i.e. engine or transmission) in the subject line of your e-mail. The email Subject Line MUST contain the TAC case number and last 8 digits of the VIN or their email can not be processed and will be deleted. Please send only REQUESTED Snapshot Data to the TAC e-mail box. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Component Information > Technical Service Bulletins > A/T Controls - Snapshot Data Upload Information > Page 8262 Continuously Variable Transmission/Transaxle: Technical Service Bulletins Vehicle - Engine Crankcase and Subsystems Flushing Info. INFORMATION Bulletin No.: 04-06-01-029E Date: April 29, 2010 Subject: Unnecessary Flushing Services, Additive Recommendations and Proper Utilization of GM Simplified Maintenance Schedule to Enhance Customer Service Experience Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years and add information about the proper transmission flush procedure. Please discard Corporate Bulletin Number 04-06-01-029D (Section 06 - Engine/Propulsion System). An Overview of Proper Vehicle Service General Motors is aware that some companies are marketing tools and equipment to support a subsystem flushing procedures. These dedicated machines are in addition to many engine oil, cooling system, fuel system, A/C, transmission flush and steering system additives available to the consumer. GM Vehicles under normal usage do not require any additional procedures or additives beyond what is advised under the former Vehicle Maintenance Schedules or the current Simplified Maintenance Schedules. Do not confuse machines available from Kent-Moore/SPX that are designed to aid and accelerate the process of fluid changing with these flushing machines. Engine Crankcase Flushing General Motors Corporation does not endorse or recommend engine crankcase flushing for any of its gasoline engines. Analysis of some of the aftermarket materials used for crankcase flushing indicate incompatibility with GM engine components and the potential for damage to some engine seals and bearings. Damage to engine components resulting from crankcase flushing IS NOT COVERED under the terms of the New Vehicle Warranty. GM Authorized Service Information: Detailed, Descriptive, and Complete If a specific model vehicle or powertrain need is identified, GM will issue an Authorized Service Document containing a procedure and, if required, provide, make available, or require the specific use of a machine, tool or chemical to accomplish proper vehicle servicing. An example of this is fuel injector cleaning. Due to variation in fuel quality in different areas of the country, GM has recognized the need for fuel injector cleaning methods on some engines, though under normal circumstances, this service is not part of the maintenance requirements. GM has published several gasoline fuel injector cleaning bulletins that fully outline the methods to be used in conjunction with GM Part Numbered solutions to accomplish proper and safe cleaning of the fuel injectors with preventative maintenance suggestions to maintain optimum performance. You may refer to Corporate Bulletin Numbers 03-06-04-030 and 04-06-04-051 for additional information on this subject. Subsystem Flushing Flushing of A/C lines, radiators, transmission coolers, and power steering systems are recognized practices to be performed after catastrophic failures or extreme corrosion when encountered in radiators. For acceptable A/C flushing concerns, refer to Corporate Bulletin Number 01-01-38-006. This practice is NOT required or recommended for normal service operations. The use of external transmission fluid exchange or flush machines is NOT recommended for the automatic or manual transmission. Use of external machines to replace the fluid may affect the operation or durability of the transmission. Transmission fluid should only be replaced by draining and refilling following directions in SI. Refer to Automatic/Manual Transmission Fluid and Filter Replacement. Approved Transmission Flushing Tool (Transmission Cooler Only) The Automatic Transmission Oil Cooler Flush and Flow Test Tool is recommended for GM vehicles. Refer to Transmission Fluid Cooler Flushing and Flow Test in SI using the J 45096. Service Is Important to You and Your Customer General Motors takes great pride in offering our dealerships and customers high quality vehicles that require extremely low maintenance over the life of the vehicle. This low cost of ownership builds repeat sales and offers our customers measurable economy of operation against competing vehicles. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Component Information > Technical Service Bulletins > A/T Controls - Snapshot Data Upload Information > Page 8263 Providing responsible services at the proper intervals will greatly aid your dealership with repeat business, and additional services when required. Most customers appreciate and gain trust in the dealership that informs and offers them just what they need for continued trouble-free operation. Examine your service department's practices and verify that all Service Consultants and Technicians focus on customer satisfaction, vehicle inspections, and other products at time of service. Use this opportunity to upgrade the services you provide to your customers. Here are a few suggestions: - Take the time required to align your dealership service practices with the new GM Simplified Maintenance Schedule. Use the new vehicle Owner's Manual Maintenance I and II schedules to create a "mirror image" in your advertising and dealer service pricing that is easily understandable to your customer. Taking advantage of this new service strategy may greatly increase your dealership service sales and customer retention while decreasing the frequency of visits and inconvenience to your customer. - Review your program to ensure that all vehicles coming in are evaluated for safety and wear items. Examine all vehicles for tire condition, signs of misalignment, brake wear, exterior lamp functionality, exhaust condition, A/C cooling performance, SRS or Air Bag MIL, along with Service Engine Soon or Check Engine indicators. If the Service Engine Soon or Check Engine MIL is illuminated, it is vital that you inform the customer of the concerns with ignoring the indicator and what the required repair would cost. In addition to the possibility of increased emissions and driveability concerns, many customers are unaware that lower gas mileage may also result, with additional cost to the customer. - Be complete in your service recommendations. Some sales opportunities are not being fully pursued nationally. Focus on overlooked but required maintenance that has real benefits to the customer. Many vehicles are equipped with cabin air filters. If these filters are used beyond replacement time, they may impede airflow decreasing A/C and heating performance. Make sure these filters are part of your recommended service. Note that some of our vehicles may not have been factory equipped but will accept the filters as an accessory. - Express the value in maintaining the finish quality of the customer's vehicle at the Maintenance I and II visits. More fully utilize the vehicle prep personnel you already have in place. In today's world, many people simply ignore the finish of their vehicle, at best infrequently using an automatic car wash for exterior cleaning. Offer vehicle detailing services in stages from just a wash and wax to a complete interior cleaning. When paired with the Simplified Maintenance visit, this will increase customer satisfaction. On return, the customer gets a visibly improved vehicle that will be a source of pride of ownership along with a vehicle that is now fully maintained. Also, reinforce the improved resale value of a completely maintained vehicle. - For customers who clean and maintain the appearance of their vehicles themselves encourage the use of GM Vehicle Care products. Many customers may have never used GM Car Wash/Wax Concentrate, GM Cleaner Wax or a longtime product, GM Glass Cleaner, which is a favorite of many customers who try it just once. If your dealership give samples of these products with new car purchases, customers may already be sold on the product but not willing to make a special trip to the dealership. Capitalize on sales at this time. Stock shelves right at the Service counter with these products and consider instituting compensation programs for Service Consultants who suggest these products. Many consumers faced with an intimidating wall full of car care products sold at local auto parts stores may find it comforting to purchase a fully tested product sold by GM that they know will not harm the finish of their vehicle. We suggest these competitively priced basic vehicle care products to emphasize: In USA: - #12378401 GM Vehicle Care Wash/Wax Concentrate 16 fl. oz. (0.473L) - #89021822 GM Vehicle Care Glass Cleaner Aerosol 18 oz. (510 g) - #12377966 GM Vehicle Care Cleaner Wax 16 fl. oz. (0.473L) - #1052929 GM Vehicle Care Chrome and Wire Wheel Cleaner 16 fl. oz. (0.473L) - #88861431 GM Vehicle Care Odor Eliminator 24 fl. oz. (0.710L) In Canada: - #10953203 GM Vehicle Care Wash & Wax Concentrate 473 mL - #992727 GM Glass Cleaner Aerosol 500 g - #10952905 GM Vehicle Care Liquid Cleaner/Wax 473 mL - #10953013 GM Vehicle Care Chrome Cleaner and Polish 454 mL - #10953202 GM Vehicle Care Wheel Brite 473 mL - #88901678 GM Vehicle Care Odor Eliminator 473 mL - Display signboards with the installed price for popular GM Accessories such as running boards and Tonneau Covers. Customers may not think to ask about these desirable items at the time of a service visit. - Finally, take advantage of the GM Goodwrench initiatives (Tire Program, Goodwrench Credit Card, etc. / Dealer Marketing Association (DMA) Promotions in Canada) to provide the customer with more reasons to identify your dealership as the best place to go for parts and service. Remember to utilize ALL of the service aspects you possess in your dealership to satisfy and provide value to your customer. Many businesses exist profitably as an oil change location, a vehicle repair facility, or a detailing shop alone. You already have the capabilities of all three and provide these services with the inherent trust of your customer, under the GM Mark of Excellence. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Actuators and Solenoids - Differential > Actuator, Differential Lock > Component Information > Service and Repair Actuator: Service and Repair Front Drive Axle Actuator Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the engine shield, if equipped. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement). 3. Disconnect the electrical connector from the actuator. 4. Remove the actuator (1) for the 8.25 inch axle (2) or (3) for the 9.5 inch axle (4) by turning the actuator counterclockwise. Installation Procedure 1. Apply sealant to the threads of the actuator (1) for the 8.25 inch axle (2) or (3) for the 9.25 inch axle (4). Use the correct sealant. Refer to Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Actuators and Solenoids - Differential > Actuator, Differential Lock > Component Information > Service and Repair > Page 8269 Adhesives, Fluids, Lubricants, and Sealers (See: Fluid - Differential/Specifications/Fluid Type Specifications). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the actuator (1 or 3). Tighten the actuator to 20 Nm (15 lb ft). 3. Connect the electrical connector to the actuator. 4. Install the engine shield, if equipped. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement). 5. Lower the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Technical Service Bulletins > Drivetrain - Front Axle Vent Hose Routing Differential Case: Technical Service Bulletins Drivetrain - Front Axle Vent Hose Routing INFORMATION Bulletin No.: 08-04-19-004A Date: January 06, 2010 Subject: Correct Front Axle Vent Hose Routing Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2010 GMC Sierra, Yukon, Yukon XL with Four Wheel Drive or All Wheel Drive Supercede: This bulletin is being revised to add the 2010 model year. Please discard Corporate Bulletin Number 08-04-19-004 (Section 04 - Driveline/Axle). The front axle vent hose is mounted in the left side of the engine compartment, and may not be correctly routed. The vent hose can get misrouted and placed in a position that is lower than the front axle harness/engine harness in-line connector. In this position, the vent tube may ingest water. The front axle vent hose may be routed to the wheel side of the wheel well. It may be hanging through the opening of the wheel well in a vertical position, with the vent cap hanging down. If you encounter a vehicle with the front axle vent hose misrouted, reroute the hose to the correct location. The hose should be mounted inside the engine compartment, in an upward position to prevent the possibility of water being drawn into the hose and axle assembly during cool-down. Tape the vent hose to the nearby wiring harness as shown. Technicians should also change the front axle fluid. Parts Information Warranty Information Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Technical Service Bulletins > Drivetrain - Front Axle Vent Hose Routing > Page 8274 For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component Information > Service and Repair > Locking Differential Clutch Disc Assembly Disassemble (8.6 Inch Axle) Differential Clutch: Service and Repair Locking Differential Clutch Disc Assembly Disassemble (8.6 Inch Axle) Locking Differential Clutch Disc Assembly Disassemble (8.6 Inch Axle) 1. Remove the guide clips (3). 2. Remove the clutch discs and the splined discs (2, 4-6) from the locking differential side gear (1). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component Information > Service and Repair > Locking Differential Clutch Disc Assembly Disassemble (8.6 Inch Axle) > Page 8279 Differential Clutch: Service and Repair Locking Differential Clutch Disc Assembly Disassemble (9.5 Inch Axle) Locking Differential Clutch Disc Assembly Disassemble (9.5 Inch Axle) 1. Remove the guide clips (2). 2. Remove the clutch discs and the splined discs (3-7) from the locking differential side gear (1). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component Information > Service and Repair > Locking Differential Clutch Disc Assembly Disassemble (8.6 Inch Axle) > Page 8280 Differential Clutch: Service and Repair Locking Differential Clutch Disc Assembly Disassemble (10.5 Inch Axle) Locking Differential Clutch Disc Assembly Disassemble (10.5 Inch Axle) 1. Remove the guide clips (6). 2. Remove the clutch discs and the splined discs (2-5, 7) from the locking differential side gear (1). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component Information > Service and Repair > Locking Differential Clutch Disc Assembly Disassemble (8.6 Inch Axle) > Page 8281 Differential Clutch: Service and Repair Locking Differential Clutch Disc Assembly Disassemble (11.5 Inch Axle) Locking Differential Clutch Disc Assembly Disassemble (11.5 Inch Axle) 1. Remove the guide clips (3). 2. Remove the clutch discs and the splined discs (2, 4-7) from the side gear (1). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component Information > Service and Repair > Locking Differential Clutch Disc Assembly Disassemble (8.6 Inch Axle) > Page 8282 Differential Clutch: Service and Repair Locking Differential Clutch Disc Assembly Disassemble (8.6 Inch Axle) Locking Differential Clutch Disc Assembly Disassemble (8.6 Inch Axle) 1. Remove the guide clips (3). 2. Remove the clutch discs and the splined discs (2, 4-6) from the locking differential side gear (1). Locking Differential Clutch Disc Assembly Disassemble (9.5 Inch Axle) Locking Differential Clutch Disc Assembly Disassemble (9.5 Inch Axle) 1. Remove the guide clips (2). 2. Remove the clutch discs and the splined discs (3-7) from the locking differential side gear (1). Locking Differential Clutch Disc Assembly Disassemble (10.5 Inch Axle) Locking Differential Clutch Disc Assembly Disassemble (10.5 Inch Axle) 1. Remove the guide clips (6). 2. Remove the clutch discs and the splined discs (2-5, 7) from the locking differential side gear (1). Locking Differential Clutch Disc Assembly Disassemble (11.5 Inch Axle) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component Information > Service and Repair > Locking Differential Clutch Disc Assembly Disassemble (8.6 Inch Axle) > Page 8283 Locking Differential Clutch Disc Assembly Disassemble (11.5 Inch Axle) 1. Remove the guide clips (3). 2. Remove the clutch discs and the splined discs (2, 4-7) from the side gear (1). Locking Differential Clutch Disc Assembly Assemble (8.6 Inch Axle) Locking Differential Clutch Disc Assembly Assemble (8.6 Inch Axle) 1. Apply the correct axle lubricant to the surface of each disc. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Fluid Differential/Specifications/Fluid Type Specifications). 2. Assemble the right side or bell-end side clutch disc assembly as follows: 1. Install the two-sided carbon eared disc (2) to the side gear (1). 2. Install the 1st splined disc (4). 3. Install the 2nd splined disc (5). 4. Install the one-sided carbon eared disc (6). 5. Install the guide clips (3) to the clutch discs (2, 4-6). Apply chassis grease to the guide clips in order to hold the clips in place on the disc ears. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Fluid - Differential/Specifications/Fluid Type Specifications). Locking Differential Clutch Disc Assembly Assemble (9.5LD Axle) Locking Differential Clutch Disc Assembly Assemble (9.5LD Axle) 1. Apply proper axle lubricant to the surface of each disc. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Fluid - Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component Information > Service and Repair > Locking Differential Clutch Disc Assembly Disassemble (8.6 Inch Axle) > Page 8284 Differential/Specifications/Fluid Type Specifications). 2. Assemble the right side or bell-end side clutch disc assembly as follows: 1. Install the 1st non-carbon eared disc (3) to the side gear (1). 2. Install the 1st splined disc (4). 3. Install the 2nd non-carbon eared disc (5). 4. Install the 2nd splined disc (6). 5. Install the 3rd non-carbon eared disc (7). 6. Install the guide clips (2) to the clutch discs (2-7). Apply chassis grease to the guide clips in order to hold the clips in place on the disc ears. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Fluid - Differential/Specifications/Fluid Type Specifications). Locking Differential Clutch Disc Assembly Assemble (10.5) Locking Differential Clutch Disc Assembly Assemble (10.5) 1. Apply the proper axle lubricant to the surface of each disc. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Fluid Differential/Specifications/Fluid Type Specifications). 2. Assemble the left side clutch disc assembly as follows: 1. Install the 1st non-carbon eared disc (2) to the side gear (1). 2. Install the 1st splined disc (3). 3. Install the 2nd non-carbon eared disc (4). 4. Install the 2nd splined disc (5). 5. Install the 3rd non-carbon eared disc (7). 6. Align the ears of all the clutch discs. 7. Install the guide clips (6) to the clutch discs (2-5, 7). Apply the proper chassis grease to the guide clips in order to hold the clips in place on the disc ears. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Fluid Differential/Specifications/Fluid Type Specifications). Locking Differential Clutch Disc Assembly Assemble (11.5 Inch Axle) Locking Differential Clutch Disc Assembly Assemble (11.5 Inch Axle) 1. Apply axle lubricant, GM P/N 12378261 (Canadian P/N 10953455) or equivalent meeting GM Specification 9986115, to the surface of each disc. 2. Assemble the right side or bell-end side clutch disc assembly as follows: 1. Install the 1st eared disc (2) to the side gear (1). 2. Install the 1st carbon splined disc (3). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component Information > Service and Repair > Locking Differential Clutch Disc Assembly Disassemble (8.6 Inch Axle) > Page 8285 3. Install the 2nd eared disc (5). 4. Install the 2nd carbon splined disc (6). 5. Install the 3rd eared disc (7). 6. Install the guide clips (3) to the clutch discs (2, 4-7). Apply grease to the guide clips in order to hold the clips in place on the disc ears. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Lock > Actuator, Differential Lock > Component Information > Service and Repair Actuator: Service and Repair Front Drive Axle Actuator Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the engine shield, if equipped. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement). 3. Disconnect the electrical connector from the actuator. 4. Remove the actuator (1) for the 8.25 inch axle (2) or (3) for the 9.5 inch axle (4) by turning the actuator counterclockwise. Installation Procedure 1. Apply sealant to the threads of the actuator (1) for the 8.25 inch axle (2) or (3) for the 9.25 inch axle (4). Use the correct sealant. Refer to Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Lock > Actuator, Differential Lock > Component Information > Service and Repair > Page 8290 Adhesives, Fluids, Lubricants, and Sealers (See: Fluid - Differential/Specifications/Fluid Type Specifications). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the actuator (1 or 3). Tighten the actuator to 20 Nm (15 lb ft). 3. Connect the electrical connector to the actuator. 4. Install the engine shield, if equipped. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement). 5. Lower the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications DRIVE AXLE FLUID CAPACITIES FRONT AXLE 1000 Series (8.25") ...................................................................................................... ..................................................................... 1.43 liters (1.51 quarts) 2000 Series (9.25") .................. ......................................................................................................................................................... 1.73 liters (1.83 quarts) REAR AXLE 1000 Series without RPO AXN (8.6") .............................................................................................................................................. 2.03 liters (2.15 quarts) 1000 Series with RPO AXN (9.5"LD) ................................................................................................................................................ 2.6 liters (2.75 quarts) 2000 Series (9.5"HD) ............................................................................................ ............................................................................. 2.6 liters (2.75 quarts) 2000 Series with RPO LY6 (10.5") .................................................................................................................................................... 2.6 liters (2.75 quarts) 2000 Series with RPO LMM (11.5") .................................................................................................................................................. 3.0 liters (3.17 quarts) 3000 Series (11.5") ................................................................................................ ............................................................................. 3.0 liters (3.17 quarts) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 8295 Fluid - Differential: Fluid Type Specifications FRONT AND REAR AXLE SAE 75W-90 Synthetic Axle Lubricant (GM Part No. U.S. 89021677, in Canada 89021678) meeting GM Specification 9986115. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Service and Repair > Procedures Fluid - Differential: Procedures Front Drive Axle Front Axle Lubricant Level Inspection (9.25 Inch Axle) 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Make sure the vehicle is level. 3. Inspect the front axle for leaks. Repair as necessary. 4. Clean the area around the front axle fill plug. 5. Remove the front axle fill plug (1). 6. Inspect the oil level. The 9.25 inch axle the oil level should be between 0-6 mm (0-0.25 in) below the fill plug opening. 7. If the level is low, add oil until the level is between 0-6 mm (0-0.25 in) for the 9.25 inch axle. Use the correct fluid. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Specifications/Fluid Type Specifications). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 8. Install the fill plug and tighten to 33 Nm (24 lb ft). 9. Lower the vehicle. Rear Axle Lubricant Level Inspection (8.6, 9.5 LD Axle) Rear Axle Lubricant Level Inspection (8.6, 9.5 LD Axle) Note: All axle assemblies are filled by volume of fluid during production. They are not filled to reach a certain level. When checking the fluid level on any axle, variations in the readings can be caused by factory fill differences between the minimum and the maximum fluid volume. Also, if a vehicle has just been driven before checking the fluid level, it may appear lower than normal because the fluid has traveled out along the axle tubes and has not drained back to the sump area. Therefore, a reading taken five minutes after the vehicle has been driven will appear to have a lower fluid level than a vehicle that has been stationary for an hour or two. Remember that the rear axle assembly must be supported to get a true reading. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Ensure the vehicle is level. 3. Inspect the rear axle for leaks. Repair as necessary. 4. Clean the area around the rear axle fill plug. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Service and Repair > Procedures > Page 8298 5. Remove the rear axle fill plug. 6. Inspect the lubricant level: The lubricant level should be between 1-19 mm (0.04-0.75 in) below the fill plug opening for the 8.6 inch axle. The lubricant level should be between 15-40 mm (0.59-1.57 in) below the fill plug opening for the 9.5 inch LD axle. 7. If the level is low, add lubricant until the level is even with the bottom edge of the fill plug opening. Use the proper fluid. Refer to Fluid and Lubricant Recommendations (USA and Canada) (See: Maintenance). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 8. Install the rear axle fill plug and tighten to 33 Nm (24 lb ft). 9. Lower the vehicle. Rear Axle Lubricant Level Inspection (11.5 Inch Axle) Rear Axle Lubricant Level Inspection (11.5 Inch Axle) 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Make sure the vehicle is level. 3. Inspect the rear axle for leaks. Repair as necessary. 4. Clean the area around the rear axle fill plug. 5. Remove the rear axle fill plug and the seal. 6. Inspect the lubricant level. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Service and Repair > Procedures > Page 8299 The lubricant level should be between 17-21 mm (0.6-0.8 in) below the fill plug opening. 7. If the level is low, add lubricant until the level is between 17-21 mm (0.6-0.8 in) below the fill plug opening. Use the proper fluid. Refer to Fluid and Lubricant Recommendations (USA and Canada) (See: Maintenance). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 8. Install the rear axle fill plug and gasket. Tighten the rear axle fill plug to 33 Nm (24 lb ft). 9. Lower the vehicle. Rear Axle Lubricant Level Inspection (10.5 Inch Axle) Rear Axle Lubricant Level Inspection (10.5 Inch Axle) 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Make sure the vehicle is level. 3. Inspect the rear axle for leaks. Repair as necessary. 4. Clean the area around the rear axle fill plug. 5. Remove the rear axle fill plug. 6. Inspect the lubricant level. The lubricant level should be between 0-10 mm (0-0.4 in) below the fill plug opening. 7. If the level is low, add lubricant until the level is even with the bottom edge of the fill plug opening. Use the proper fluid. Refer to Fluid and Lubricant Recommendations (USA and Canada) (See: Maintenance). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 8. Install the rear axle fill plug. Tighten the rear axle fill plug to 33 Nm (24 lb ft). 9. Lower the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Service and Repair > Procedures > Page 8300 Fluid - Differential: Removal and Replacement Front Drive Axle Front Axle Lubricant Replacement Removal Procedure 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the engine shield, if equipped. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement). 3. Clean the area around the front axle fill plug and the drain plug. 4. Remove the fill plug. 5. Remove the drain plug. 6. Drain the fluid from the front differential carrier assembly. Installation Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the drain plug. Tighten the drain plug to 33 Nm (24 lb ft). 2. Fill the differential carrier assembly with axle lubricant. Use the correct fluid. Refer to Approximate Fluid Capacities (See: Maintenance/Specifications) and Adhesives, Fluids, Lubricants, and Sealers (See: Specifications/Fluid Type Specifications). 3. Install the fill plug. Tighten the fill plug to 33 Nm (24 lb ft). 4. Install the engine shield, if equipped. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement). 5. Lower the vehicle. Differential Oil Replacement (8.6 Inch Axle) Differential Oil Replacement (8.6 Inch Axle) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Service and Repair > Procedures > Page 8301 Removal Procedure 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Clean the area around the rear axle fill plug. 3. Remove the rear axle fill plug. 4. Remove the rear axle cover. Refer to Rear Axle Housing Cover and Gasket Replacement (8.6, 9.5 Inch Axles) ()Rear Axle Housing Cover and Gasket Replacement (10.5/11.5 Inch Axle) (). 5. Drain the lubricant into a suitable container. Installation Procedure 1. Install the rear axle cover. Refer to Rear Axle Housing Cover and Gasket Replacement (8.6, 9.5 Inch Axles) ()Rear Axle Housing Cover and Gasket Replacement (10.5/11.5 Inch Axle) (). 2. Fill the rear axle with axle lubricant. Use the proper fluid. Refer to Approximate Fluid Capacities (See: Maintenance/Specifications) and Adhesives, Fluids, Lubricants, and Sealers (See: Specifications/Fluid Type Specifications). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the rear axle fill plug and tighten to 33 Nm (24 lb ft). 4. Lower the vehicle. Differential Oil Replacement (9.5LD Inch Axle) Differential Oil Replacement (9.5LD Inch Axle) Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Service and Repair > Procedures > Page 8302 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the drain plug. 3. Remove the fill plug. Installation Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the drain plug and tighten to 33 Nm (24 lb ft). 2. Fill the rear drive axle. * Use the proper fluid, refer to Approximate Fluid Capacities (See: Maintenance/Specifications). * For the proper capacity, refer to Fluid and Lubricant Recommendations (USA and Canada) (See: Maintenance). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Service and Repair > Procedures > Page 8303 3. Install the fill plug and tighten to 33 Nm (24 lb ft). 4. Remove the support and lower the vehicle. Differential Oil Replacement (10.5 Inch Axle) Differential Oil Replacement (10.5 Inch Axle) Removal Procedure 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the fill plug (1). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Service and Repair > Procedures > Page 8304 3. Remove the rear axle drain plug (1). 4. Drain the lubricant into a suitable container. Installation Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the rear axle drain plug (1) and tighten to 33 Nm (24 lb ft). 2. Fill the rear axle with the proper fluid. Refer to Approximate Fluid Capacities (See: Maintenance/Specifications) and Fluid and Lubricant Recommendations (USA and Canada) (See: Maintenance). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Service and Repair > Procedures > Page 8305 3. Install the fill plug (1) and tighten to 33 Nm (24 lb ft). 4. Remove the support and lower the vehicle. Differential Oil Replacement (11.5 Inch Axle) Differential Oil Replacement (11.5 Inch Axle) Removal Procedure 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) in General Information. 2. Remove the fill plug. 3. Remove the rear axle drain plug. 4. Drain the lubricant into a suitable container. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Service and Repair > Procedures > Page 8306 5. Inspect the drain plug for excessive metal particle accumulation. This accumulation is symptomatic of extreme wear. 6. Clean the drain plug. Installation Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the rear axle drain plug and tighten to 33 Nm (24 lb ft). 2. Fill the rear axle. Use the proper fluid. Refer to Approximate Fluid Capacities (See: Maintenance/Specifications) and Fluid and Lubricant Recommendations (USA and Canada) (See: Maintenance) in Maintenance and Lubrication. 3. Install the fill plug and washer and tighten to 33 Nm (24 lb ft). 4. Lower the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential Output Shaft Bearing > Component Information > Adjustments Differential Output Shaft Bearing: Adjustments Inner Axle Shaft Shim Adjustment Special Tools * J 34672 Depth Micrometer * J 34673 Flat Gauge Bar * J 8001 Dial Indicator Set The front drive axle clutch gear shim needs to be measured and adjusted if any of the following parts are replaced: * The inner axle shaft * The inner axle shaft housing * The clutch shaft * The differential carrier case * The ring and pinion gears * The differential assembly * The differential bearings * The carrier connector Front drive axle clutch shims are available in the following sizes: 1. Install the inner axle bearing and the inner axle seal, if necessary. Refer to Front Drive Axle Inner Shaft Seal and Inner Shaft Bearing Replacement (See: Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential Output Shaft Bearing > Component Information > Adjustments > Page 8311 2. Install the following components into the inner axle shaft housing: 1. Install the inner axle shaft (1) into the inner axle shaft housing (4). 2. Install the thrust washer (with tabs) (5). Ensure the tabs on the thrust washer are aligned with the slots in the inner shaft housing. 3. Install the thrust washer (without tabs) (6). 4. Install the retaining ring (7) into the inner axle shaft (1). 3. Install the inner axle shaft housing into a vise. Clamp only on the mounting flange of the inner axle shaft housing. Note: In order to obtain an accurate measurement, the inner axle shaft must be moved outwards before measuring. 4. Push on the inner end of the inner axle shaft and move the shaft outboard as far as it will go. 5. Install the J 34673 (1) and the J 34672 (2) onto the inner shaft housing as shown. 6. Using the J 34672 , measure the distance from the edge of the inner axle shaft to the surface of the J 34673 . Ensure the base of the J 34672 is flat against the inner axle shaft. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential Output Shaft Bearing > Component Information > Adjustments > Page 8312 7. Using the J 34672 , measure the distance from the machined surface of the differential carrier housing to the outer surface of the front drive axle clutch shaft. 8. Subtract the measurement obtained in step 6 from the measurement obtained in step 7. This measurement is the distance between the inner axle shaft and the clutch shaft before subtracting the J 34673 . 9. Using a micrometer, measure the thickness of the J 34673 . 10. Subtract the thickness of the J 34673 , measured in step 9, from the measurement determined in step 8. This is the shim thickness for the front axle without having any axle shaft endplay. 11. The correct shim size will be one size smaller than the figure obtained in the previous step. Note the following examples: * If the figure obtained in step 8 was 3.53 mm (0.139 in), use a 3.30 mm (0.130 in) shim. * If the figure obtained in step 8 was 3.30 mm (0.130 in), use a 3.05 mm (0.120 in) shim. Alternate Adjustment Method Note: Use this method only if the proper tools for calculating the shim size are unavailable. 1. Install the original shim to the shaft. Use the chassis grease in order to hold the shim in place. 2. Install the inner axle housing assembly to the differential carrier case. Do not use sealer at this time. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the bolts and tighten to 40 Nm (30 lb ft). 4. Measure the shaft end play using the following procedure: 1. Install the J 8001 or the equivalent on the axle tube end. The plunger of the indicator must be at a right angle to the axle flange. 2. Move the shaft back and forth and read the end play. The correct end play is 0.03-0.51 mm (0.001-0.020 in). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential Output Shaft Bearing > Component Information > Adjustments > Page 8313 3. If the end play is incorrect, install a thicker or thinner shim as needed in order to bring the end play into the specified range. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential Output Shaft Bearing > Component Information > Adjustments > Page 8314 Differential Output Shaft Bearing: Service and Repair Front Drive Axle Inner Shaft Seal and Inner Shaft Bearing Replacement Special Tools * J 8092 Universal Driver Handle - 3/4 in - 10 * J 2619-01 Slide Hammer * J 29369-1 Bushing and Bearing Remover * J 29369-2 Bushing and Bearing Remover (2-3 inch) * J 36609 Axle Tube Bearing Installer * J 45225 Axle Seal Installer Removal Procedure 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Drain the differential carrier assembly. Refer to Front Axle Lubricant Replacement (See: Fluid - Differential/Service and Repair/Removal and Replacement). 3. Remove the right side seal and/or bearing by performing the following steps: 1. Remove the inner axle shaft and housing assembly from the differential carrier case assembly. Refer to Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement (8.25 F4WD Axle) (See: Service and Repair)Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement (8.25 S4WD and 9.25 Axles) (See: Service and Repair). 2. Remove the clutch fork assembly components and the inner axle shaft from the inner axle shaft housing. Refer to Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement (8.25 F4WD Axle) (See: Service and Repair)Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement (8.25 S4WD and 9.25 Axles) (See: Service and Repair). 3. Install the inner axle shaft housing into a vise. Clamp only on the mounting flange of the inner axle shaft housing. 4. Install the J 29369-1 , 8.25 inch axle, or the J 29369-2 , 9.25 inch axle, behind the inner axle shaft seal or the inner axle shaft bearing as necessary. 5. Install the J 2619-01 (2) to the J 29369-1 or the J 29369-2 (1). 6. Remove the inner axle shaft seal and/or the inner axle shaft bearing using the J 2619-01 . Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential Output Shaft Bearing > Component Information > Adjustments > Page 8315 Note: Support the wheel drive shaft in order to not over flex the CV joint. 4. If only replacing the left side seal, perform the following steps: 1. Place an alignment mark between the inner axle shaft and the wheel drive shaft. 2. If servicing the 8.25 inch axle, remove the shock module. Refer to Shock Absorber and Spring Assembly Replacement (See: Steering and Suspension/Suspension/Suspension Strut / Shock Absorber/Service and Repair/Front Suspension Shock Absorber/Shock Absorber and Spring Assembly Replacement). 3. Disconnect the wheel drive shaft from the inner axle shaft. 4. Remove the inner axle shaft using a hammer and a brass drift. 5. Remove the inner axle shaft seal using a suitable seal remover tool. 5. If replacing both the left side seal and bearing, perform the following steps: 1. Remove the differential carrier assembly. Refer to Differential Carrier Assembly Replacement (1500 FWD) (See: Service and Repair )Differential Carrier Assembly Replacement (2500 4WD) (See: Service and Repair). 2. Place the differential carrier assembly into a vise. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential Output Shaft Bearing > Component Information > Adjustments > Page 8316 Clamp only on the mounting flange of the differential carrier assembly case. 3. Remove the inner axle shaft using a hammer and a brass drift. 4. Install the J 29369-1 , 8.25 inch axle, or the J 29369-2 , 9.25 inch axle (1), behind the inner axle shaft seal or the inner axle shaft bearing as necessary. 5. Install the J 2619-01 (2) to the J 29369-1 or the J 29369-2 . 6. Remove the inner axle shaft seal and/or the inner axle shaft bearing using the J 2619-01 . Installation Procedure 1. Install the right side bearing with the square shoulder in using the J 36609 (1) and the J 8092 (2). 2. Install the new axle shaft seal using the J 45225 (1) and the J 8092 (2). 3. Install the inner axle shaft into the inner axle shaft housing. Carefully tap the inner axle shaft into place with a soft-faced mallet. 4. Install the inner axle shaft and clutch fork assembly components into the inner shaft housing. Refer to Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement (8.25 F4WD Axle) (See: Service and Repair)Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement (8.25 S4WD and 9.25 Axles) (See: Service and Repair). 5. Install the inner axle shaft and housing assembly to the differential carrier case assembly. Refer to Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement (8.25 F4WD Axle) (See: Service and Repair)Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement (8.25 S4WD and 9.25 Axles) (See: Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential Output Shaft Bearing > Component Information > Adjustments > Page 8317 6. If both the left side bearing and seal was removed, perform the following step. Install the left side bearing with the square shoulder in using the J 36609 (1) and the J 8092 (2). 7. If both the left side bearing and seal was removed, perform the following step. Install the new axle shaft seal using the J 45225 (1) and the J 8092 (2). 8. If both the left side bearing and seal was removed, perform the following step. Install the inner axle shaft into the differential case side gear using a soft-faced mallet until the retaining ring on the inner axle shaft is fully seated within the groove in the differential case side gear. Pull back on the inner axle shaft to ensure that the inner axle shaft is properly retained in the differential case side gear. 9. If both the left side bearing and seal was removed, perform the following step. Install the front differential carrier assembly. Refer to Differential Carrier Assembly Replacement (1500 FWD) (See: Service and Repair)Differential Carrier Assembly Replacement (2500 4WD) (See: Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential Output Shaft Bearing > Component Information > Adjustments > Page 8318 10. If only the left side seal was removed, perform the following step. Install the seal using the J 45225 and a soft-faced mallet. Tap only on the center portion of the J 45225 in order to drive the seal in evenly. 11. If only the left side seal was removed, perform the following step. Install the inner axle shaft into the differential case side gear using a soft-faced mallet until the retaining ring on the inner axle shaft is fully seated within the groove in the differential case side gear. Pull back on the inner axle shaft to ensure that the inner axle shaft is properly retained in the differential case side gear. 12. If servicing the 8.25 inch axle, install the shock module. Refer to Shock Absorber and Spring Assembly Replacement (See: Steering and Suspension/Suspension/Suspension Strut / Shock Absorber/Service and Repair/Front Suspension Shock Absorber/Shock Absorber and Spring Assembly Replacement). 13. If only the left side seal was removed, perform the following step. Install the wheel drive shaft to the inner axle shaft. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 14. If only the left side seal was removed, perform the following step. Install the wheel drive shaft to the inner axle shaft bolts and tighten to 79 Nm (58 lb ft). 15. Fill the differential carrier assembly. Use the correct fluid. Refer to Front Axle Lubricant Replacement (See: Fluid - Differential/Service and Repair/Removal and Replacement). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Output Shaft, Differential > Differential Output Shaft Bearing > Component Information > Adjustments > Page 8319 16. Lower the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > Differential Drive Pinion Gear Bearing Replacement (8.6, 9.5, 11.5 Inch Axle) Pinion Bearing: Service and Repair Differential Drive Pinion Gear Bearing Replacement (8.6, 9.5, 11.5 Inch Axle) Differential Drive Pinion Gear Bearing Replacement (8.6, 9.5, 11.5 Inch Axle) Special Tools * DT 47688 - Pinion Bearing Remover * J 7818 - Inner Bearing race Installer * J 8092 - Universal Driver Handle 3/4-10 * J 8611-01 - Pinion Bearing Cup Installer * J 8614-01 - Flange Holder and Remover * J 22306 - Bearing Race Installer * J 22828 - Input Shaft Gear Installer * J 22912 - Bearing Remover * J 36614 - Inner Pinion Bearing Installer * J 45870 - Inner Pinion Bearing Race Installer Disassemble Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the differential assembly. Refer to Differential Replacement (8.6, 9.5/9.5 LD Inch Axles) ()Differential Replacement (10.5 Inch, 11.5 Inch Axle) (). 3. Remove the drive pinion from the axle. Refer to Drive Pinion and Ring Gear Replacement (8.6, 9.5/9.5 LD, and 11.5 Inch Axles) ()Drive Pinion and Ring Gear Replacement (10.5 Inch Axle) (See: Pinion Gear/Service and Repair/Drive Pinion and Ring Gear Replacement (10.5 Inch Axle)). Note: Step 4 is for those vehicles equipped with the 8.6 inch axle. 4. Using the DT 47688 - remover and a press, remove the bearing from the drive pinion. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > Differential Drive Pinion Gear Bearing Replacement (8.6, 9.5, 11.5 Inch Axle) > Page 8324 Note: Step 5 is for those vehicles equipped with the 9.5 LD inch axle. 5. Using the J 22912 - remover and a press, remove the differential pinion bearing. 6. Remove the shim (1). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > Differential Drive Pinion Gear Bearing Replacement (8.6, 9.5, 11.5 Inch Axle) > Page 8325 Note: Move the drift back and forth between one side of the cup and the other in order to work the cups out of the housing evenly. 7. Using a hammer and a brass drift in the slots provided, remove the outer pinion bearing cup from the axle housing. Note: Move the drift back and forth between one side of the cup and the other in order to work the cups out of the housing evenly. 8. Using a hammer and a brass drift in the slots provided, remove the inner pinion bearing cup from the axle housing. Assemble Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > Differential Drive Pinion Gear Bearing Replacement (8.6, 9.5, 11.5 Inch Axle) > Page 8326 1. Using the J 8611-01 - installer , 8.6 inch axle, or the J 7818 - installer , 9.5/9.5LD inch axle (1), and the J 8092 (2), install the outer pinion bearing cup. 2. Using the J 45870 , 8.6 inch axle, or the J 22306 , 9.5/9.5LD inch axle (2), and the J 8092 (1), install the inner pinion bearing cup. 3. Determine the selective shim thickness for the drive pinion. Refer to Pinion Depth Adjustment (8.6, 9.5/9.5 LD and 11.5 Inch Axles) ()Pinion Depth Adjustment (10.5 Inch Axle) (). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > Differential Drive Pinion Gear Bearing Replacement (8.6, 9.5, 11.5 Inch Axle) > Page 8327 4. Install the selective shim (1) on the shoulder on the differential pinion gear (2). Note: Press the bearing on until the cone seats on the pinion shim. 5. Using the J 22828 - installer or the J 36614 - installer , install the inner pinion bearing. 6. Install a new collapsible spacer. 7. Lubricate the pinion bearings with axle lubricant. Use the proper fluid. Refer to Fluid and Lubricant Recommendations (USA and Canada) (See: Maintenance). 8. Install the outer pinion bearing into the axle housing. 9. Install the differential pinion gear into the axle housing. Note: DO NOT re-use the old pinion nut, replace with NEW only. 10. Install the NEW differential pinion oil seal, flange/yoke, and the NEW nut and washer. Refer to Drive Pinion Flange/Yoke and/or Oil Seal Replacement (See: Pinion Flange/Service and Repair/Rear Drive Axle). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > Differential Drive Pinion Gear Bearing Replacement (8.6, 9.5, 11.5 Inch Axle) > Page 8328 11. Using an inch-pound torque wrench, measure the rotating torque of the pinion should be between 1.0-2.3 Nm (10-20 lb in) for used bearings, or 1.7-3.4 Nm (15-30 lb in) for new bearings. 12. If the rotating torque measurement is below 1.0 Nm (10 lb in) for used bearings, or 1.7 Nm (15 lb in) for new bearings, continue to tighten the pinion nut in small increments, until the torque required in order to rotate the pinion is between 1.0-2.3 Nm (10-20 lb in) for used bearings, or 1.7-3.4 Nm (15-30 lb in) for new bearings. 13. Once the specified torque is obtained, rotate the pinion several times to ensure the bearings have seated. 14. Recheck the rotating torque of the pinion bearing and adjust if necessary. 15. Install the differential assembly. Refer to Differential Replacement (8.6, 9.5/9.5 LD Inch Axles) ()Differential Replacement (10.5 Inch, 11.5 Inch Axle) (). 16. Fill the axle with lubricant. Use the proper fluid. Refer to Differential Oil Replacement (10.5 Inch Axle) (See: Fluid - Differential/Service and Repair/Removal and Replacement)Differential Oil Replacement (11.5 Inch Axle) (See: Fluid Differential/Service and Repair/Removal and Replacement)Differential Oil Replacement (8.6 Inch Axle) (See: Fluid - Differential/Service and Repair/Removal and Replacement)Differential Oil Replacement (9.5LD Inch Axle) (See: Fluid - Differential/Service and Repair/Removal and Replacement). 17. Remove the support and lower the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > Differential Drive Pinion Gear Bearing Replacement (8.6, 9.5, 11.5 Inch Axle) > Page 8329 Pinion Bearing: Service and Repair Differential Drive Pinion Gear Bearing Replacement (10.5 Inch Axle) Differential Drive Pinion Gear Bearing Replacement (10.5 Inch Axle) Special Tools * J 8092 - Universal Driver Handle - 3/4 in - 10 * J 8608 - Pinion Bearing Cup Installer * J 8614-01 - Flange Holder and Remover * J 22761 - Side Bearing Installer * J 22912-B - Bearing Remove * J 24433 - Pinion Bearing Installer * J 37624 - Pinion Bearing Installer * J 44414 - Pinion Oil Seal Installer For equivalent regional tools, refer to Special Tools (See: Tools and Equipment/Rear Drive Axle). Removal Procedure 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the differential assembly. Refer to Differential Replacement (8.6, 9.5/9.5 LD Inch Axles) ()Differential Replacement (10.5 Inch, 11.5 Inch Axle) (). 3. Remove the pinion gear bearing retainer. Refer to Differential Drive Pinion Gear Bearing Replacement (8.6, 9.5, 11.5 Inch Axle) (See: Differential Drive Pinion Gear Bearing Replacement (8.6, 9.5, 11.5 Inch Axle))Differential Drive Pinion Gear Bearing Replacement (10.5 Inch Axle) . 4. Remove the pinion yoke and the oil seal. Refer to Drive Pinion Flange/Yoke and/or Oil Seal Replacement (See: Pinion Flange/Service and Repair/Rear Drive Axle). 5. Remove the outer pinion bearing. 6. Using an hydraulic press and the appropriate supports, remove the differential pinion gear. 7. Remove the collapsible spacer. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > Differential Drive Pinion Gear Bearing Replacement (8.6, 9.5, 11.5 Inch Axle) > Page 8330 8. Using the J 22912-B - remover and a hydraulic press, remove the inner pinion bearing from the differential pinion gear. Note: * Insert the brass drift in the slots to remove the bearing cup. * Move the drift back and forth between one side of the cup and the other in order to work the cups out of the retainer evenly. 9. Using a hammer and a brass drift, remove the outer pinion bearing cup. Note: * Insert the brass drift in the slots to remove the bearing cup. * Move the drift back and forth between one side of the cup and the other in order to work the cups out of the retainer evenly. 10. Using a hammer and a brass drift, remove the inner pinion bearing cup. 11. Using a brass drift and a hammer, remove the pinion gear pilot bearing. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > Differential Drive Pinion Gear Bearing Replacement (8.6, 9.5, 11.5 Inch Axle) > Page 8331 Installation Procedure 1. Position the drive pinion pilot gear bearing (1) in the differential housing. 2. Using the J 22761 - installer (1) and the J 8092 - driver (2), install the drive pinion gear pilot bearing in the differential housing (3). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > Differential Drive Pinion Gear Bearing Replacement (8.6, 9.5, 11.5 Inch Axle) > Page 8332 3. Using the J 37624 - installer (2) and the J 8092 - driver (1), install the inner pinion bearing cup in the pinion gear bearing retainer. 4. Using the J 8608 - installer (2) and the J 8092 - driver (1), install the outer pinion bearing cup in the pinion gear bearing retainer. Note: Press the bearing on until the cone seats on the pinion. 5. Using the J 24433 - installer and a hydraulic press, install the inner pinion bearing. 6. Install the new collapsible spacer. 7. Lubricate the pinion bearings with axle lubricant. Refer to Fluid and Lubricant Recommendations (USA and Canada) (See: Maintenance). 8. Install the outer pinion bearing into the pinion bearing retainer. 9. Using the J 44414 - installer , install the new pinion oil seal. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > Differential Drive Pinion Gear Bearing Replacement (8.6, 9.5, 11.5 Inch Axle) > Page 8333 10. Install the pinion in the pinion gear bearing retainer. 11. Install the drive pinion flange/yoke. Refer to Drive Pinion Flange/Yoke and/or Oil Seal Replacement (See: Pinion Flange/Service and Repair/Rear Drive Axle). Note: Do not apply sealant to the pinion gear bearing retainer at this time. 12. Install the original shim to the pinion bearing retainer. If the original shim is not available, install a 0.41 mm (0.016 in) shim to build pinion depth. 13. Install the pinion gear bearing retainer to the axle housing. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 14. Install the pinion bearing retainer bolts and tighten to 88 Nm (65 lb ft). 15. Using an inch-pound torque wrench, measure the rotational torque of the pinion it should be between 1.0-2.3 Nm (10-20 lb in) for used bearings, or 1.7-3.4 Nm (15-30 lb in) for new bearings. 16. If the rotating torque measurement is below 1.0 Nm (10 lb in) for used bearings, or 1.7 Nm (15 lb in) for new bearings, use the J 8614-01 remover and continue to tighten the pinion nut in small increments until the rotational torque is between 1.0-2.3 Nm (10-20 lb in) for used bearings, or 1.7-3.4 Nm (15-30 lb in) for new bearings. 17. Once the specified torque is obtained, rotate the pinion several times to ensure the bearings have seated. Recheck the rotating torque and adjust if necessary. 18. Install the differential assembly. Refer to Differential Replacement (8.6, 9.5/9.5 LD Inch Axles) ()Differential Replacement (10.5 Inch, 11.5 Inch Axle) (). 19. Adjust the differential side bearing preload. Refer to Differential Carrier Bearing Preload Adjustment (8.6 Inch Axle) ()Differential Carrier Bearing Preload Adjustment (10.5/11.5 Inch Axles) (). 20. Determine the selective shim thickness for the drive pinion. Refer to Pinion Depth Adjustment (8.6, 9.5/9.5 LD and 11.5 Inch Axles) ()Pinion Depth Adjustment (10.5 Inch Axle) (). 21. Adjust the backlash. Refer to Backlash Adjustment (8.6 Inch Axle) ()Backlash Adjustment (10.5/11.5 Inch Axle) ()Backlash Adjustment (9.5 LD Axle) (). 22. Fill the axle with lubricant. Refer to Differential Oil Replacement (10.5 Inch Axle) (See: Fluid Differential/Service and Repair/Removal and Replacement)Differential Oil Replacement (11.5 Inch Axle) (See: Fluid - Differential/Service and Repair/Removal and Replacement)Differential Oil Replacement (8.6 Inch Axle) (See: Fluid Differential/Service and Repair/Removal and Replacement)Differential Oil Replacement (9.5LD Inch Axle) (See: Fluid - Differential/Service and Repair/Removal and Replacement). 23. Remove the support and lower the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Front Drive Axle Pinion Flange: Service and Repair Front Drive Axle Front Differential Drive Pinion Gear Yoke Replacement Special Tools * J 8614-01 Flange and Pulley Holding Tool * J 36366 Pinion Oil Seal Installer Removal Procedure 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Drain the drive axle. Refer to Front Axle Lubricant Replacement (See: Fluid - Differential/Service and Repair/Removal and Replacement). 3. Remove the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 4. Remove the brake calipers. Refer to Front Brake Caliper Replacement (JD9, JF3, JF7, JG4) (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Front Brake Caliper Replacement (JD9, JF3, JF7, JG4))Front Brake Caliper Replacement (JH6, JH7) (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Front Brake Caliper Replacement (JH6, JH7)). 5. Remove the engine shield, if equipped. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement). 6. Reference mark the relationship of the propeller shaft to the front axle pinon yoke. 7. Remove the yoke retainer bolts (6) and the yoke retainers (7) from the front axle pinion yoke (1). Caution: When removing the propeller shaft, do not attempt to remove the shaft by pounding on the yoke ears or using a tool between the yoke and the universal joint. If the propeller shaft is removed by using such means, the injection joints may fracture and lead to premature failure of the joint. 8. Disconnect the propeller shaft universal joint (2) from the front axle pinion yoke (1). Wrap the bearing caps with tape in order to prevent the loss of bearing rollers. 9. Support the propeller shaft and move out of the way as necessary. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Front Drive Axle > Page 8338 10. Measure the torque required in order to rotate the pinion. Use an inch-pound torque wrench. Record the torque value for reassembly. This will give the combined preload for the following components: * The pinion bearings * The pinion seal * The carrier bearings * The axle bearings * The axle seals 11. Scribe an alignment line between the pinion shaft and the pinion yoke. 12. Install the J 8614-01 onto the pinion as shown. 13. Remove the pinion nut while holding the J 8614-01 . Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Front Drive Axle > Page 8339 14. Install the J 8614-2 (2) and the J 8614-3 (3) into the J 8614-01 (1) as shown. 15. Remove the pinon yoke by turning the J 8614-3 (3) clockwise while holding the J 8614-01 (1). Note: Carefully remove the oil seal from the bore. Do not distort or scratch the aluminum case. 16. Remove the oil seal using a suitable seal removal tool. Installation Procedure 1. Install the oil seal by doing the following: 1. Position the oil seal over the seal bore. 2. Install the J 36366 over the oil seal. 3. Strike the J 36366 with a hammer until the seal flange seats on the axle housing surface. 2. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the splines of the drive pinion yoke. 3. Install the pinion yoke. Align the reference marks made during removal. Caution: Refer to Pinion Flange/Yoke Installation Caution (See: Service Precautions/Vehicle Damage Warnings/Pinion Flange/Yoke Installation Caution). 4. Seat the pinion yoke onto the pinion shaft by tapping it with a soft-faced hammer until a few pinion shaft threads show through the yoke. 5. Install the washer and a new pinion nut. 6. Install the J 8614-01 onto the pinion yoke as shown. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Front Drive Axle > Page 8340 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Note: If the rotating torque is exceeded, the pinion will have to be removed and a new collapsible spacer installed. 7. Tighten the pinion nut while holding the J 8614-01 . Tighten the pinion nut until the pinion end play is just taken up. Rotate the pinion while tightening the nut to seat the bearings. 8. Measure the rotating torque of the pinion using an inch-pound torque wrench. Compare the measurement with the rotating torque recorded earlier. Tighten the pinion nut, in small increments, as needed, until the torque required in order to rotate the pinion is 0.40-0.57 Nm (3-5 lb in) greater than the torque recorded during removal. 9. Once the specified torque is obtained, rotate the pinion several times to ensure the bearings have seated. Recheck the rotating torque and adjust if necessary. 10. Install the propeller shaft universal joint (2) to the pinion yoke (1). Align the reference marks made during removal. 11. Install the yoke retainers (7) and the yoke retainer bolts (6) to the pinion yoke (1). Tighten the yoke retainer bolts to 25 Nm (18 lb ft). 12. Inspect the axle lubricant level, and add, if necessary. Refer to Front Axle Lubricant Level Inspection (9.25 Inch Axle) (See: Fluid Differential/Service and Repair/Procedures/Front Drive Axle). 13. Install the engine shield, if equipped. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement). 14. Install the brake calipers. Refer to Front Brake Caliper Replacement (JD9, JF3, JF7, JG4) (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Front Brake Caliper Replacement (JD9, JF3, JF7, JG4))Front Brake Caliper Replacement (JH6, JH7) (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Front Brake Caliper Replacement (JH6, JH7)). 15. Fill the drive axle. Refer to Front Axle Lubricant Replacement (See: Fluid - Differential/Service and Repair/Removal and Replacement). 16. Install the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair ). 17. Lower the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Front Drive Axle > Page 8341 Pinion Flange: Service and Repair Rear Drive Axle Drive Pinion Flange/Yoke and/or Oil Seal Replacement Special Tools * J 8614-01 - Flange Holder and Remover * J 22388 - Pinion Oil Seal Installer * J 44414 - Pinion Oil Seal Installer Removal Procedure Note: Observe and mark the positions of all the driveline components, relative to the propeller shaft and the axles, prior to disassembly. These components include the propeller shafts, drive axles, pinion flanges, output shafts, etc. Reassemble all the components in the exact places in which you removed the parts. Follow any specifications, torque values, and any measurements made prior to disassembly. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the rear tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 3. Remove the rear brake drum, if equipped. Refer to Brake Drum Replacement (See: Brakes and Traction Control/Drum Brake System/Brake Drum/Service and Repair/Removal and Replacement). 4. Remove the rear disc brake rotor, if equipped. Refer to Rear Brake Rotor Replacement (JD9) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JD9))Rear Brake Rotor Replacement (JH6) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JH6))Rear Brake Rotor Replacement (JH7) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JH7)). Note: The following procedure is for the 10.5 or 11.5 inch axles. 5. Remove the rear axle shafts. Refer to Rear Axle Shaft and/or Gasket Replacement (See: Drive Axles, Bearings and Joints/Seals and Gaskets/Service and Repair/Rear Axle Shaft and/or Gasket Replacement). Note: Reference mark the rear propeller shaft to the rear axle pinion yoke. 6. Remove the propeller shaft. * For vehicles equipped the a one piece propeller shaft, refer to One-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/One-Piece Propeller Shaft Replacement). * For vehicles equipped with a two piece propeller shaft, refer to Two-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Two-Piece Propeller Shaft Replacement). Note: Record this measurement for reassembly. 7. Using an inch-pound torque wrench, measure the rotational torque of the differential ring and pinion gear and related components. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Front Drive Axle > Page 8342 8. Place an alignment mark between the pinion and the pinion yoke. Note: * DO NOT reuse the pinion nut, replace with NEW. * For the 11.5 inch axle, use J-34826 socket. 9. Using the J 8614-01 - holder and remover or the J-34826 socket, remove and discard the pinion the pinion nut. Note: Remove the pinion yoke by turning the J 8614-3 (3) clockwise. 10. Using the J 8614-2 (2), J 8614-3 (3) and the J 8614-01 - remover (1), remove the pinion yoke. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Front Drive Axle > Page 8343 Note: DO NOT damage the axle housing. 11. Using a suitable tool, remove the pinion oil seal. Installation Procedure 1. Using the J 22388 - installer , install the new pinion oil seal. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Front Drive Axle > Page 8344 2. Apply the proper sealant to the splines of the pinion yoke. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Fluid Differential/Specifications/Fluid Type Specifications). 3. Align the reference marks and install the pinion yoke. Caution: Refer to Pinion Flange/Yoke Installation Caution (See: Service Precautions/Vehicle Damage Warnings/Pinion Flange/Yoke Installation Caution). Note: Tap the pinion yoke until a few threads show through the pinion yoke. 4. Using a soft faced hammer, seat the pinion yoke onto the pinion shaft. 5. Install the washer and a NEW pinion nut. Note: * If the rotating torque is exceeded, the pinion will have to be removed and a new collapsible spacer installed. * For the 11.5 inch axle, use J-34826 socket. 6. Holding the J 8614-01 - holder or the J-34826 socket, tighten the pinion nut until the pinion end play is just taken up. 7. Rotate the pinion while tightening the nut to seat the bearings. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Front Drive Axle > Page 8345 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Note: Compare this measurement with the rotating torque recorded during removal. 8. Using an inch pound torque wrench and tightening in small increments, measure the rotating torque of the pinion until the reading is greater than 0.40-0.57 Nm (3-5 lb in) , the rotational torque noted at removal. Note: Recheck the rotating torque and adjust if necessary. 9. Once the specified torque is obtained, rotate the pinion several times to seat the bearings. Note: Reference mark the rear propeller shaft to the rear axle pinion yoke. 10. Install the propeller shaft. * For vehicles equipped the a one piece propeller shaft, refer to One-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/One-Piece Propeller Shaft Replacement). * For vehicles equipped with a two piece propeller shaft, refer to Two-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Two-Piece Propeller Shaft Replacement). Note: The following procedure is for the 10.5 or 11.5 inch axles. 11. Install the rear axle shafts. Refer to Rear Axle Shaft and/or Gasket Replacement (See: Drive Axles, Bearings and Joints/Seals and Gaskets/Service and Repair/Rear Axle Shaft and/or Gasket Replacement). 12. Install the rear brake drum, if equipped. Refer to Brake Drum Replacement (See: Brakes and Traction Control/Drum Brake System/Brake Drum/Service and Repair/Removal and Replacement). 13. Install the rear disc brake rotor, if equipped. Refer to Rear Brake Rotor Replacement (JD9) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JD9))Rear Brake Rotor Replacement (JH6) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JH6))Rear Brake Rotor Replacement (JH7) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JH7)). 14. Install the rear tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 15. Inspect and add axle lubricant to the axle housing, if necessary. Refer to Rear Axle Lubricant Level Inspection (8.6, 9.5 LD Axle) (See: Fluid Differential/Service and Repair/Procedures/Rear Drive Axle/Rear Axle Lubricant Level Inspection (8.6, 9.5 LD Axle))Rear Axle Lubricant Level Inspection (10.5 Inch Axle) (See: Fluid Differential/Service and Repair/Procedures/Rear Drive Axle/Rear Axle Lubricant Level Inspection (10.5 Inch Axle))Rear Axle Lubricant Level Inspection (11.5 Inch Axle) (See: Fluid Differential/Service and Repair/Procedures/Rear Drive Axle/Rear Axle Lubricant Level Inspection (11.5 Inch Axle)). 16. Remove the support and lower the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Front Drive Axle > Page 8346 Pinion Flange: Service and Repair Allison - Automatic Transmission Differential Drive Pinion Gear Yoke Replacement Removal Procedure 1. Place the transmission in the Park (P) selector position. Warning Apply the parking brake and block the drive wheels before performing this procedure in order to prevent bodily injury. 2. Apply the parking brake and chock the wheels to prevent vehicle movement. 3. Remove the vehicle driveline from the transmission yoke assembly (1). Refer to Transmission Replacement (See: Automatic Transmission/Transaxle/Service and Repair). Remove the bolt (3) and seal-ring washer (2). 4. Remove the yoke assembly (1). Note: Do the following prior to installation of the yoke assembly: * Be sure the yoke, output shaft and retaining hardware are clean. * Verify the output seal is free of tears or cuts. * DO NOT attempt to remove scratches from the output seal journal on the yoke assembly. Repair may produce machine lead and leakage. 5. Inspect the yoke assembly and replace it whenever there are nicks or scratches on the seal journal or on the lead-in chamfer just ahead of the seal journal. Installation Procedure 1. Lubricate the internal splines and the rear seal journal of the yoke assembly with clean transmission fluid. 2. Install the yoke assembly (1) onto the transmission output shaft. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the bolt (3) and seal-ring washer (2). Tighten the bolt to 123 Nm (91 lb ft). 4. Attach the vehicle driveline to the transmission yoke assembly. Refer to Transmission Replacement (See: Automatic Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > Front Drive Axle > Page 8347 Transmission/Transaxle/Service and Repair). 5. Be sure the selector is in the Park (P) position. 6. Remove the wheel chocks before continuing operation of the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Drive Pinion Housing and/or Seal Replacement Pinion Gear: Service and Repair Drive Pinion Housing and/or Seal Replacement Drive Pinion Housing and/or Seal Replacement Special Tools * J 8092 - Universal Driver Handle 3/4 x 10 inch * J 8608 - Pinion bearing Cup Installer * J 24433 - Pinion Bearing Installer * J 37624 - Pinion Bearing Installer * J 44414 - Pinion Oil Seal Installer Removal Procedure Note: Observe and mark the positions of all the driveline components, relative to the propeller shaft and the axles, prior to disassembly. These components include the propeller shafts, drive axles, pinion flanges, output shafts, etc. Reassemble all the components in the exact places in which you removed the parts. Follow any specifications, torque values, and any measurements made prior to disassembly. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Drain the axle lubricant. Refer to Differential Oil Replacement (10.5 Inch Axle) (See: Fluid - Differential/Service and Repair/Removal and Replacement)Differential Oil Replacement (11.5 Inch Axle) (See: Fluid - Differential/Service and Repair/Removal and Replacement)Differential Oil Replacement (8.6 Inch Axle) (See: Fluid Differential/Service and Repair/Removal and Replacement)Differential Oil Replacement (9.5LD Inch Axle) (See: Fluid - Differential/Service and Repair/Removal and Replacement). 3. Remove the rear axle shafts. Refer to Rear Axle Shaft and/or Gasket Replacement (See: Drive Axles, Bearings and Joints/Seals and Gaskets/Service and Repair/Rear Axle Shaft and/or Gasket Replacement). 4. Remove the rear propeller shaft. * For vehicles equipped with the one piece propeller shaft, refer to One-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/One-Piece Propeller Shaft Replacement). * For vehicles equipped with the two piece propeller shaft, refer to Two-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Two-Piece Propeller Shaft Replacement). 5. Remove the drive pinion flange/yoke and/or oil seal. Refer to Drive Pinion Flange/Yoke and/or Oil Seal Replacement (See: Pinion Flange/Service and Repair/Rear Drive Axle). 6. Using a hydraulic press and an appropriate tool, remove the pinion. 7. Remove the collapsible spacer. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Drive Pinion Housing and/or Seal Replacement > Page 8352 Note: When performing the following service procedure, move the drift back and forth between one side of the cup and the other in order to work the cups out of the retainer evenly. 8. Using a hammer and a brass drift in the slots provided, remove the outer pinion bearing cup. Note: When performing the following service procedure, move the drift back and forth between one side of the cup and the other in order to work the cups out of the retainer evenly. 9. Using a hammer and a brass drift in the slots provided, remove the inner pinion bearing cup. Installation Procedure 1. Using the J 37624 (2) and the J 8092 (1), Install the inner pinion bearing cup into the pinion gear bearing retainer. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Drive Pinion Housing and/or Seal Replacement > Page 8353 2. Using the J 8608 (2) and the J 8092 (1), install the outer pinion bearing cup into the pinion gear bearing retainer. 3. Apply sealant to surface of the selective shim. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Fluid - Differential/Specifications/Fluid Type Specifications). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the pinion gear bearing retainer and bolts tighten to 88 Nm (65 lb ft). 5. Install the drive pinion flange/yoke and/or oil seal. Refer to Drive Pinion Flange/Yoke and/or Oil Seal Replacement (See: Pinion Flange/Service and Repair/Rear Drive Axle). 6. Install the propeller shaft. * For vehicles equipped with the one piece propeller shaft, refer to One-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/One-Piece Propeller Shaft Replacement). * For vehicles equipped with the two piece propeller shaft, refer to Two-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Two-Piece Propeller Shaft Replacement). 7. Install the rear axle shafts. Refer to Rear Axle Shaft and/or Gasket Replacement (See: Drive Axles, Bearings and Joints/Seals and Gaskets/Service and Repair/Rear Axle Shaft and/or Gasket Replacement). 8. Fill the axle with axle lubricant. Refer to Differential Oil Replacement (10.5 Inch Axle) (See: Fluid - Differential/Service and Repair/Removal and Replacement)Differential Oil Replacement (11.5 Inch Axle) (See: Fluid - Differential/Service and Repair/Removal and Replacement )Differential Oil Replacement (8.6 Inch Axle) (See: Fluid Differential/Service and Repair/Removal and Replacement)Differential Oil Replacement (9.5LD Inch Axle) (See: Fluid - Differential/Service and Repair/Removal and Replacement). 9. Remove the support and lower the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Drive Pinion Housing and/or Seal Replacement > Page 8354 Pinion Gear: Service and Repair Drive Pinion and Ring Gear Replacement (10.5 Inch Axle) Drive Pinion and Ring Gear Replacement (10.5 Inch Axle) Removal Procedure 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the differential case assembly. Refer to Differential Replacement (8.6, 9.5/9.5 LD Inch Axles) ()Differential Replacement (10.5 Inch, 11.5 Inch Axle) (). 3. Remove the drive pinion housing assembly. Refer to Drive Pinion Housing and/or Seal Replacement (See: Drive Pinion Housing and/or Seal Replacement). 4. Remove and discard the gear bolts. Replace with NEW only. Caution: Refer to Ring Gear Removal Caution (See: Service Precautions/Vehicle Damage Warnings/Ring Gear Removal Caution). 5. Using a brass drift and a hammer, remove the ring gear from the differential case. Installation Procedure 1. If the differential case has become separated, assemble the differential case by aligning the two arrows inside the differential case. Note: The mating surface of the ring gear and the differential case must be clean and free of burrs before installing the ring gear. 2. Install the ring gear to the differential case. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Drive Pinion Housing and/or Seal Replacement > Page 8355 Note: Use hand tools ONLY. DO NOT use power tools for the following procedure. 3. Hand tighten the new ring gear bolts. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the NEW ring gear bolts and tighten to 165 Nm (122 lb ft). in a criss cross pattern to draw and seat the ring gear and the on the differential case. 5. Install the drive pinion housing assembly. Refer to Drive Pinion Housing and/or Seal Replacement (See: Drive Pinion Housing and/or Seal Replacement). 6. Install the differential assembly. Refer to Differential Replacement (8.6, 9.5/9.5 LD Inch Axles) ()Differential Replacement (10.5 Inch, 11.5 Inch Axle) (). 7. Fill the axle with the proper lubricant. Refer to Differential Oil Replacement (10.5 Inch Axle) (See: Fluid - Differential/Service and Repair/Removal and Replacement)Differential Oil Replacement (11.5 Inch Axle) (See: Fluid Differential/Service and Repair/Removal and Replacement)Differential Oil Replacement (8.6 Inch Axle) (See: Fluid - Differential/Service and Repair/Removal and Replacement)Differential Oil Replacement (9.5LD Inch Axle) (See: Fluid - Differential/Service and Repair/Removal and Replacement). 8. Remove the support and lower the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair Ring Gear: Service and Repair Drive Pinion and Ring Gear Replacement (10.5 Inch Axle) Removal Procedure 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the differential case assembly. Refer to Differential Replacement (8.6, 9.5/9.5 LD Inch Axles) ()Differential Replacement (10.5 Inch, 11.5 Inch Axle) (). 3. Remove the drive pinion housing assembly. Refer to Drive Pinion Housing and/or Seal Replacement (See: Pinion Gear/Service and Repair/Drive Pinion Housing and/or Seal Replacement). 4. Remove and discard the gear bolts. Replace with NEW only. Caution: Refer to Ring Gear Removal Caution (See: Service Precautions/Vehicle Damage Warnings/Ring Gear Removal Caution). 5. Using a brass drift and a hammer, remove the ring gear from the differential case. Installation Procedure 1. If the differential case has become separated, assemble the differential case by aligning the two arrows inside the differential case. Note: The mating surface of the ring gear and the differential case must be clean and free of burrs before installing the ring gear. 2. Install the ring gear to the differential case. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Service and Repair > Page 8359 Note: Use hand tools ONLY. DO NOT use power tools for the following procedure. 3. Hand tighten the new ring gear bolts. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the NEW ring gear bolts and tighten to 165 Nm (122 lb ft). in a criss cross pattern to draw and seat the ring gear and the on the differential case. 5. Install the drive pinion housing assembly. Refer to Drive Pinion Housing and/or Seal Replacement (See: Pinion Gear/Service and Repair/Drive Pinion Housing and/or Seal Replacement). 6. Install the differential assembly. Refer to Differential Replacement (8.6, 9.5/9.5 LD Inch Axles) ()Differential Replacement (10.5 Inch, 11.5 Inch Axle) (). 7. Fill the axle with the proper lubricant. Refer to Differential Oil Replacement (10.5 Inch Axle) (See: Fluid - Differential/Service and Repair/Removal and Replacement)Differential Oil Replacement (11.5 Inch Axle) (See: Fluid Differential/Service and Repair/Removal and Replacement)Differential Oil Replacement (8.6 Inch Axle) (See: Fluid - Differential/Service and Repair/Removal and Replacement)Differential Oil Replacement (9.5LD Inch Axle) (See: Fluid - Differential/Service and Repair/Removal and Replacement). 8. Remove the support and lower the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle Seals and Gaskets: Service and Repair Front Drive Axle Front Drive Axle Inner Shaft Seal and Inner Shaft Bearing Replacement Special Tools * J 8092 Universal Driver Handle - 3/4 in - 10 * J 2619-01 Slide Hammer * J 29369-1 Bushing and Bearing Remover * J 29369-2 Bushing and Bearing Remover (2-3 inch) * J 36609 Axle Tube Bearing Installer * J 45225 Axle Seal Installer Removal Procedure 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Drain the differential carrier assembly. Refer to Front Axle Lubricant Replacement (See: Fluid - Differential/Service and Repair/Removal and Replacement). 3. Remove the right side seal and/or bearing by performing the following steps: 1. Remove the inner axle shaft and housing assembly from the differential carrier case assembly. Refer to Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement (8.25 F4WD Axle) (See: Service and Repair)Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement (8.25 S4WD and 9.25 Axles) (See: Service and Repair). 2. Remove the clutch fork assembly components and the inner axle shaft from the inner axle shaft housing. Refer to Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement (8.25 F4WD Axle) (See: Service and Repair)Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement (8.25 S4WD and 9.25 Axles) (See: Service and Repair). 3. Install the inner axle shaft housing into a vise. Clamp only on the mounting flange of the inner axle shaft housing. 4. Install the J 29369-1 , 8.25 inch axle, or the J 29369-2 , 9.25 inch axle, behind the inner axle shaft seal or the inner axle shaft bearing as necessary. 5. Install the J 2619-01 (2) to the J 29369-1 or the J 29369-2 (1). 6. Remove the inner axle shaft seal and/or the inner axle shaft bearing using the J 2619-01 . Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle > Page 8364 Note: Support the wheel drive shaft in order to not over flex the CV joint. 4. If only replacing the left side seal, perform the following steps: 1. Place an alignment mark between the inner axle shaft and the wheel drive shaft. 2. If servicing the 8.25 inch axle, remove the shock module. Refer to Shock Absorber and Spring Assembly Replacement (See: Steering and Suspension/Suspension/Suspension Strut / Shock Absorber/Service and Repair/Front Suspension Shock Absorber/Shock Absorber and Spring Assembly Replacement). 3. Disconnect the wheel drive shaft from the inner axle shaft. 4. Remove the inner axle shaft using a hammer and a brass drift. 5. Remove the inner axle shaft seal using a suitable seal remover tool. 5. If replacing both the left side seal and bearing, perform the following steps: 1. Remove the differential carrier assembly. Refer to Differential Carrier Assembly Replacement (1500 FWD) (See: Service and Repair )Differential Carrier Assembly Replacement (2500 4WD) (See: Service and Repair). 2. Place the differential carrier assembly into a vise. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle > Page 8365 Clamp only on the mounting flange of the differential carrier assembly case. 3. Remove the inner axle shaft using a hammer and a brass drift. 4. Install the J 29369-1 , 8.25 inch axle, or the J 29369-2 , 9.25 inch axle (1), behind the inner axle shaft seal or the inner axle shaft bearing as necessary. 5. Install the J 2619-01 (2) to the J 29369-1 or the J 29369-2 . 6. Remove the inner axle shaft seal and/or the inner axle shaft bearing using the J 2619-01 . Installation Procedure 1. Install the right side bearing with the square shoulder in using the J 36609 (1) and the J 8092 (2). 2. Install the new axle shaft seal using the J 45225 (1) and the J 8092 (2). 3. Install the inner axle shaft into the inner axle shaft housing. Carefully tap the inner axle shaft into place with a soft-faced mallet. 4. Install the inner axle shaft and clutch fork assembly components into the inner shaft housing. Refer to Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement (8.25 F4WD Axle) (See: Service and Repair)Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement (8.25 S4WD and 9.25 Axles) (See: Service and Repair). 5. Install the inner axle shaft and housing assembly to the differential carrier case assembly. Refer to Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement (8.25 F4WD Axle) (See: Service and Repair)Front Drive Axle Inner Shaft and Inner Shaft Housing Replacement (8.25 S4WD and 9.25 Axles) (See: Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle > Page 8366 6. If both the left side bearing and seal was removed, perform the following step. Install the left side bearing with the square shoulder in using the J 36609 (1) and the J 8092 (2). 7. If both the left side bearing and seal was removed, perform the following step. Install the new axle shaft seal using the J 45225 (1) and the J 8092 (2). 8. If both the left side bearing and seal was removed, perform the following step. Install the inner axle shaft into the differential case side gear using a soft-faced mallet until the retaining ring on the inner axle shaft is fully seated within the groove in the differential case side gear. Pull back on the inner axle shaft to ensure that the inner axle shaft is properly retained in the differential case side gear. 9. If both the left side bearing and seal was removed, perform the following step. Install the front differential carrier assembly. Refer to Differential Carrier Assembly Replacement (1500 FWD) (See: Service and Repair)Differential Carrier Assembly Replacement (2500 4WD) (See: Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle > Page 8367 10. If only the left side seal was removed, perform the following step. Install the seal using the J 45225 and a soft-faced mallet. Tap only on the center portion of the J 45225 in order to drive the seal in evenly. 11. If only the left side seal was removed, perform the following step. Install the inner axle shaft into the differential case side gear using a soft-faced mallet until the retaining ring on the inner axle shaft is fully seated within the groove in the differential case side gear. Pull back on the inner axle shaft to ensure that the inner axle shaft is properly retained in the differential case side gear. 12. If servicing the 8.25 inch axle, install the shock module. Refer to Shock Absorber and Spring Assembly Replacement (See: Steering and Suspension/Suspension/Suspension Strut / Shock Absorber/Service and Repair/Front Suspension Shock Absorber/Shock Absorber and Spring Assembly Replacement). 13. If only the left side seal was removed, perform the following step. Install the wheel drive shaft to the inner axle shaft. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 14. If only the left side seal was removed, perform the following step. Install the wheel drive shaft to the inner axle shaft bolts and tighten to 79 Nm (58 lb ft). 15. Fill the differential carrier assembly. Use the correct fluid. Refer to Front Axle Lubricant Replacement (See: Fluid - Differential/Service and Repair/Removal and Replacement). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle > Page 8368 16. Lower the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle > Page 8369 Seals and Gaskets: Service and Repair Rear Drive Axle Drive Pinion Flange/Yoke and/or Oil Seal Replacement Drive Pinion Flange/Yoke and/or Oil Seal Replacement Special Tools * J 8614-01 - Flange Holder and Remover * J 22388 - Pinion Oil Seal Installer * J 44414 - Pinion Oil Seal Installer Removal Procedure Note: Observe and mark the positions of all the driveline components, relative to the propeller shaft and the axles, prior to disassembly. These components include the propeller shafts, drive axles, pinion flanges, output shafts, etc. Reassemble all the components in the exact places in which you removed the parts. Follow any specifications, torque values, and any measurements made prior to disassembly. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the rear tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 3. Remove the rear brake drum, if equipped. Refer to Brake Drum Replacement (See: Brakes and Traction Control/Drum Brake System/Brake Drum/Service and Repair/Removal and Replacement). 4. Remove the rear disc brake rotor, if equipped. Refer to Rear Brake Rotor Replacement (JD9) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JD9))Rear Brake Rotor Replacement (JH6) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JH6))Rear Brake Rotor Replacement (JH7) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JH7)). Note: The following procedure is for the 10.5 or 11.5 inch axles. 5. Remove the rear axle shafts. Refer to Rear Axle Shaft and/or Gasket Replacement (See: Drive Axles, Bearings and Joints/Seals and Gaskets/Service and Repair/Rear Axle Shaft and/or Gasket Replacement). Note: Reference mark the rear propeller shaft to the rear axle pinion yoke. 6. Remove the propeller shaft. * For vehicles equipped the a one piece propeller shaft, refer to One-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/One-Piece Propeller Shaft Replacement). * For vehicles equipped with a two piece propeller shaft, refer to Two-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Two-Piece Propeller Shaft Replacement). Note: Record this measurement for reassembly. 7. Using an inch-pound torque wrench, measure the rotational torque of the differential ring and pinion gear and related components. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle > Page 8370 8. Place an alignment mark between the pinion and the pinion yoke. Note: * DO NOT reuse the pinion nut, replace with NEW. * For the 11.5 inch axle, use J-34826 socket. 9. Using the J 8614-01 - holder and remover or the J-34826 socket, remove and discard the pinion the pinion nut. Note: Remove the pinion yoke by turning the J 8614-3 (3) clockwise. 10. Using the J 8614-2 (2), J 8614-3 (3) and the J 8614-01 - remover (1), remove the pinion yoke. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle > Page 8371 Note: DO NOT damage the axle housing. 11. Using a suitable tool, remove the pinion oil seal. Installation Procedure 1. Using the J 22388 - installer , install the new pinion oil seal. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle > Page 8372 2. Apply the proper sealant to the splines of the pinion yoke. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Fluid Differential/Specifications/Fluid Type Specifications). 3. Align the reference marks and install the pinion yoke. Caution: Refer to Pinion Flange/Yoke Installation Caution (See: Service Precautions/Vehicle Damage Warnings/Pinion Flange/Yoke Installation Caution). Note: Tap the pinion yoke until a few threads show through the pinion yoke. 4. Using a soft faced hammer, seat the pinion yoke onto the pinion shaft. 5. Install the washer and a NEW pinion nut. Note: * If the rotating torque is exceeded, the pinion will have to be removed and a new collapsible spacer installed. * For the 11.5 inch axle, use J-34826 socket. 6. Holding the J 8614-01 - holder or the J-34826 socket, tighten the pinion nut until the pinion end play is just taken up. 7. Rotate the pinion while tightening the nut to seat the bearings. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle > Page 8373 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Note: Compare this measurement with the rotating torque recorded during removal. 8. Using an inch pound torque wrench and tightening in small increments, measure the rotating torque of the pinion until the reading is greater than 0.40-0.57 Nm (3-5 lb in) , the rotational torque noted at removal. Note: Recheck the rotating torque and adjust if necessary. 9. Once the specified torque is obtained, rotate the pinion several times to seat the bearings. Note: Reference mark the rear propeller shaft to the rear axle pinion yoke. 10. Install the propeller shaft. * For vehicles equipped the a one piece propeller shaft, refer to One-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/One-Piece Propeller Shaft Replacement). * For vehicles equipped with a two piece propeller shaft, refer to Two-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Two-Piece Propeller Shaft Replacement). Note: The following procedure is for the 10.5 or 11.5 inch axles. 11. Install the rear axle shafts. Refer to Rear Axle Shaft and/or Gasket Replacement (See: Drive Axles, Bearings and Joints/Seals and Gaskets/Service and Repair/Rear Axle Shaft and/or Gasket Replacement). 12. Install the rear brake drum, if equipped. Refer to Brake Drum Replacement (See: Brakes and Traction Control/Drum Brake System/Brake Drum/Service and Repair/Removal and Replacement). 13. Install the rear disc brake rotor, if equipped. Refer to Rear Brake Rotor Replacement (JD9) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JD9))Rear Brake Rotor Replacement (JH6) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JH6))Rear Brake Rotor Replacement (JH7) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JH7)). 14. Install the rear tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 15. Inspect and add axle lubricant to the axle housing, if necessary. Refer to Rear Axle Lubricant Level Inspection (8.6, 9.5 LD Axle) (See: Fluid Differential/Service and Repair/Procedures/Rear Drive Axle/Rear Axle Lubricant Level Inspection (8.6, 9.5 LD Axle))Rear Axle Lubricant Level Inspection (10.5 Inch Axle) (See: Fluid Differential/Service and Repair/Procedures/Rear Drive Axle/Rear Axle Lubricant Level Inspection (10.5 Inch Axle))Rear Axle Lubricant Level Inspection (11.5 Inch Axle) (See: Fluid Differential/Service and Repair/Procedures/Rear Drive Axle/Rear Axle Lubricant Level Inspection (11.5 Inch Axle)). 16. Remove the support and lower the vehicle. Rear Axle Shaft and/or Gasket Replacement Rear Axle Shaft and/or Gasket Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle > Page 8374 Rear Axle Hub, Bearing, Cup, and/or Seal Replacement Rear Axle Hub, Bearing, Cup, and/or Seal Replacement Special Tools * J 2222-C - Wheel Bearing Nut Wrench * J 8092 - Universal Driver Handle - 3/4 x 10 inch * J 24426 - Outer Wheel Bearing Race Installer * J 24427 - Inner Wheel Bearing Race Installer * J 44419 - Hub Bearing Installer * J 44420 - Differential Bearing Installer For equivalent regional tools, refer to Special Tools (See: Steering and Suspension/Suspension/Tools and Equipment/Rear Suspension). Removal Procedure Note: * The wheel speed sensor ring is NOT serviced separately. The hub and wheel speed senor ring are serviced as an assembly. * The rear axle hub seal must be replaced anytime the rear axle hub assembly is removed from the axle housing. * The wheel studs are serviced separately from the rear axle hub. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) Lifting and Jacking the Vehicle. 2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair ) Tire and Wheel Removal and Installation. Note: In the following service procedure, it is not necessary to remove the brake caliper from the bracket. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle > Page 8375 3. Remove the brake caliper bracket. Refer to Rear Brake Caliper Bracket Replacement (JD9) (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Rear Brake Caliper Bracket Replacement (JD9))Rear Brake Caliper Bracket Replacement (JH6, JH7) (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Rear Brake Caliper Bracket Replacement (JH6, JH7)) Rear Brake Caliper Bracket Replacement. 4. Remove the rear axle shaft. Refer to Rear Axle Shaft and/or Gasket Replacement (See: Drive Axles, Bearings and Joints/Seals and Gaskets/Service and Repair/Rear Axle Shaft and/or Gasket Replacement) Rear Axle Shaft and/or Gasket Replacement. 5. Remove the rear axle nut retaining ring. 6. Remove the rear wheel bearing adjuster key. 7. Using the J 2222-C - wrench , remove the rear wheel bearing adjuster nut. Note: If the oil seal remains on the axle hub, remove the seal using a suitable seal removal tool. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle > Page 8376 8. Remove the rear axle hub from the axle housing. 9. Remove the rear brake rotor, if necessary. Refer to Rear Brake Rotor Replacement (JD9) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JD9))Rear Brake Rotor Replacement (JH6) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JH6))Rear Brake Rotor Replacement (JH7) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JH7)) Rear Brake Rotor Replacement. 10. Using a suitable seal removal tool, remove the oil seal from the wheel hub. 11. Remove the inner hub bearing. 12. Using a brass drift and a hammer, remove the inner hub bearing cup. 13. Remove the retaining ring from the wheel hub. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle > Page 8377 14. Using the J 24426 - installer (2) and the J 8092 - handle (1), remove the outer hub bearing and bearing cup. 15. For those vehicles equipped with RPO code JH6, use the J 45270 (1) to remove the wheel studs (2). 16. For those vehicles equipped with RPO code JH7, use a hydraulic press to remove the wheel studs. 17. Remove the rear brake disc from the rear axle hub. Installation Procedure 1. For vehicles equipped RPO code JH7, position the brake rotor on the rear axle hub. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle > Page 8378 2. Position the wheel stud in the rear axle hub. 3. Using washers and a wheel nut, tighten the wheel nut until the wheel stud is fully seated in the rear axle hub. 4. Remove the lug nut and the washers. 5. Lubricate the following with a light coat of high melting point EP bearing lubricant: * The outer wheel bearing * The inner wheel bearing * The outer wheel bearing cup * The inner wheel bearing cup * The axle hub spindle 6. Install the outer bearing into the rear axle hub. Note: Drive the outer bearing cup into the wheel hub until it is just past the retaining ring groove. Do not bottom out the bearing assembly in the bore. 7. Using the J 44419 - installer (2) and the J 8092 - handle (1), install the outer bearing cup into the rear axle hub. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle > Page 8379 Note: Ensure that the retaining ring is fully and evenly seated in the groove. 8. Install the retaining ring into the groove. Note: Ensure that the outer bearing assembly rotates freely in the hub 9. Using the J 24426 - installer (2) and the J 8092 - handle (1), turn the rear axle hub over and seat the outer bearing assembly against the retaining ring. 10. Turn the rear axle hub over and install the inner bearing cup. 11. Using the J 24427 - installer (2) and the J 8092 - handle (1), install the inner bearing cup into the wheel hub. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle > Page 8380 12. Install the inner bearing. Note: Ensure the seal is fully seated in the hub bore. 13. Using the J 44420 - installer (2) and the J 8092 - handle (1), install the new oil seal. 14. Apply a light coat of high melting point EP bearing lubricant to the axle housing spindle. Note: If the rear axle hub assembly does not fully seat itself onto the axle shaft spindle and is removed, the rear axle hub seal must be replaced. 15. Install the rear axle hub. Note: Install the rear wheel bearing adjuster nut by hand. 16. Using the J 2222-C - wrench , adjust the rear wheel bearings. Refer to Wheel Bearing Adjustment (See: Service and Repair/Procedures/Rear Drive Axle/Wheel Bearing Adjustment) Wheel Bearing Adjustment Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle > Page 8381 17. Install the rear axle shaft. Refer to Rear Axle Shaft and/or Gasket Replacement (See: Drive Axles, Bearings and Joints/Seals and Gaskets/Service and Repair/Rear Axle Shaft and/or Gasket Replacement) Rear Axle Shaft and/or Gasket Replacement. 18. Install the brake caliper bracket. Refer to Rear Brake Caliper Bracket Replacement (JD9) (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Rear Brake Caliper Bracket Replacement (JD9))Rear Brake Caliper Bracket Replacement (JH6, JH7) (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Rear Brake Caliper Bracket Replacement (JH6, JH7)) Rear Brake Caliper Bracket Replacement. 19. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair) Tire and Wheel Removal and Installation. 20. Inspect and add axle lubricant to the axle housing, if necessary. Refer to Rear Axle Lubricant Level Inspection (8.6, 9.5 LD Axle) (See: Fluid Differential/Service and Repair/Procedures/Rear Drive Axle/Rear Axle Lubricant Level Inspection (8.6, 9.5 LD Axle))Rear Axle Lubricant Level Inspection (10.5 Inch Axle) (See: Fluid Differential/Service and Repair/Procedures/Rear Drive Axle/Rear Axle Lubricant Level Inspection (10.5 Inch Axle))Rear Axle Lubricant Level Inspection (11.5 Inch Axle) (See: Fluid Differential/Service and Repair/Procedures/Rear Drive Axle/Rear Axle Lubricant Level Inspection (11.5 Inch Axle)) Rear Axle Lubricant Level Inspection. 21. Remove the supports and lower the vehicle. Drive Pinion Housing and/or Seal Replacement Drive Pinion Housing and/or Seal Replacement Special Tools * J 8092 - Universal Driver Handle 3/4 x 10 inch * J 8608 - Pinion bearing Cup Installer * J 24433 - Pinion Bearing Installer * J 37624 - Pinion Bearing Installer * J 44414 - Pinion Oil Seal Installer Removal Procedure Note: Observe and mark the positions of all the driveline components, relative to the propeller shaft and the axles, prior to disassembly. These components include the propeller shafts, drive axles, pinion flanges, output shafts, etc. Reassemble all the components in the exact places in which you removed the parts. Follow any specifications, torque values, and any measurements made prior to disassembly. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Drain the axle lubricant. Refer to Differential Oil Replacement (10.5 Inch Axle) (See: Fluid - Differential/Service and Repair/Removal and Replacement)Differential Oil Replacement (11.5 Inch Axle) (See: Fluid - Differential/Service and Repair/Removal and Replacement)Differential Oil Replacement (8.6 Inch Axle) (See: Fluid Differential/Service and Repair/Removal and Replacement)Differential Oil Replacement (9.5LD Inch Axle) (See: Fluid - Differential/Service and Repair/Removal and Replacement). 3. Remove the rear axle shafts. Refer to Rear Axle Shaft and/or Gasket Replacement (See: Drive Axles, Bearings and Joints/Seals and Gaskets/Service and Repair/Rear Axle Shaft and/or Gasket Replacement). 4. Remove the rear propeller shaft. * For vehicles equipped with the one piece propeller shaft, refer to One-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/One-Piece Propeller Shaft Replacement). * For vehicles equipped with the two piece propeller shaft, refer to Two-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Two-Piece Propeller Shaft Replacement). 5. Remove the drive pinion flange/yoke and/or oil seal. Refer to Drive Pinion Flange/Yoke and/or Oil Seal Replacement (See: Pinion Flange/Service and Repair/Rear Drive Axle). 6. Using a hydraulic press and an appropriate tool, remove the pinion. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle > Page 8382 7. Remove the collapsible spacer. Note: When performing the following service procedure, move the drift back and forth between one side of the cup and the other in order to work the cups out of the retainer evenly. 8. Using a hammer and a brass drift in the slots provided, remove the outer pinion bearing cup. Note: When performing the following service procedure, move the drift back and forth between one side of the cup and the other in order to work the cups out of the retainer evenly. 9. Using a hammer and a brass drift in the slots provided, remove the inner pinion bearing cup. Installation Procedure 1. Using the J 37624 (2) and the J 8092 (1), Install the inner pinion bearing cup into the pinion gear bearing retainer. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Drive Axle > Page 8383 2. Using the J 8608 (2) and the J 8092 (1), install the outer pinion bearing cup into the pinion gear bearing retainer. 3. Apply sealant to surface of the selective shim. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Fluid - Differential/Specifications/Fluid Type Specifications). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the pinion gear bearing retainer and bolts tighten to 88 Nm (65 lb ft). 5. Install the drive pinion flange/yoke and/or oil seal. Refer to Drive Pinion Flange/Yoke and/or Oil Seal Replacement (See: Pinion Flange/Service and Repair/Rear Drive Axle). 6. Install the propeller shaft. * For vehicles equipped with the one piece propeller shaft, refer to One-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/One-Piece Propeller Shaft Replacement). * For vehicles equipped with the two piece propeller shaft, refer to Two-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Two-Piece Propeller Shaft Replacement). 7. Install the rear axle shafts. Refer to Rear Axle Shaft and/or Gasket Replacement (See: Drive Axles, Bearings and Joints/Seals and Gaskets/Service and Repair/Rear Axle Shaft and/or Gasket Replacement). 8. Fill the axle with axle lubricant. Refer to Differential Oil Replacement (10.5 Inch Axle) (See: Fluid - Differential/Service and Repair/Removal and Replacement)Differential Oil Replacement (11.5 Inch Axle) (See: Fluid - Differential/Service and Repair/Removal and Replacement )Differential Oil Replacement (8.6 Inch Axle) (See: Fluid Differential/Service and Repair/Removal and Replacement)Differential Oil Replacement (9.5LD Inch Axle) (See: Fluid - Differential/Service and Repair/Removal and Replacement). 9. Remove the support and lower the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Rear Axle Shaft Seal and/or Bearing Replacement Axle Bearing: Service and Repair Rear Axle Shaft Seal and/or Bearing Replacement Rear Axle Shaft Seal and/or Bearing Replacement Special Tools * J 2619-01 - Slide Hammer W 1/2 x 13 Adapter * J 8092 - Universal Driver Handle 3/4 x 10 inch * J 21128 - Axle Pinion Oil Seal Installer * J 23690 - Axle Bearing Installer * J 44685 - Rear Axle Seal and Bearing Remover * J 45857 - VSES Wheel Bearing Remover Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair ). 3. Remove the rear axle housing cover. Refer to Rear Axle Housing Cover and Gasket Replacement (8.6, 9.5 Inch Axles) ()Rear Axle Housing Cover and Gasket Replacement (10.5/11.5 Inch Axle) (). 4. Remove the axle shaft. Refer to Rear Axle Shaft Replacement (See: Axle Shaft Assembly/Axle Shaft/Service and Repair). Note: If the vehicle is equipped with VSES, proceed to step 5. 5. Using the J 44685 - remover (1) and the J 2619-01 - hammer (2), remove the rear axle shaft seal. 6. Using the J 45857 - remover (1) and the J 2619-01 - hammer (2), remove the rear axle shaft seal, bearing and the wheel speed sensor reluctor ring, if equipped. Installation Procedure 1. Install the rear wheel speed sensor reluctor ring, if equipped. * For vehicles with the HP2 (Hybrid) option, refer to Rear Wheel Speed Sensor Ring Replacement (). * For vehicles that are NON-Hybrid less than 3900 kg (8600 lbs) GVW, refer to Rear Wheel Speed Sensor Ring Replacement (See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Wheel Speed Sensor/Service and Repair/Rear Wheel Speed Sensor Ring Replacement/Non-Hybrid Less than 3900 kg (8600 lb) GVW). * For vehicles that are NON-Hybrid greater than/equal to 3900 kg (8600 lbs) GVW, refer to Rear Wheel Speed Sensor Ring Replacement (See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Wheel Speed Sensor/Service and Repair/Rear Wheel Speed Sensor Ring Replacement/Non-Hybrid Greater than/Equal to 3900 kg (8600 lb) GVW). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Rear Axle Shaft Seal and/or Bearing Replacement > Page 8389 Note: Ensure that the axle shaft bearing is fully seated in the rear axle shaft housing. 2. Using the J 23690 - installer (1) and the J 8092 - driver (2), install the axle shaft bearing. 3. Using the J 21128 - installer , install the axle shaft seal. 4. Drive the tool into the bore until the axle shaft seal bottoms flush with the tube. 5. Install the rear axle shaft. Refer to Rear Axle Shaft Replacement (See: Axle Shaft Assembly/Axle Shaft/Service and Repair). 6. Install the rear axle housing cover. Refer to Rear Axle Housing Cover and Gasket Replacement (8.6, 9.5 Inch Axles) ()Rear Axle Housing Cover and Gasket Replacement (10.5/11.5 Inch Axle) (). 7. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 8. Fill the rear axle. Refer to Differential Oil Replacement (10.5 Inch Axle) (See: Differential Assembly/Fluid - Differential/Service and Repair/Removal and Replacement)Differential Oil Replacement (11.5 Inch Axle) (See: Differential Assembly/Fluid - Differential/Service and Repair/Removal and Replacement)Differential Oil Replacement (8.6 Inch Axle) (See: Differential Assembly/Fluid - Differential/Service and Repair/Removal and Replacement)Differential Oil Replacement (9.5LD Inch Axle) (See: Differential Assembly/Fluid - Differential/Service and Repair/Removal and Replacement). 9. Remove the support and lower the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Rear Axle Shaft Seal and/or Bearing Replacement > Page 8390 Axle Bearing: Service and Repair Rear Axle Hub, Bearing, Cup, and/or Seal Replacement Rear Axle Hub, Bearing, Cup, and/or Seal Replacement Special Tools * J 2222-C - Wheel Bearing Nut Wrench * J 8092 - Universal Driver Handle - 3/4 x 10 inch * J 24426 - Outer Wheel Bearing Race Installer * J 24427 - Inner Wheel Bearing Race Installer * J 44419 - Hub Bearing Installer * J 44420 - Differential Bearing Installer For equivalent regional tools, refer to Special Tools (See: Steering and Suspension/Suspension/Tools and Equipment/Rear Suspension). Removal Procedure Note: * The wheel speed sensor ring is NOT serviced separately. The hub and wheel speed senor ring are serviced as an assembly. * The rear axle hub seal must be replaced anytime the rear axle hub assembly is removed from the axle housing. * The wheel studs are serviced separately from the rear axle hub. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) Lifting and Jacking the Vehicle. 2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair ) Tire and Wheel Removal and Installation. Note: In the following service procedure, it is not necessary to remove the brake caliper from the bracket. 3. Remove the brake caliper bracket. Refer to Rear Brake Caliper Bracket Replacement (JD9) (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Rear Brake Caliper Bracket Replacement (JD9))Rear Brake Caliper Bracket Replacement (JH6, JH7) (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Rear Brake Caliper Bracket Replacement (JH6, JH7)) Rear Brake Caliper Bracket Replacement. 4. Remove the rear axle shaft. Refer to Rear Axle Shaft and/or Gasket Replacement (See: Seals and Gaskets/Service and Repair/Rear Axle Shaft and/or Gasket Replacement) Rear Axle Shaft and/or Gasket Replacement. 5. Remove the rear axle nut retaining ring. 6. Remove the rear wheel bearing adjuster key. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Rear Axle Shaft Seal and/or Bearing Replacement > Page 8391 7. Using the J 2222-C - wrench , remove the rear wheel bearing adjuster nut. Note: If the oil seal remains on the axle hub, remove the seal using a suitable seal removal tool. 8. Remove the rear axle hub from the axle housing. 9. Remove the rear brake rotor, if necessary. Refer to Rear Brake Rotor Replacement (JD9) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JD9))Rear Brake Rotor Replacement (JH6) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JH6))Rear Brake Rotor Replacement (JH7) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JH7)) Rear Brake Rotor Replacement. 10. Using a suitable seal removal tool, remove the oil seal from the wheel hub. 11. Remove the inner hub bearing. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Rear Axle Shaft Seal and/or Bearing Replacement > Page 8392 12. Using a brass drift and a hammer, remove the inner hub bearing cup. 13. Remove the retaining ring from the wheel hub. 14. Using the J 24426 - installer (2) and the J 8092 - handle (1), remove the outer hub bearing and bearing cup. 15. For those vehicles equipped with RPO code JH6, use the J 45270 (1) to remove the wheel studs (2). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Rear Axle Shaft Seal and/or Bearing Replacement > Page 8393 16. For those vehicles equipped with RPO code JH7, use a hydraulic press to remove the wheel studs. 17. Remove the rear brake disc from the rear axle hub. Installation Procedure 1. For vehicles equipped RPO code JH7, position the brake rotor on the rear axle hub. 2. Position the wheel stud in the rear axle hub. 3. Using washers and a wheel nut, tighten the wheel nut until the wheel stud is fully seated in the rear axle hub. 4. Remove the lug nut and the washers. 5. Lubricate the following with a light coat of high melting point EP bearing lubricant: * The outer wheel bearing * The inner wheel bearing * The outer wheel bearing cup * The inner wheel bearing cup * The axle hub spindle Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Rear Axle Shaft Seal and/or Bearing Replacement > Page 8394 6. Install the outer bearing into the rear axle hub. Note: Drive the outer bearing cup into the wheel hub until it is just past the retaining ring groove. Do not bottom out the bearing assembly in the bore. 7. Using the J 44419 - installer (2) and the J 8092 - handle (1), install the outer bearing cup into the rear axle hub. Note: Ensure that the retaining ring is fully and evenly seated in the groove. 8. Install the retaining ring into the groove. Note: Ensure that the outer bearing assembly rotates freely in the hub 9. Using the J 24426 - installer (2) and the J 8092 - handle (1), turn the rear axle hub over and seat the outer bearing assembly against the retaining ring. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Rear Axle Shaft Seal and/or Bearing Replacement > Page 8395 10. Turn the rear axle hub over and install the inner bearing cup. 11. Using the J 24427 - installer (2) and the J 8092 - handle (1), install the inner bearing cup into the wheel hub. 12. Install the inner bearing. Note: Ensure the seal is fully seated in the hub bore. 13. Using the J 44420 - installer (2) and the J 8092 - handle (1), install the new oil seal. 14. Apply a light coat of high melting point EP bearing lubricant to the axle housing spindle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Rear Axle Shaft Seal and/or Bearing Replacement > Page 8396 Note: If the rear axle hub assembly does not fully seat itself onto the axle shaft spindle and is removed, the rear axle hub seal must be replaced. 15. Install the rear axle hub. Note: Install the rear wheel bearing adjuster nut by hand. 16. Using the J 2222-C - wrench , adjust the rear wheel bearings. Refer to Wheel Bearing Adjustment (See: Differential Assembly/Service and Repair/Procedures/Rear Drive Axle/Wheel Bearing Adjustment) Wheel Bearing Adjustment 17. Install the rear axle shaft. Refer to Rear Axle Shaft and/or Gasket Replacement (See: Seals and Gaskets/Service and Repair/Rear Axle Shaft and/or Gasket Replacement) Rear Axle Shaft and/or Gasket Replacement. 18. Install the brake caliper bracket. Refer to Rear Brake Caliper Bracket Replacement (JD9) (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Rear Brake Caliper Bracket Replacement (JD9))Rear Brake Caliper Bracket Replacement (JH6, JH7) (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Rear Brake Caliper Bracket Replacement (JH6, JH7)) Rear Brake Caliper Bracket Replacement. 19. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair) Tire and Wheel Removal and Installation. 20. Inspect and add axle lubricant to the axle housing, if necessary. Refer to Rear Axle Lubricant Level Inspection (8.6, 9.5 LD Axle) (See: Differential Assembly/Fluid - Differential/Service and Repair/Procedures/Rear Drive Axle/Rear Axle Lubricant Level Inspection (8.6, 9.5 LD Axle))Rear Axle Lubricant Level Inspection (10.5 Inch Axle) (See: Differential Assembly/Fluid - Differential/Service and Repair/Procedures/Rear Drive Axle/Rear Axle Lubricant Level Inspection (10.5 Inch Axle))Rear Axle Lubricant Level Inspection (11.5 Inch Axle) (See: Differential Assembly/Fluid - Differential/Service and Repair/Procedures/Rear Drive Axle/Rear Axle Lubricant Level Inspection (11.5 Inch Axle)) Rear Axle Lubricant Level Inspection. 21. Remove the supports and lower the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair Axle Shaft: Service and Repair Rear Axle Shaft Replacement Special Tools * J 2619-01 - Slide Hammer W/1/2 x 13 Adapter * J 45859 - Axle Shaft Remover/Installer For equivalent regional tools, refer to Special Tools (See: Differential Assembly/Tools and Equipment/Rear Drive Axle). Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair ). 3. Remove the wheel speed sensor. * For Hybrid vehicles, refer to Rear Wheel Speed Sensor Replacement (). * For non Hybrid vehicles (1500 series), refer to Rear Wheel Speed Sensor Replacement (See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Wheel Speed Sensor/Service and Repair/Rear Wheel Speed Sensor Replacement/Non-Hybrid Less than 3900 kg (8600 lb) GVW). * For non Hybrid vehicles (2500 series), refer to Rear Wheel Speed Sensor Replacement (See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Wheel Speed Sensor/Service and Repair/Rear Wheel Speed Sensor Replacement/Non-Hybrid Greater than/Equal to 3900 kg (8600 lb) GVW). 4. Remove the rear brake drum, if equipped. Refer to Brake Drum Replacement (See: Brakes and Traction Control/Drum Brake System/Brake Drum/Service and Repair/Removal and Replacement). 5. Remove the brake caliper mounting bracket, if equipped. Refer to Rear Brake Caliper Bracket Replacement (JD9) (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Rear Brake Caliper Bracket Replacement (JD9))Rear Brake Caliper Bracket Replacement (JH6, JH7) (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Rear Brake Caliper Bracket Replacement (JH6, JH7)). 6. Remove the rear axle housing cover and gasket. Refer to Rear Axle Housing Cover and Gasket Replacement (8.6, 9.5 Inch Axles) ()Rear Axle Housing Cover and Gasket Replacement (10.5/11.5 Inch Axle) (). 7. Remove the and discard differential pinion gear shaft bolt. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Page 8401 Note: For those vehicles NOT equipped with the locking differential proceed to step 8. If the vehicle is equipped WITH the locking differential, proceed to step 9 and 10. 8. Remove the differential pinion gear shaft. Note: Rotate the differential case until the differential pinion shaft just touches the rear axle housing. 9. Remove the differential pinion gear shaft part way from the differential case. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Page 8402 10. Use a screw driver, or similar tool to rotate the lock (1) until the lock (1) aligns with the thrust block. 11. Push in on the rear axle shaft (2) and remove the lock (1). Note: If the rear axle shaft is difficult to remove, proceed to step 14. 12. Remove the rear drum brake axle shaft (2) from the rear axle assembly (1), if equipped. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Page 8403 Note: If the rear axle shaft is difficult to remove, proceed to step 14. 13. Remove the rear disc brake axle shaft (1) from the rear axle assembly (2), if equipped 14. Using the J 2619-01 - hammer (2) and the J 45859 - remover/installer (1), remove the rear axle shaft from the rear axle assembly. 15. Replace the rear axle shaft seal and or bearing, if needed. Refer to Rear Axle Shaft Seal and/or Bearing Replacement (See: Axle Bearing/Service and Repair/Rear Axle Shaft Seal and/or Bearing Replacement). Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Page 8404 Note: When installing the rear axle shaft, ensure that the seal is not damaged. 1. Install the disc brake axle shaft (1) in the rear axle assembly (2), if equipped. 2. Install the drum brake axle shaft (2) in the rear axle assembly (1), if equipped. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Page 8405 Note: In steps 3 and 4, pull out on the axle shaft after the lock has been installed to ensure that the lock is seated properly. 3. Install the lock (1) in the rear axle (2), without a locking differential. 4. Install the lock (1) on the rear axle shaft (3), with a locking differential. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Page 8406 Note: On axles with a locking differential, keep the differential pinion shaft slightly withdrawn. 5. Install the differential pinion gear shaft. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 6. Install the NEW differential pinion gear shaft bolt and tighten to 34 Nm (25 lb ft) for the 8.6 inch axle and 50 Nm (37 lb ft) for the 9.5 inch axle. Note: End play is the in and out movement of the rear axle shaft. Radial play is the up and own movement in the rear axle shaft. 7. Check the rear axle shaft end play and the radial play. The rear axle shaft end play should be 0.012 inch per side and the radial play should be 0.002-0.003 inch. If the rear axle shaft is NOT within the specifications, replace any excessively worn parts. 8. Install the rear axle housing cover and gasket. Refer to Rear Axle Housing Cover and Gasket Replacement (8.6, 9.5 Inch Axles) ()Rear Axle Housing Cover and Gasket Replacement (10.5/11.5 Inch Axle) (). 9. Install the wheel speed sensor. * For Hybrid vehicles, refer to Rear Wheel Speed Sensor Replacement (). * For non Hybrid vehicles (1500 series), refer to Rear Wheel Speed Sensor Replacement (See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Wheel Speed Sensor/Service and Repair/Rear Wheel Speed Sensor Replacement/Non-Hybrid Less than 3900 kg (8600 lb) GVW). * For non Hybrid vehicles (2500 series), refer to Rear Wheel Speed Sensor Replacement (See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Wheel Speed Sensor/Service and Repair/Rear Wheel Speed Sensor Replacement/Non-Hybrid Greater than/Equal to 3900 kg (8600 lb) GVW). 10. Install the brake caliper mounting bracket, if equipped. Refer to Rear Brake Caliper Bracket Replacement (JD9) (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Rear Brake Caliper Bracket Replacement (JD9))Rear Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Page 8407 Brake Caliper Bracket Replacement (JH6, JH7) (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Rear Brake Caliper Bracket Replacement (JH6, JH7)). 11. Install the rear brake drum, if equipped. Refer to Brake Drum Replacement (See: Brakes and Traction Control/Drum Brake System/Brake Drum/Service and Repair/Removal and Replacement). 12. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 13. Remove the support and lower the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot Replacement Constant Velocity Joint: Service and Repair Wheel Drive Shaft Inner Joint and Boot Replacement Wheel Drive Shaft Inner Joint and Boot Replacement Special Tools * J-35910 - Drive Axle Seal Clamp Pliers * J-36652-1 - Drive Axle Clamp Swage Tool * J-36652-98 - Axle Swage Tool Disassemble Procedure 1. Remove the wheel drive shaft. Refer to Wheel Drive Shaft Replacement (2500) (See: Service and Repair)Wheel Drive Shaft Replacement (1500) (See: Service and Repair). Note: Use caution when removing the tripot housing (1). 2. Using the appropriate tool, remove the boot clamp (2). 3. Remove the tripot housing (1). Note: If using denatured alcohol or any other recommend cleaning solvent, allow the tripot housing to air dry. 4. Remove any grease from of the housing (1). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot Replacement > Page 8412 5. Using side cutters, remove the small boot retaining clamp (4). 6. Using the appropriate tool, remove the retaining ring (1), then the spider assembly (2), and the boot (3). 7. Using the appropriate tool, remove the any rust in the seal mounting area (grooves) (1). 8. If any of the internal components of the tripot assembly are found to be damaged or have excessive wear, replace the tripot as an assembly. Assemble Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot Replacement > Page 8413 1. Position the boot (1) so that it is seated properly in the groove (2) in the wheel drive shaft (3). 2. Install the small boot clamp (2) on the boot (1). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot Replacement > Page 8414 3. Using the J-35910 - pliers , a breaker bar, and a torque wrench (1), close the boot clamp (2) until the gap (3) measures 2.15 mm (0.085 inch). 4. Install the spider assembly (2). 5. Using the appropriate tool, install the retaining ring (1). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot Replacement > Page 8415 Note: Position the boot clamp so that it is at the small end of the boot. 6. Install the tripot assembly (1) and the boot clamp (2) 7. Place approximately half of the lubricant (2) in the boot (1) and the remaining half in the tripot housing (3). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot Replacement > Page 8416 Note: Pinch the slightly by hand in order to distort it into an oval shape. 8. Install the boot (1) and the boot clamp (2) on the tripot housing (3). 9. For the 1500 models, assemble the bolts and the support plate to the base of the J-36652-98 tool and secure the base in a vise. 10. For the 2500, 3500 models, assemble the bolts and the support plate to the base of the J-36652-1 - tool and secure the base in a vise. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot Replacement > Page 8417 11. Position the tripot end of the wheel drive shaft assembly into the base of the J-36652-98 - tool for the 1500 models or J-36652-1 - tool for the 2500, 3500 models. 12. Install the top half of the J-36652-98 - Tool for the 1500 models or J-36652-1 - tool for the 2500, 3500 models. 13. Align the boot clamp (2) and the clamp. Note: Hand tighten the bolts until the bolts are snug. 14. Insert the bolts. 15. Align the tripot boot, tripot housing, and the boot clamp. Note: Alternate between the bolts until both sides of the top half of the tool touch the bottom half. 16. Tighten each bolt 180 degrees at a time. 17. Loosen the bolts and remove the halfshaft assembly from the tool. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot Replacement > Page 8418 18. Inspect the inboard stroke position. * Measurement A for the 1500 models should be 170 mm (6 11/16 inch). * Measurement A for the 2500, 3500, should be 178 mm (7 inch). 19. Install the wheel drive shaft. Refer to Wheel Drive Shaft Replacement (2500) (See: Service and Repair)Wheel Drive Shaft Replacement (1500) (See: Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot Replacement > Page 8419 Constant Velocity Joint: Service and Repair Wheel Drive Shaft Outer Joint and Boot Replacement Wheel Drive Shaft Outer Joint and Boot Replacement Special Tools * J 8059 Snap Ring Pliers * J 35910 Drive Axle Seal Clamp Pliers * J 36652-1 Drive Axle Clamp Swage Tool * J 36652-2 Axle Swage Tool Removal Procedure 1. Remove the wheel drive shaft. Refer to Wheel Drive Shaft Replacement (2500) (See: Service and Repair)Wheel Drive Shaft Replacement (1500) (See: Service and Repair). 2. Remove the wheel drive shaft seal cover, if applicable. Refer to Front Wheel Drive Shaft Seal Protector Replacement (See: Service and Repair). Note: Use caution when using the hand grinder by the CV joint outer race (1). 3. Use a hand grinder to cut through the swage ring (2). 4. Use side cutters to cut off the small boot clamp (4). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot Replacement > Page 8420 5. Slide the boot (5) down the halfshaft bar (4) and away from the CV joint outer race (1). 6. Wipe all grease away from the face of the CV joint. 7. Find the halfshaft bar retaining snap ring (3), which is located in the inner race (2). 8. Spread the snap ring ears apart using J 8059 (or equivalent). 9. Pull the CV joint (1) and the CV joint boot (5) from the halfshaft bar (4). 10. Discard the old CV joint boot (5). 11. Place a brass drift against the CV joint cage (1). 12. Tap gently on the brass drift with a hammer in order to tilt the cage (1). 13. Remove the first chrome alloy ball (2) when the CV joint cage (1) tilts. 14. Tilt the CV joint cage (1) in the opposite direction to remove the opposing chrome alloy ball (2). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot Replacement > Page 8421 15. Repeat this process to remove all six of the balls. 16. Pivot the CV joint cage (4) and the inner race 90 degrees to the center line of the outer race (1). At the same time, align the cage windows (3) with the lands of the outer race (2). 17. Lift out the cage (4) and the inner race. 18. Remove the inner race (1) from the cage (2) by rotating the inner race (1) upward. 19. Clean the following items thoroughly with cleaning solvent. Remove all traces of old grease and any contaminates. 1. The inner and outer race assemblies 2. The CV joint cage 3. The chrome alloy balls 20. Dry all the parts. 21. Check the CV joint assembly for unusual wear, cracks, or other damage. 22. Replace any damaged parts. 23. Clean the halfshaft bar. Use a wire brush to remove any rust in the seal mounting area (grooves). Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot Replacement > Page 8422 1. Inspect all of the parts for unusual wear, cracks, or other damage. Replace the CV joint assembly if necessary. 2. Put a light coat of the recommended grease on the inner (6) and the outer race (8) grooves. 3. Hold the inner race (1) at 90 degrees to the centerline of the cage (2). 4. Align the lands of the inner race (1) with the windows of the cage (2). 5. Insert the inner race (1) into the cage (2), by rotating the inner race (1) downward. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot Replacement > Page 8423 6. Insert the cage (4) and inner race into the outer race (1). 7. Place a brass drift against the CV joint cage (1). 8. Tap gently on the brass drift with a hammer in order to tilt the cage (1). 9. Install the first chrome alloy ball (2) when the CV joint cage (1) tilts. 10. Tilt the CV joint cage (1) in the opposite direction to install the opposing chrome alloy ball (2). 11. Repeat this process in order to install all six of the balls. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot Replacement > Page 8424 12. Pack the CV joint boot (1) and the CV joint assembly with the grease supplied in the kit. The amount of grease supplied in this kit has been pre-measured for this application. 13. Place the new small boot clamp (2) onto the CV joint seal (1). 14. Slide the CV joint boot (1) onto the halfshaft bar. 15. Position the small end of the CV joint boot (1) into the joint boot groove (3) on the halfshaft bar. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot Replacement > Page 8425 16. Secure the small boot clamp (1) using J 35910 (or equivalent), a breaker bar, and a torque wrench. Tighten the small clamp (1) to 136 Nm (100 lb ft). 17. Check the gap dimension on the clamp ear. Continue tightening until the gap dimension is reached. 18. Pinch the new swage ring (2) slightly by hand to distort it into an oval shape. 19. Slide the distorted swage ring (2) over the large diameter of the boot (1). Note: Be sure that the retaining ring side of the CV joint inner race faces the halfshaft bar (3) before installation. 20. Slide the CV joint (4) onto the halfshaft bar (3). The retaining snap ring inside of the inner race engages in the halfshaft bar groove with a click when the CV joint (4) is in the proper position. 21. Pull on the CV joint (4) to verify engagement. 22. Slide the large diameter of the CV joint boot (1), with the large swage ring (2) in place, over the outside edge of the CV joint outer race (4). 23. Clamp the CV joint boot (2) tightly to the CV joint outer race (1) with the large swage ring (4), using the following procedure: 24. For the 1500 models, assemble the bolts and the support plate to the base of the J 36652-1 and secure the base in a vise. For the 2500 and 3500 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot Replacement > Page 8426 models, use the J 36652-2 . 25. Position the CV joint end (outboard end) of the halfshaft assembly in the bottom half of J 36652-1 or J 36652-2 . 26. Align the following during this procedure: * The CV joint boot (3) * The CV joint assembly (1) * The swage ring (2) 27. Install the top half of J 36652-1 or J 36652-2 onto the lower half of the tool, over the CV joint boot (3) and the CV joint assembly (1). 28. Align the swage ring (2) and the swage ring clamp. 29. Insert the bolts into J 36652-1 or J 36652-2 . Hand tighten the bolts until the bolts are snug. Tighten each bolt 180 degrees at a time. Alternate between the bolts until both sides of the top half of the tool touch the bottom half of the tool. 30. Loosen the bolts and remove the halfshaft assembly from the tool. 31. Install the wheel drive shaft seal cover, if applicable. Refer to Front Wheel Drive Shaft Seal Protector Replacement (See: Service and Repair). 32. Install the wheel drive shaft. Refer to Wheel Drive Shaft Replacement (2500) (See: Service and Repair)Wheel Drive Shaft Replacement (1500) (See: Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot Replacement Constant Velocity Joint Boot: Service and Repair Wheel Drive Shaft Inner Joint and Boot Replacement Wheel Drive Shaft Inner Joint and Boot Replacement Special Tools * J-35910 - Drive Axle Seal Clamp Pliers * J-36652-1 - Drive Axle Clamp Swage Tool * J-36652-98 - Axle Swage Tool Disassemble Procedure 1. Remove the wheel drive shaft. Refer to Wheel Drive Shaft Replacement (2500) (See: Service and Repair)Wheel Drive Shaft Replacement (1500) (See: Service and Repair). Note: Use caution when removing the tripot housing (1). 2. Using the appropriate tool, remove the boot clamp (2). 3. Remove the tripot housing (1). Note: If using denatured alcohol or any other recommend cleaning solvent, allow the tripot housing to air dry. 4. Remove any grease from of the housing (1). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot Replacement > Page 8431 5. Using side cutters, remove the small boot retaining clamp (4). 6. Using the appropriate tool, remove the retaining ring (1), then the spider assembly (2), and the boot (3). 7. Using the appropriate tool, remove the any rust in the seal mounting area (grooves) (1). 8. If any of the internal components of the tripot assembly are found to be damaged or have excessive wear, replace the tripot as an assembly. Assemble Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot Replacement > Page 8432 1. Position the boot (1) so that it is seated properly in the groove (2) in the wheel drive shaft (3). 2. Install the small boot clamp (2) on the boot (1). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot Replacement > Page 8433 3. Using the J-35910 - pliers , a breaker bar, and a torque wrench (1), close the boot clamp (2) until the gap (3) measures 2.15 mm (0.085 inch). 4. Install the spider assembly (2). 5. Using the appropriate tool, install the retaining ring (1). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot Replacement > Page 8434 Note: Position the boot clamp so that it is at the small end of the boot. 6. Install the tripot assembly (1) and the boot clamp (2) 7. Place approximately half of the lubricant (2) in the boot (1) and the remaining half in the tripot housing (3). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot Replacement > Page 8435 Note: Pinch the slightly by hand in order to distort it into an oval shape. 8. Install the boot (1) and the boot clamp (2) on the tripot housing (3). 9. For the 1500 models, assemble the bolts and the support plate to the base of the J-36652-98 tool and secure the base in a vise. 10. For the 2500, 3500 models, assemble the bolts and the support plate to the base of the J-36652-1 - tool and secure the base in a vise. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot Replacement > Page 8436 11. Position the tripot end of the wheel drive shaft assembly into the base of the J-36652-98 - tool for the 1500 models or J-36652-1 - tool for the 2500, 3500 models. 12. Install the top half of the J-36652-98 - Tool for the 1500 models or J-36652-1 - tool for the 2500, 3500 models. 13. Align the boot clamp (2) and the clamp. Note: Hand tighten the bolts until the bolts are snug. 14. Insert the bolts. 15. Align the tripot boot, tripot housing, and the boot clamp. Note: Alternate between the bolts until both sides of the top half of the tool touch the bottom half. 16. Tighten each bolt 180 degrees at a time. 17. Loosen the bolts and remove the halfshaft assembly from the tool. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot Replacement > Page 8437 18. Inspect the inboard stroke position. * Measurement A for the 1500 models should be 170 mm (6 11/16 inch). * Measurement A for the 2500, 3500, should be 178 mm (7 inch). 19. Install the wheel drive shaft. Refer to Wheel Drive Shaft Replacement (2500) (See: Service and Repair)Wheel Drive Shaft Replacement (1500) (See: Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot Replacement > Page 8438 Constant Velocity Joint Boot: Service and Repair Wheel Drive Shaft Outer Joint and Boot Replacement Wheel Drive Shaft Outer Joint and Boot Replacement Special Tools * J 8059 Snap Ring Pliers * J 35910 Drive Axle Seal Clamp Pliers * J 36652-1 Drive Axle Clamp Swage Tool * J 36652-2 Axle Swage Tool Removal Procedure 1. Remove the wheel drive shaft. Refer to Wheel Drive Shaft Replacement (2500) (See: Service and Repair)Wheel Drive Shaft Replacement (1500) (See: Service and Repair). 2. Remove the wheel drive shaft seal cover, if applicable. Refer to Front Wheel Drive Shaft Seal Protector Replacement (See: Service and Repair). Note: Use caution when using the hand grinder by the CV joint outer race (1). 3. Use a hand grinder to cut through the swage ring (2). 4. Use side cutters to cut off the small boot clamp (4). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot Replacement > Page 8439 5. Slide the boot (5) down the halfshaft bar (4) and away from the CV joint outer race (1). 6. Wipe all grease away from the face of the CV joint. 7. Find the halfshaft bar retaining snap ring (3), which is located in the inner race (2). 8. Spread the snap ring ears apart using J 8059 (or equivalent). 9. Pull the CV joint (1) and the CV joint boot (5) from the halfshaft bar (4). 10. Discard the old CV joint boot (5). 11. Place a brass drift against the CV joint cage (1). 12. Tap gently on the brass drift with a hammer in order to tilt the cage (1). 13. Remove the first chrome alloy ball (2) when the CV joint cage (1) tilts. 14. Tilt the CV joint cage (1) in the opposite direction to remove the opposing chrome alloy ball (2). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot Replacement > Page 8440 15. Repeat this process to remove all six of the balls. 16. Pivot the CV joint cage (4) and the inner race 90 degrees to the center line of the outer race (1). At the same time, align the cage windows (3) with the lands of the outer race (2). 17. Lift out the cage (4) and the inner race. 18. Remove the inner race (1) from the cage (2) by rotating the inner race (1) upward. 19. Clean the following items thoroughly with cleaning solvent. Remove all traces of old grease and any contaminates. 1. The inner and outer race assemblies 2. The CV joint cage 3. The chrome alloy balls 20. Dry all the parts. 21. Check the CV joint assembly for unusual wear, cracks, or other damage. 22. Replace any damaged parts. 23. Clean the halfshaft bar. Use a wire brush to remove any rust in the seal mounting area (grooves). Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot Replacement > Page 8441 1. Inspect all of the parts for unusual wear, cracks, or other damage. Replace the CV joint assembly if necessary. 2. Put a light coat of the recommended grease on the inner (6) and the outer race (8) grooves. 3. Hold the inner race (1) at 90 degrees to the centerline of the cage (2). 4. Align the lands of the inner race (1) with the windows of the cage (2). 5. Insert the inner race (1) into the cage (2), by rotating the inner race (1) downward. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot Replacement > Page 8442 6. Insert the cage (4) and inner race into the outer race (1). 7. Place a brass drift against the CV joint cage (1). 8. Tap gently on the brass drift with a hammer in order to tilt the cage (1). 9. Install the first chrome alloy ball (2) when the CV joint cage (1) tilts. 10. Tilt the CV joint cage (1) in the opposite direction to install the opposing chrome alloy ball (2). 11. Repeat this process in order to install all six of the balls. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot Replacement > Page 8443 12. Pack the CV joint boot (1) and the CV joint assembly with the grease supplied in the kit. The amount of grease supplied in this kit has been pre-measured for this application. 13. Place the new small boot clamp (2) onto the CV joint seal (1). 14. Slide the CV joint boot (1) onto the halfshaft bar. 15. Position the small end of the CV joint boot (1) into the joint boot groove (3) on the halfshaft bar. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot Replacement > Page 8444 16. Secure the small boot clamp (1) using J 35910 (or equivalent), a breaker bar, and a torque wrench. Tighten the small clamp (1) to 136 Nm (100 lb ft). 17. Check the gap dimension on the clamp ear. Continue tightening until the gap dimension is reached. 18. Pinch the new swage ring (2) slightly by hand to distort it into an oval shape. 19. Slide the distorted swage ring (2) over the large diameter of the boot (1). Note: Be sure that the retaining ring side of the CV joint inner race faces the halfshaft bar (3) before installation. 20. Slide the CV joint (4) onto the halfshaft bar (3). The retaining snap ring inside of the inner race engages in the halfshaft bar groove with a click when the CV joint (4) is in the proper position. 21. Pull on the CV joint (4) to verify engagement. 22. Slide the large diameter of the CV joint boot (1), with the large swage ring (2) in place, over the outside edge of the CV joint outer race (4). 23. Clamp the CV joint boot (2) tightly to the CV joint outer race (1) with the large swage ring (4), using the following procedure: 24. For the 1500 models, assemble the bolts and the support plate to the base of the J 36652-1 and secure the base in a vise. For the 2500 and 3500 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Boot Replacement > Page 8445 models, use the J 36652-2 . 25. Position the CV joint end (outboard end) of the halfshaft assembly in the bottom half of J 36652-1 or J 36652-2 . 26. Align the following during this procedure: * The CV joint boot (3) * The CV joint assembly (1) * The swage ring (2) 27. Install the top half of J 36652-1 or J 36652-2 onto the lower half of the tool, over the CV joint boot (3) and the CV joint assembly (1). 28. Align the swage ring (2) and the swage ring clamp. 29. Insert the bolts into J 36652-1 or J 36652-2 . Hand tighten the bolts until the bolts are snug. Tighten each bolt 180 degrees at a time. Alternate between the bolts until both sides of the top half of the tool touch the bottom half of the tool. 30. Loosen the bolts and remove the halfshaft assembly from the tool. 31. Install the wheel drive shaft seal cover, if applicable. Refer to Front Wheel Drive Shaft Seal Protector Replacement (See: Service and Repair). 32. Install the wheel drive shaft. Refer to Wheel Drive Shaft Replacement (2500) (See: Service and Repair)Wheel Drive Shaft Replacement (1500) (See: Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Rear Axle Hub, Bearing, Cup, and/or Seal Replacement Seals and Gaskets: Service and Repair Rear Axle Hub, Bearing, Cup, and/or Seal Replacement Rear Axle Hub, Bearing, Cup, and/or Seal Replacement Special Tools * J 2222-C - Wheel Bearing Nut Wrench * J 8092 - Universal Driver Handle - 3/4 x 10 inch * J 24426 - Outer Wheel Bearing Race Installer * J 24427 - Inner Wheel Bearing Race Installer * J 44419 - Hub Bearing Installer * J 44420 - Differential Bearing Installer For equivalent regional tools, refer to Special Tools (See: Steering and Suspension/Suspension/Tools and Equipment/Rear Suspension). Removal Procedure Note: * The wheel speed sensor ring is NOT serviced separately. The hub and wheel speed senor ring are serviced as an assembly. * The rear axle hub seal must be replaced anytime the rear axle hub assembly is removed from the axle housing. * The wheel studs are serviced separately from the rear axle hub. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair) Lifting and Jacking the Vehicle. 2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair ) Tire and Wheel Removal and Installation. Note: In the following service procedure, it is not necessary to remove the brake caliper from the bracket. 3. Remove the brake caliper bracket. Refer to Rear Brake Caliper Bracket Replacement (JD9) (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Rear Brake Caliper Bracket Replacement (JD9))Rear Brake Caliper Bracket Replacement (JH6, JH7) (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Rear Brake Caliper Bracket Replacement (JH6, JH7)) Rear Brake Caliper Bracket Replacement. 4. Remove the rear axle shaft. Refer to Rear Axle Shaft and/or Gasket Replacement (See: Rear Axle Shaft and/or Gasket Replacement) Rear Axle Shaft and/or Gasket Replacement. 5. Remove the rear axle nut retaining ring. 6. Remove the rear wheel bearing adjuster key. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Rear Axle Hub, Bearing, Cup, and/or Seal Replacement > Page 8450 7. Using the J 2222-C - wrench , remove the rear wheel bearing adjuster nut. Note: If the oil seal remains on the axle hub, remove the seal using a suitable seal removal tool. 8. Remove the rear axle hub from the axle housing. 9. Remove the rear brake rotor, if necessary. Refer to Rear Brake Rotor Replacement (JD9) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JD9))Rear Brake Rotor Replacement (JH6) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JH6))Rear Brake Rotor Replacement (JH7) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JH7)) Rear Brake Rotor Replacement. 10. Using a suitable seal removal tool, remove the oil seal from the wheel hub. 11. Remove the inner hub bearing. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Rear Axle Hub, Bearing, Cup, and/or Seal Replacement > Page 8451 12. Using a brass drift and a hammer, remove the inner hub bearing cup. 13. Remove the retaining ring from the wheel hub. 14. Using the J 24426 - installer (2) and the J 8092 - handle (1), remove the outer hub bearing and bearing cup. 15. For those vehicles equipped with RPO code JH6, use the J 45270 (1) to remove the wheel studs (2). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Rear Axle Hub, Bearing, Cup, and/or Seal Replacement > Page 8452 16. For those vehicles equipped with RPO code JH7, use a hydraulic press to remove the wheel studs. 17. Remove the rear brake disc from the rear axle hub. Installation Procedure 1. For vehicles equipped RPO code JH7, position the brake rotor on the rear axle hub. 2. Position the wheel stud in the rear axle hub. 3. Using washers and a wheel nut, tighten the wheel nut until the wheel stud is fully seated in the rear axle hub. 4. Remove the lug nut and the washers. 5. Lubricate the following with a light coat of high melting point EP bearing lubricant: * The outer wheel bearing * The inner wheel bearing * The outer wheel bearing cup * The inner wheel bearing cup * The axle hub spindle Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Rear Axle Hub, Bearing, Cup, and/or Seal Replacement > Page 8453 6. Install the outer bearing into the rear axle hub. Note: Drive the outer bearing cup into the wheel hub until it is just past the retaining ring groove. Do not bottom out the bearing assembly in the bore. 7. Using the J 44419 - installer (2) and the J 8092 - handle (1), install the outer bearing cup into the rear axle hub. Note: Ensure that the retaining ring is fully and evenly seated in the groove. 8. Install the retaining ring into the groove. Note: Ensure that the outer bearing assembly rotates freely in the hub 9. Using the J 24426 - installer (2) and the J 8092 - handle (1), turn the rear axle hub over and seat the outer bearing assembly against the retaining ring. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Rear Axle Hub, Bearing, Cup, and/or Seal Replacement > Page 8454 10. Turn the rear axle hub over and install the inner bearing cup. 11. Using the J 24427 - installer (2) and the J 8092 - handle (1), install the inner bearing cup into the wheel hub. 12. Install the inner bearing. Note: Ensure the seal is fully seated in the hub bore. 13. Using the J 44420 - installer (2) and the J 8092 - handle (1), install the new oil seal. 14. Apply a light coat of high melting point EP bearing lubricant to the axle housing spindle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Rear Axle Hub, Bearing, Cup, and/or Seal Replacement > Page 8455 Note: If the rear axle hub assembly does not fully seat itself onto the axle shaft spindle and is removed, the rear axle hub seal must be replaced. 15. Install the rear axle hub. Note: Install the rear wheel bearing adjuster nut by hand. 16. Using the J 2222-C - wrench , adjust the rear wheel bearings. Refer to Wheel Bearing Adjustment (See: Differential Assembly/Service and Repair/Procedures/Rear Drive Axle/Wheel Bearing Adjustment) Wheel Bearing Adjustment 17. Install the rear axle shaft. Refer to Rear Axle Shaft and/or Gasket Replacement (See: Rear Axle Shaft and/or Gasket Replacement) Rear Axle Shaft and/or Gasket Replacement. 18. Install the brake caliper bracket. Refer to Rear Brake Caliper Bracket Replacement (JD9) (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Rear Brake Caliper Bracket Replacement (JD9))Rear Brake Caliper Bracket Replacement (JH6, JH7) (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Rear Brake Caliper Bracket Replacement (JH6, JH7)) Rear Brake Caliper Bracket Replacement. 19. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair) Tire and Wheel Removal and Installation. 20. Inspect and add axle lubricant to the axle housing, if necessary. Refer to Rear Axle Lubricant Level Inspection (8.6, 9.5 LD Axle) (See: Differential Assembly/Fluid - Differential/Service and Repair/Procedures/Rear Drive Axle/Rear Axle Lubricant Level Inspection (8.6, 9.5 LD Axle))Rear Axle Lubricant Level Inspection (10.5 Inch Axle) (See: Differential Assembly/Fluid - Differential/Service and Repair/Procedures/Rear Drive Axle/Rear Axle Lubricant Level Inspection (10.5 Inch Axle))Rear Axle Lubricant Level Inspection (11.5 Inch Axle) (See: Differential Assembly/Fluid - Differential/Service and Repair/Procedures/Rear Drive Axle/Rear Axle Lubricant Level Inspection (11.5 Inch Axle)) Rear Axle Lubricant Level Inspection. 21. Remove the supports and lower the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Rear Axle Hub, Bearing, Cup, and/or Seal Replacement > Page 8456 Seals and Gaskets: Service and Repair Rear Axle Shaft and/or Gasket Replacement Rear Axle Shaft and/or Gasket Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications FRONT WHEEL BEARINGS Wheel bearing lubricant meeting requirements of NLGI #2, Category GC or GC-LB (GM Part No. U.S. 1051344, in Canada 993037). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications > Page 8460 Wheel Bearing: Testing and Inspection Wheel Bearings Diagnosis Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Wheel Drive Shaft Nut ......................................................................................................................... .................................................... 240 Nm (177 lb ft) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support > Component Information > Service and Repair Center Support: Service and Repair Propeller Shaft Center Support Bearing Replacement Special Tools * J 22833 Input/Countershaft Race Installer * J 24433 Pinion Cone & Side Bearing Installer * J 39477 Puller Kit Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the propeller shaft assembly. Refer to Two-Piece Propeller Shaft Replacement (See: Drive/Propeller Shaft/Service and Repair/Two-Piece Propeller Shaft Replacement). 3. Install the J 39477 (1) on the center bearing assembly (2). 4. Position the J 39477 (1) in a vise 5. Using the J 39477 (1), remove the center bearing assembly (2) from the propeller shaft. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support > Component Information > Service and Repair > Page 8469 1. Place the propeller shaft assembly (3) on a block of wood. 2. Position the center bearing assembly (2) on the propeller shaft (3). 3. Using the J 22833 (1), install the center bearing assembly (2) on the propeller shaft (3). 4. For HD vehicles, use the J 24433 (1) to install the propeller shaft boot retainer (2) on the center bearing assembly (3). 5. Install the propeller shaft assembly. Refer to Two-Piece Propeller Shaft Replacement (See: Drive/Propeller Shaft/Service and Repair/Two-Piece Propeller Shaft Replacement) 6. Lower the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Specifications > Mechanical Specifications Drive/Propeller Shaft: Mechanical Specifications Fastener Tightening Specifications Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Specifications > Mechanical Specifications > Page 8474 Drive/Propeller Shaft: Fluid Type Specifications Adhesives, Fluids, Lubricants, and Sealers Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Specifications > Page 8475 Drive/Propeller Shaft: Locations Driveline Disassembled Views Front Propeller Shaft 1 - Propeller Shaft Universal Joint 2 - Propeller Shaft Tube 3 - Propeller Shaft Universal Joint 4 Propeller Shaft Slip Yoke 5 - Propeller Shaft Rear Slip Yoke Boot Clamp - Front 6 - Propeller Shaft Rear Slip Yoke Boot One-Piece Propeller Shaft Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Specifications > Page 8476 1 - Propeller Shaft Slip Yoke 2 - Propeller Shaft Universal Joint Spider Bearing Retainer Ring 3 Propeller Shaft Universal Joint 4 - Propeller Shaft Tube 5 - Propeller Shaft Universal Joint Spider Bearing Retainer Ring 6 - Propeller Shaft Universal Joint 7 - Propeller Shaft Bearing Retainer 8 Propeller Shaft Bearing Retainer Bolt Two-Piece Propeller Shaft 1 - Propeller Shaft Slip Yoke 2 - Propeller Shaft Universal Joint Spider Bearing Retainer Ring 3 Propeller Shaft Universal Joint 4 - Propeller Shaft Tube 5 - Propeller Shaft Bearing Shield 6 Propeller Shaft Bearing Insulator 7 - Propeller Shaft Bearing Support Bolt 8 - Propeller Shaft Bearing Support 9 - Propeller Shaft Retainer 10 - Propeller Shaft Center Support Bearing 11 Propeller Shaft Retainer 12 - Propeller Shaft Bearing Slinger 13 - Propeller Shaft Universal Joint 14 - Propeller Shaft Universal Joint Spider Bearing Retainer Ring 15 - Propeller Shaft Tube 16 Propeller Shaft Universal Joint 17 - Propeller Shaft Universal Joint Spider Bearing Retainer Ring 18 - Propeller Shaft Slip Yoke 19 - Propeller Shaft Slip Yoke Boot Clamp 20 - Propeller Shaft Slip Yoke Boot 21 - Propeller Shaft Slip Yoke Boot Clamp Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Specifications > Page 8477 Drive/Propeller Shaft: Description and Operation Propeller Shaft Description and Operation The propeller shaft is a tube with universal joints at both ends which do not require periodic maintenance, that transmit power from the transfer case or transmission output shaft to the differential. Front Propeller Shaft Description The front propeller shaft transmits rotating force from the transfer case to the front differential when the transfer case is engaged. The front propeller shaft connects to the transfer case using a splined slip joint. One Piece Propeller Shaft Description A 1 piece propeller shaft uses a splined slip joint to connect the driveline to the transmission or transfer case. Two Piece Propeller Shaft Description There are 3 universal joints used on the two piece propeller shaft, A center bearing assembly is used to support the propeller shaft connection point, and help isolate the vehicle from vibration. Propeller Shaft Phasing Description The propeller shaft is designed and built with the yoke lugs (ears) in line with each other. This produces the smoothest running shaft possible. A propeller shaft designed with built in yoke lugs in line is known as in - phase. An out of phase propeller shaft often causes vibration. The propeller shaft generates vibration from speeding up and slowing down each time the universal joint goes around. The vibration is the same as a person snapping a rope and watching the wave reaction flow to the end. An in phase propeller shaft is similar to 2 persons snapping a rope at the same time and watching the waves meet and cancel each other out. A total cancellation of vibration produces a smooth flow of power in the drive line. All splined shaft slip yokes are keyed in order to ensure proper phasing. Universal Joint Description The universal joint is connected to the propeller shaft. The universal consist of 4 caps with needle bearings and grease seals mounted on the trunnions of a cross or spider. These bearings and caps are greased at the factory and no periodic maintenance is required. There are 2 universal joints used in a one piece propeller shaft and 3 used in two piece propeller shaft. The bearings and caps are pressed into the yokes and held in place with snap rings, except for 2 bearings on some models witch are strapped onto the pinion flange of the differential. Universal joints are designed to handle the effects of various loads and rear axle windup conditions during acceleration and braking. The universal joint operates efficiently and safely within the designed angle variations. when the design angles are exceeded, the operational life of the joint decreases. Center Bearing Description Center bearings support the driveline when using 2 or more propeller shafts. The center bearing is a ball bearing mounted in a rubber cushion that attaches to a frame crossmember. The manufacturer prelubricates and seals the bearing. The cushion allows vertical motion at the driveline and helps isolate the vehicle from vibration. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Testing and Inspection > Symptoms - Propeller Shaft Drive/Propeller Shaft: Testing and Inspection Symptoms - Propeller Shaft Symptoms - Propeller Shaft Before beginning diagnosis, review the system description and operation in order to familiarize yourself with the system function. Refer to Propeller Shaft Description and Operation (See: Description and Operation). Classifying the Symptom Propeller Shaft symptoms can usually be classified into the following categories: * Leaks * Noises * Vibrations Leak and noise related symptoms are diagnosed within the Propeller Shaft section. For vibration related symptoms, refer to Vibration Diagnosis, Starting Point, and Correction (See: Testing and Inspection/Symptom Related Diagnostic Procedures/Vibration Diagnosis and Correction/Diagnostic Information and Procedures/Vibration Diagnosis, Starting Point, and Correction). Visual/Physical Inspection * Inspect the system for aftermarket devices which could affect the operation of the Propeller Shaft. * Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom. Symptom List Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom: * Leak at Front Slip Yoke (See: Leak at Front Slip Yoke) * Universal Joint Noise (See: Universal Joint Noise) * Ping, Snap, or Click Noise (See: Ping, Snap, or Click Noise) * Knock or Clunk Noise (See: Knock or Clunk Noise) * Scraping Noise (See: Scraping Noise) * Squeak Noise (See: Squeak Noise) * Shudder on Acceleration at Low Speed (See: Shudder on Acceleration at Low Speed) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Testing and Inspection > Symptoms - Propeller Shaft > Page 8480 Drive/Propeller Shaft: Testing and Inspection Knock or Clunk Noise Knock or Clunk Noise Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Testing and Inspection > Symptoms - Propeller Shaft > Page 8481 Drive/Propeller Shaft: Testing and Inspection Leak at Front Slip Yoke Leak at Front Slip Yoke Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Testing and Inspection > Symptoms - Propeller Shaft > Page 8482 Drive/Propeller Shaft: Testing and Inspection Ping, Snap, or Click Noise Ping, Snap, or Click Noise Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Testing and Inspection > Symptoms - Propeller Shaft > Page 8483 Drive/Propeller Shaft: Testing and Inspection Symptoms - Propeller Shaft Symptoms - Propeller Shaft Before beginning diagnosis, review the system description and operation in order to familiarize yourself with the system function. Refer to Propeller Shaft Description and Operation (See: Description and Operation). Classifying the Symptom Propeller Shaft symptoms can usually be classified into the following categories: * Leaks * Noises * Vibrations Leak and noise related symptoms are diagnosed within the Propeller Shaft section. For vibration related symptoms, refer to Vibration Diagnosis, Starting Point, and Correction (See: Testing and Inspection/Symptom Related Diagnostic Procedures/Vibration Diagnosis and Correction/Diagnostic Information and Procedures/Vibration Diagnosis, Starting Point, and Correction). Visual/Physical Inspection * Inspect the system for aftermarket devices which could affect the operation of the Propeller Shaft. * Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom. Symptom List Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom: * Leak at Front Slip Yoke (See: Leak at Front Slip Yoke) * Universal Joint Noise (See: Universal Joint Noise) * Ping, Snap, or Click Noise (See: Ping, Snap, or Click Noise) * Knock or Clunk Noise (See: Knock or Clunk Noise) * Scraping Noise (See: Scraping Noise) * Squeak Noise (See: Squeak Noise) * Shudder on Acceleration at Low Speed (See: Shudder on Acceleration at Low Speed) Knock or Clunk Noise Knock or Clunk Noise Leak at Front Slip Yoke Leak at Front Slip Yoke Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Testing and Inspection > Symptoms - Propeller Shaft > Page 8484 Ping, Snap, or Click Noise Ping, Snap, or Click Noise Scraping Noise Scraping Noise Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Testing and Inspection > Symptoms - Propeller Shaft > Page 8485 Shudder on Acceleration at Low Speed Shudder on Acceleration at Low Speed Squeak Noise Squeak Noise Universal Joint Noise Universal Joint Noise Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Front Propeller Shaft Replacement Drive/Propeller Shaft: Service and Repair Front Propeller Shaft Replacement Front Propeller Shaft Replacement Special Tools J 43218 Clamp Pliers - Narrow Jaw Removal Procedure Note: Before disassembly, observe and accurately reference mark all driveline components relative to the propeller shaft and axles. These items include the following components: * The propeller shafts * The wheel drive shafts * The pinion flanges * The output shafts Assemble all components in the exact relationship to each other as they were prior to removal. Observe all published specifications and torque values, and any measurements obtained prior to disassembly. 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the clamp (4) at the transfer case by prying up the exposed end of the clamp with a flat-bladed tool. 3. Reference mark the relationship of the propeller shaft to the front axle pinon yoke. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Front Propeller Shaft Replacement > Page 8488 Caution: When removing the propeller shaft, do not attempt to remove the shaft by pounding on the yoke ears or using a tool between the yoke and the universal joint. If the propeller shaft is removed by using such means, the injection joints may fracture and lead to premature failure of the joint. 4. Remove the bolts (6) and the yoke retainers (7) from the front axle pinion yoke (1). Note: Do not drop the bearing cap assemblies of the yoke end. 5. Disconnect the propeller shaft (2) from the front axle pinion yoke (1). Wrap the bearing caps with tape in order to prevent the loss of bearing rollers. 6. Use tape to secure the bearing caps. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Front Propeller Shaft Replacement > Page 8489 7. Remove the boot from the groove on the transfer case output shaft. 8. Remove the propeller shaft from the transfer case output shaft by sliding the propeller shaft forward. 9. Remove the clamp (1) from the propeller shaft boot (2), if needed. 10. Remove the propeller shaft boot (2) from the propeller shaft, if needed. Installation Procedure 1. Inspect the splines of the transfer case output shaft for a sufficient coating of lubricant. If the output shaft does not have a sufficient coating of lubricant, lubricate the shaft with grease, GM P/N 12345879 (Canadian P/N 10953511), or equivalent lubricant meeting GM Specification 9985830. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Front Propeller Shaft Replacement > Page 8490 2. Install the propeller shaft boot (2). 3. Install the propeller shaft boot clamp (1). 4. Install the propeller shaft splines into the transfer case output shaft. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Front Propeller Shaft Replacement > Page 8491 5. Install the propeller shaft (5) to the front axle pinion yoke (1). Align the reference marks made during removal. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 6. Install the yoke retainers (7) and the bolts (6). Tighten the yoke retainer bolts to 25 Nm (18 lb ft). 7. Install the boot onto the transfer case output shaft until the boot snaps into the groove on the output shaft. 8. Using the J 43218 to crimp both clamps. 9. Lower the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Front Propeller Shaft Replacement > Page 8492 Drive/Propeller Shaft: Service and Repair Rear Propeller Shaft Replacement Rear Propeller Shaft Replacement Removal Procedure Note: Observe and accurately reference mark all driveline components relative to the propeller shaft and axles before disassembly. These components include the propeller shafts, the drive axles, the pinion flanges, the output shafts, etc. All components must be reassembled in the exact relationship to each other as they were when removed. In addition, published specifications and torque values, as well as any measurements made prior to disassembly must be followed. 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Reference mark the propeller shaft to the rear axle pinion yoke. 3. Reference mark the propeller shaft to the transmission or transfer case. 4. Remove the bolts (1) and the yoke retainers (2) from the rear axle pinion yoke (3). Caution: When removing the propeller shaft, do not attempt to remove the shaft by pounding on the yoke ears or using a tool between the yoke and the universal joint. If the propeller shaft is removed by using such means, the injection joints may fracture and lead to premature failure of the joint. 5. Slide the propeller shaft forward in order to disconnect the propeller shaft from the rear axle pinion yoke. 6. Slide the propeller shaft rearward in order to disconnect the propeller shaft from the transmission or transfer case. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Front Propeller Shaft Replacement > Page 8493 7. Remove the propeller shaft from the vehicle. Installation Procedure 1. Inspect the splines of the slip yoke for a sufficient coating of lubricant. If the splines of the slip yoke do not have a sufficient coating of lubricant, lubricate the shaft with lubricant GM P/N 12345879 (Canadian P/N 10953511) or with an equivalent lubricant meeting GM specification 9985830 (RWD w/4-speed Automatic Transmission). 2. Install the propeller shaft into the transmission or transfer case. Align the reference marks made during removal. 3. Install the propeller shaft (3) to the rear axle pinion yoke (4). Align the reference marks made during removal. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the yoke retainers (2) and bolts (1) and tighten to 25 Nm (18 lb ft). 5. Lower the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Front Propeller Shaft Replacement > Page 8494 Drive/Propeller Shaft: Service and Repair One-Piece Propeller Shaft Replacement One-Piece Propeller Shaft Replacement Removal Procedure Note: Observe and accurately reference mark all driveline components relative to the propeller shaft and axles before disassembly. These components include the propeller shafts, the drive axles, the pinion flanges, the output shafts, etc. All components must be reassembled in the exact relationship to each other as they were when removed. In addition, published specifications and torque values, as well as any measurements made prior to disassembly must be followed. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Reference mark the propeller shaft (1), the universal joint strap (2), universal bearing cap (4), the drive pinion yoke (5), and the rear axle housing (6). 3. Remove the bolts (3) and the universal straps (2) from the rear axle pinion yoke (5). Caution: When removing the propeller shaft, do not attempt to remove the shaft by pounding on the yoke ears or using a tool between the yoke and the universal joint. If the propeller shaft is removed by using such means, the injection joints may fracture and lead to premature failure of the joint. 4. Remove the propeller shaft from the rear axle pinion yoke. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Front Propeller Shaft Replacement > Page 8495 5. Reference mark the transmission or the transfer case (1), propeller shaft flip yoke (2), universal joint bearing cap (3), and the propeller shaft (4). 6. Remove the propeller shaft from the vehicle. Installation Procedure 1. Inspect the splines of the slip yoke for a sufficient coating of grease. If the splines of the slip yoke does not have a sufficient coating of grease, lubricate the shaft with clean grease or transmission fluid. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Front Propeller Shaft Replacement > Page 8496 2. Align the reference marks on the propeller shaft (4), the slip yoke (2), the universal bearing caps (3), the transmission or the transfer case (1). 3. Install the propeller shaft in the transmission or transfer the case. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Front Propeller Shaft Replacement > Page 8497 Note: Ensure that the reference marks are aligned before installing the propeller shaft. 4. Align the reference marks on the propeller shaft (1), universal bearing cap (4), pinion flange (5), and the rear axle housing (6). 5. With the reference marks aligned, install the propeller shaft (1) on the rear axle (6). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 6. Install the rear propeller shaft bolts (3) and the strap (2). Tighten the yoke retainer bolts to 25 Nm (18 lb ft). 7. Remove the support and lower the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Front Propeller Shaft Replacement > Page 8498 Drive/Propeller Shaft: Service and Repair Two-Piece Propeller Shaft Replacement Two-Piece Propeller Shaft Replacement Special Tools J 43218 Clamp Pliers - Narrow Jaw Removal Procedure Note: Observe and accurately reference mark all driveline components relative to the propeller shaft and axles before disassembly. These components include the propeller shafts, the drive axles, the pinion flanges, the output shafts, etc. All components must be reassembled in the exact relationship to each other as they were when removed. In addition, published specifications and torque values, as well as any measurements made prior to disassembly must be followed. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Reference mark the propeller shaft (1), the universal joint strap (2), the universal bearing cap (4), the drive pinion yoke (5), and the rear axle housing (6). 3. Remove the rear propeller shaft bolts (3) and the universal joint strap (2). 4. Using a flat bladed tool, remove the clamp (2) securing the boot (3) to the front propeller slip yoke (4) and at the center bearing (1) by prying up the exposed end of the clamp (2). Caution: When removing the propeller shaft, do not attempt to remove the shaft by pounding on the yoke ears or using a tool between the yoke and the universal joint. If the propeller shaft is removed by using such means, the injection joints may fracture and lead to premature failure of the Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Front Propeller Shaft Replacement > Page 8499 joint. 5. Remove the rear propeller shaft from the rear axle and the center support bearing. Note: Step 6 is for those vehicles that have a slip yoke from the transmission from transfer case to the propeller shaft. 6. Reference mark the transmission or the transfer case (1), propeller shaft slip yoke (2), universal bearing cap (3), and the propeller shaft (4). Note: Step 7 is for those vehicles that have the yoke attached to the output shaft. 7. Reference mark the transmission or transfer case (1), output shaft flange (2), universal joint bearing cap (3), and the propeller shaft. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Front Propeller Shaft Replacement > Page 8500 8. Remove the center bearing support nuts (1). 9. Remove the center bearing support (2). Note: For those vehicles equipped with the yoke attached to the output shaft, proceed to step 10. Those vehicles equipped with a slip yoke, proceed to step 12. 10. For vehicles equipped with the yoke attached to the output shaft, use a suitable jack stand support the propeller shaft until propeller shaft is to be removed. 11. Remove the propeller shaft bolts (3), the straps (4), and the propeller shaft (2) from the transmission or the transfer case (1). 12. Remove the propeller shaft from the transmission or the transfer case. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Front Propeller Shaft Replacement > Page 8501 Note: If servicing a propeller shaft with a slip yoke, proceed to step 1. If servicing a propeller shaft with the yoke attached to the output shaft of the transmission or the transfer case, proceed to step 3. 1. Align the reference marks on the transmission or the transfer case (1), slip yoke (2), universal bearing cap (3), and the propeller shaft. 2. Install the propeller shaft. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Front Propeller Shaft Replacement > Page 8502 3. Align the reference marks on the transmission or the transfer case (1), output shaft yoke (2), and the propeller shaft (6). Note: When installing the propeller shaft bolts, hand tighten the bolts. DO NOT tighten them to specification until the center bearing support bolts have been installed and torqued to specifications. 4. Install the propeller shaft (2), the straps (3), the propeller shaft bolts (3) on the transmission or the transfer case (1). 5. Position the center support bearing (1) on the frame. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Front Propeller Shaft Replacement > Page 8503 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 6. Install the center bearing support nuts. Tighten the center support bearing nuts to 40 Nm (30 lb ft). 7. Tighten the propeller shaft bolts (3) to specifications. Tighten the propeller shaft bolts to 25 Nm (18 lb ft). 8. Install the boot (3) and the new clamps (2) onto the front propeller shaft slip yoke (4). Note: Ensure that the master splines on the slip yoke and the stub shaft are aligned before installing the rear propeller shaft. 9. Apply a small amount of clean chassis grease to the slip yoke and the rear propeller shaft. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Front Propeller Shaft Replacement > Page 8504 10. Install the rear portion of the propeller into the front portion of the propeller shaft. 11. Align the reference marks on the rear axle housing (6), pinion yoke (5), universal bearing cap (4), and the rear propeller shaft (1). 12. Install the straps (2) and the bolts (3). Tighten the yoke retainer bolts to 25 Nm (18 lb ft). 13. Using the J 43218 , crimp the boot clamps until the dimensions shown are obtained. 14. Remove the support and lower that vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Front Propeller Shaft Replacement > Page 8505 Drive/Propeller Shaft: Service and Repair Front Propeller Shaft Replacement Front Propeller Shaft Replacement Special Tools J 43218 Clamp Pliers - Narrow Jaw Removal Procedure Note: Before disassembly, observe and accurately reference mark all driveline components relative to the propeller shaft and axles. These items include the following components: * The propeller shafts * The wheel drive shafts * The pinion flanges * The output shafts Assemble all components in the exact relationship to each other as they were prior to removal. Observe all published specifications and torque values, and any measurements obtained prior to disassembly. 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the clamp (4) at the transfer case by prying up the exposed end of the clamp with a flat-bladed tool. 3. Reference mark the relationship of the propeller shaft to the front axle pinon yoke. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Front Propeller Shaft Replacement > Page 8506 Caution: When removing the propeller shaft, do not attempt to remove the shaft by pounding on the yoke ears or using a tool between the yoke and the universal joint. If the propeller shaft is removed by using such means, the injection joints may fracture and lead to premature failure of the joint. 4. Remove the bolts (6) and the yoke retainers (7) from the front axle pinion yoke (1). Note: Do not drop the bearing cap assemblies of the yoke end. 5. Disconnect the propeller shaft (2) from the front axle pinion yoke (1). Wrap the bearing caps with tape in order to prevent the loss of bearing rollers. 6. Use tape to secure the bearing caps. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Front Propeller Shaft Replacement > Page 8507 7. Remove the boot from the groove on the transfer case output shaft. 8. Remove the propeller shaft from the transfer case output shaft by sliding the propeller shaft forward. 9. Remove the clamp (1) from the propeller shaft boot (2), if needed. 10. Remove the propeller shaft boot (2) from the propeller shaft, if needed. Installation Procedure 1. Inspect the splines of the transfer case output shaft for a sufficient coating of lubricant. If the output shaft does not have a sufficient coating of lubricant, lubricate the shaft with grease, GM P/N 12345879 (Canadian P/N 10953511), or equivalent lubricant meeting GM Specification 9985830. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Front Propeller Shaft Replacement > Page 8508 2. Install the propeller shaft boot (2). 3. Install the propeller shaft boot clamp (1). 4. Install the propeller shaft splines into the transfer case output shaft. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Front Propeller Shaft Replacement > Page 8509 5. Install the propeller shaft (5) to the front axle pinion yoke (1). Align the reference marks made during removal. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 6. Install the yoke retainers (7) and the bolts (6). Tighten the yoke retainer bolts to 25 Nm (18 lb ft). 7. Install the boot onto the transfer case output shaft until the boot snaps into the groove on the output shaft. 8. Using the J 43218 to crimp both clamps. 9. Lower the vehicle. Rear Propeller Shaft Replacement Rear Propeller Shaft Replacement Removal Procedure Note: Observe and accurately reference mark all driveline components relative to the propeller shaft and axles before disassembly. These components include the propeller shafts, the drive axles, the pinion flanges, the output shafts, etc. All components must be reassembled in the exact relationship to each other as they were when removed. In addition, published specifications and torque values, as well as any measurements made prior to disassembly must be followed. 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Reference mark the propeller shaft to the rear axle pinion yoke. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Front Propeller Shaft Replacement > Page 8510 3. Reference mark the propeller shaft to the transmission or transfer case. 4. Remove the bolts (1) and the yoke retainers (2) from the rear axle pinion yoke (3). Caution: When removing the propeller shaft, do not attempt to remove the shaft by pounding on the yoke ears or using a tool between the yoke and the universal joint. If the propeller shaft is removed by using such means, the injection joints may fracture and lead to premature failure of the joint. 5. Slide the propeller shaft forward in order to disconnect the propeller shaft from the rear axle pinion yoke. 6. Slide the propeller shaft rearward in order to disconnect the propeller shaft from the transmission or transfer case. 7. Remove the propeller shaft from the vehicle. Installation Procedure 1. Inspect the splines of the slip yoke for a sufficient coating of lubricant. If the splines of the slip yoke do not have a sufficient coating of lubricant, lubricate the shaft with lubricant GM P/N 12345879 (Canadian P/N 10953511) or with an equivalent lubricant meeting GM specification 9985830 (RWD w/4-speed Automatic Transmission). 2. Install the propeller shaft into the transmission or transfer case. Align the reference marks made during removal. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Front Propeller Shaft Replacement > Page 8511 3. Install the propeller shaft (3) to the rear axle pinion yoke (4). Align the reference marks made during removal. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the yoke retainers (2) and bolts (1) and tighten to 25 Nm (18 lb ft). 5. Lower the vehicle. One-Piece Propeller Shaft Replacement One-Piece Propeller Shaft Replacement Removal Procedure Note: Observe and accurately reference mark all driveline components relative to the propeller shaft and axles before disassembly. These components include the propeller shafts, the drive axles, the pinion flanges, the output shafts, etc. All components must be reassembled in the exact relationship to each other as they were when removed. In addition, published specifications and torque values, as well as any measurements made prior to disassembly must be followed. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Reference mark the propeller shaft (1), the universal joint strap (2), universal bearing cap (4), the drive pinion yoke (5), and the rear axle housing (6). 3. Remove the bolts (3) and the universal straps (2) from the rear axle pinion yoke (5). Caution: When removing the propeller shaft, do not attempt to remove the shaft by pounding on the yoke ears or using a tool between the yoke and the universal joint. If the propeller shaft is removed by using such means, the injection joints may fracture and lead to premature failure of the Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Front Propeller Shaft Replacement > Page 8512 joint. 4. Remove the propeller shaft from the rear axle pinion yoke. 5. Reference mark the transmission or the transfer case (1), propeller shaft flip yoke (2), universal joint bearing cap (3), and the propeller shaft (4). 6. Remove the propeller shaft from the vehicle. Installation Procedure 1. Inspect the splines of the slip yoke for a sufficient coating of grease. If the splines of the slip yoke does not have a sufficient coating of grease, lubricate the shaft with clean grease or transmission fluid. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Front Propeller Shaft Replacement > Page 8513 2. Align the reference marks on the propeller shaft (4), the slip yoke (2), the universal bearing caps (3), the transmission or the transfer case (1). 3. Install the propeller shaft in the transmission or transfer the case. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Front Propeller Shaft Replacement > Page 8514 Note: Ensure that the reference marks are aligned before installing the propeller shaft. 4. Align the reference marks on the propeller shaft (1), universal bearing cap (4), pinion flange (5), and the rear axle housing (6). 5. With the reference marks aligned, install the propeller shaft (1) on the rear axle (6). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 6. Install the rear propeller shaft bolts (3) and the strap (2). Tighten the yoke retainer bolts to 25 Nm (18 lb ft). 7. Remove the support and lower the vehicle. Two-Piece Propeller Shaft Replacement Two-Piece Propeller Shaft Replacement Special Tools J 43218 Clamp Pliers - Narrow Jaw Removal Procedure Note: Observe and accurately reference mark all driveline components relative to the propeller shaft and axles before disassembly. These components include the propeller shafts, the drive axles, the pinion flanges, the output shafts, etc. All components must be reassembled in the exact relationship to each other as they were when removed. In addition, published specifications and torque values, as well as any measurements made prior to disassembly must be followed. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Reference mark the propeller shaft (1), the universal joint strap (2), the universal bearing cap (4), the drive pinion yoke (5), and the rear axle housing (6). 3. Remove the rear propeller shaft bolts (3) and the universal joint strap (2). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Front Propeller Shaft Replacement > Page 8515 4. Using a flat bladed tool, remove the clamp (2) securing the boot (3) to the front propeller slip yoke (4) and at the center bearing (1) by prying up the exposed end of the clamp (2). Caution: When removing the propeller shaft, do not attempt to remove the shaft by pounding on the yoke ears or using a tool between the yoke and the universal joint. If the propeller shaft is removed by using such means, the injection joints may fracture and lead to premature failure of the joint. 5. Remove the rear propeller shaft from the rear axle and the center support bearing. Note: Step 6 is for those vehicles that have a slip yoke from the transmission from transfer case to the propeller shaft. 6. Reference mark the transmission or the transfer case (1), propeller shaft slip yoke (2), universal bearing cap (3), and the propeller shaft (4). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Front Propeller Shaft Replacement > Page 8516 Note: Step 7 is for those vehicles that have the yoke attached to the output shaft. 7. Reference mark the transmission or transfer case (1), output shaft flange (2), universal joint bearing cap (3), and the propeller shaft. 8. Remove the center bearing support nuts (1). 9. Remove the center bearing support (2). Note: For those vehicles equipped with the yoke attached to the output shaft, proceed to step 10. Those vehicles equipped with a slip yoke, proceed to step 12. 10. For vehicles equipped with the yoke attached to the output shaft, use a suitable jack stand support the propeller shaft until propeller shaft is to be removed. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Front Propeller Shaft Replacement > Page 8517 11. Remove the propeller shaft bolts (3), the straps (4), and the propeller shaft (2) from the transmission or the transfer case (1). 12. Remove the propeller shaft from the transmission or the transfer case. Installation Procedure Note: If servicing a propeller shaft with a slip yoke, proceed to step 1. If servicing a propeller shaft with the yoke attached to the output shaft of the transmission or the transfer case, proceed to step 3. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Front Propeller Shaft Replacement > Page 8518 1. Align the reference marks on the transmission or the transfer case (1), slip yoke (2), universal bearing cap (3), and the propeller shaft. 2. Install the propeller shaft. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Front Propeller Shaft Replacement > Page 8519 3. Align the reference marks on the transmission or the transfer case (1), output shaft yoke (2), and the propeller shaft (6). Note: When installing the propeller shaft bolts, hand tighten the bolts. DO NOT tighten them to specification until the center bearing support bolts have been installed and torqued to specifications. 4. Install the propeller shaft (2), the straps (3), the propeller shaft bolts (3) on the transmission or the transfer case (1). 5. Position the center support bearing (1) on the frame. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 6. Install the center bearing support nuts. Tighten the center support bearing nuts to 40 Nm (30 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Front Propeller Shaft Replacement > Page 8520 7. Tighten the propeller shaft bolts (3) to specifications. Tighten the propeller shaft bolts to 25 Nm (18 lb ft). 8. Install the boot (3) and the new clamps (2) onto the front propeller shaft slip yoke (4). Note: Ensure that the master splines on the slip yoke and the stub shaft are aligned before installing the rear propeller shaft. 9. Apply a small amount of clean chassis grease to the slip yoke and the rear propeller shaft. 10. Install the rear portion of the propeller into the front portion of the propeller shaft. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Front Propeller Shaft Replacement > Page 8521 11. Align the reference marks on the rear axle housing (6), pinion yoke (5), universal bearing cap (4), and the rear propeller shaft (1). 12. Install the straps (2) and the bolts (3). Tighten the yoke retainer bolts to 25 Nm (18 lb ft). 13. Using the J 43218 , crimp the boot clamps until the dimensions shown are obtained. 14. Remove the support and lower that vehicle. Propeller Shaft Slip Yoke Boot Replacement Propeller Shaft Slip Yoke Boot Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Front Propeller Shaft Replacement > Page 8522 Propeller Shaft Slip Yoke Replacement Propeller Shaft Slip Yoke Replacement To replace the propeller shaft slip yoke, refer to Universal Joint Replacement (See: Universal Joint/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Page 8523 Drive/Propeller Shaft: Tools and Equipment Special Tools Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair Universal Joint: Service and Repair Universal Joint Replacement Special Tools * J-9522-3 - U-Joint Bearing Separator * J-9522-5 - U-Joint Bearing Spacer Remover Removal Procedure Caution: Never clamp propeller shaft tubing in a vise. Clamping propeller shaft tubing in a vise could dent or deform the tube causing an imbalance or unsafe condition. Always clamp on one of the yokes and support the shaft horizontally. Avoid damaging the slip yoke sealing surface. Nicks may damage the bushing or cut the lip seal. Note: The following service procedure can be used for either the external retaining ring or the nylon injected ring. Note: If replacing the propeller shaft slip yoke, proceed to step 10. 1. Using a hammer (2), tap the yoke (1) lightly in order to relieve the pressure from the universal joint retaining ring. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Page 8527 2. Using a pair of pliers, remove the retaining ring (2) from the yoke (1). 3. With the aide of an assistant, support the propeller shaft so that it level with the press. 4. Using the appropriate size socket (2), support the universal joint opposite of the J-9522-3 U-Joint Bearing Separator. 5. Using the J-9522-3 - Separator (1) and the press, remove the universal bearing from the yoke. 6. If you are unable to completely remove the universal bearing with the J-9522-3 - Separator , proceed to step 7. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Page 8528 7. Position the J-9522-5 - U-Joint Bearing Spacer Remover (1) on the universal joint. Note: The following procedure is also used for the breaking of the nylon injected ring for those universal joints that are equipped. 8. Using the J-9522-3 - Separator , J-9522-5 - Remover and a press, remove the universal bearing from the yoke. 9. Rotate the propeller shaft and repeat steps 1-8 to remove the opposite universal joint. Note: If the slip yoke is found to be damaged, replace the slip yoke and use a NEW universal joint. DO NOT re-use the old universal joint. 10. Remove the slip yoke (1) from the propeller shaft (2). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Page 8529 11. Remove the retaining ring (1) from the slip yoke (3). 12. Using the J-9522-3 - Separator , J-9522-5 - Remover and a press, remove the universal bearing (2) from the yoke (3). 13. Remove the spider (2) from the slip yoke (1). 14. Thoroughly clean the slip yoke and the propeller shaft yoke of any contaminates that could prevent the retaining rings or the bearing cups from being properly installed. Installation Procedure Note: If replacing the propeller shaft slip yoke, proceed to step 8. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Page 8530 1. Position the universal bearings in either side of the yoke on the propeller shaft. 2. Install the universal joint spider until it is seated in the universal bearing. 3. Press the universal joint spider until the bearing is even with the yoke. 4. Install the retaining ring (1) in the yoke (2). 5. Rotate the propeller shaft and repeat steps 1-4 for the opposite universal bearing. 6. Rotate the universal joint to ensure that the universal joint moves freely. If not, use a hammer and lightly tap the yoke to seat the universal bearing against the retaining ring. 7. Install the other two universal bearings and wrap them with electrical tape or equivalent to hold the bearing in place until the propeller shaft is installed in the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Page 8531 8. Position the universal spider (2) in the slip yoke (1). 9. Install the universal bearings (2) in either side of the slip yoke (2). 10. Fully seat one of the universal spiders in the universal bearing. 11. Press the universal bearings (2) into the slip yoke (2) until it is even with the yoke. 12. Install the retaining ring (1) in the slip yoke (3). 13. Rotate the slip yoke and repeat steps 3-5 for the opposite universal bearing. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Page 8532 14. Position the slip yoke (1) in the propeller shaft (2). 15. Position the universal bearing (1) in the yoke of the propeller shaft (2). 16. Center the universal spider in the universal bearing. 17. Press the universal bearing into the yoke. 18. Install the retaining ring (2) in the propeller shaft yoke (1). 19. Rotate the propeller shaft and repeat steps 8-11 or the opposite universal bearing. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Page 8533 20. Rotate the universal joint to ensure that the universal joint moves freely. If not, use a hammer (2) and lightly tap each of the yokes (1) to seat the universal bearing against the retaining ring. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications Flex Plate: Specifications NEW Flywheel Bolts First pass ........................................................................................................... ........................................................................................... 79 Nm (58 lb ft) Second pass .................. .............................................................................................................................................................. ........................... 60 degrees Final pass ............................................................................................. ............................................................................................ an additional 60 degrees Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Service and Repair > Engine Flywheel Replacement Flex Plate: Service and Repair Engine Flywheel Replacement Engine Flywheel Replacement Special Tools * J 44643 Flywheel Holding Tool * J 45059 Angle Meter Removal Procedure 1. Remove the transmission. Refer to Transmission Replacement (See: Automatic Transmission/Transaxle/Service and Repair) for the 4L60-E /4L65-E/4L70-E transmission, Transmission Replacement (See: Automatic Transmission/Transaxle/Service and Repair) for the 4L50/4L80/4L90 transmission, or Transmission Replacement (See: Automatic Transmission/Transaxle/Service and Repair) for the Allison transmission. 2. Install J 44643 in order to hold the flywheel. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Service and Repair > Engine Flywheel Replacement > Page 8539 Warning When removing, handling or installing this component wear protective gloves. The sharp edges on the component may be very sharp and may cause injury. 3. Remove and discard the flywheel bolts. 4. Remove the flywheel washer and flywheel. Installation Procedure Warning When removing, handling or installing this component wear protective gloves. The sharp edges on the component may be very sharp and may cause injury. Note: When installing the flywheel, ensure that the tapered side of the teeth are facing the starter. 1. Install the flywheel. 2. Install the flywheel washer with the beveled side facing the engine. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Caution: This component uses bolts with a preapplied molybdenum disulfide coating for thread lubrication. Do not remove the coating or use any additional lubricant. Improperly lubricated threads will adversely affect the bolt torque and clamp load. Improper bolt torque and clamp load can lead to engine damage. 3. Install NEW flywheel bolts. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Service and Repair > Engine Flywheel Replacement > Page 8540 4. Tighten the flywheel bolts in the proper sequence. 1. Tighten the bolts a first pass to 79 Nm (58 lb ft). 2. Tighten the bolts a second pass to 60 degrees using J 45059 . 3. Tighten the bolts a final pass an additional 60 degrees using J 45059 . 5. Remove J 44643 from the flywheel. 6. Install the transmission. Refer to Transmission Replacement (See: Automatic Transmission/Transaxle/Service and Repair) for the 4L60-E/4L65-E/4L70-E transmission, Transmission Replacement (See: Automatic Transmission/Transaxle/Service and Repair) for the 4L50/4L80/4L90 transmission, or Transmission Replacement (See: Automatic Transmission/Transaxle/Service and Repair) for the Allison transmission. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Service and Repair > Engine Flywheel Replacement > Page 8541 Flex Plate: Service and Repair Automatic Transmission Flex Plate Replacement Automatic Transmission Flex Plate Replacement Removal Procedure 1. Remove the automatic transmission. Refer to Transmission Replacement (See: Automatic Transmission/Transaxle/Service and Repair) for the 4L60-E. Note: Note the position and direction of the engine flywheel before removal. 2. Remove the flywheel bolts. 3. Remove the flywheel. 4. Install two M11x1.5 mm bolts (1) to the threaded holes of the spacer, if applicable. 5. Rotate the bolts clockwise to remove the spacer. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Service and Repair > Engine Flywheel Replacement > Page 8542 6. Remove the spacer from the rear of the crankshaft, if applicable. Installation Procedure Note: * The flywheel does not use a locating pin for alignment and will not initially seat against the crankshaft flange or spacer, if applicable, but will be pulled onto the crankshaft by the engine flywheel bolts. This procedure requires a three stage tightening process. * Certain applications (6.0L) require a spacer and longer bolts for proper flywheel position. 1. Install the spacer, if applicable, onto the rear of the crankshaft. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Service and Repair > Engine Flywheel Replacement > Page 8543 Note: Longer flywheel bolts must be used on applications using a flywheel spacer. 2. Install the flywheel and bolts to the crankshaft. 3. Apply threadlock to the threads of the flywheel bolts. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Engine, Cooling and Exhaust/Engine/Specifications/Adhesives, Fluids, Lubricants, and Sealers) for the correct part number. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Tighten the flywheel bolts. * Tighten the bolts (1-6) a first pass in sequence to 20 Nm (15 lb ft). * Tighten the bolts (1-6) a second pass in sequence to 50 Nm (37 lb ft). * Tighten the bolts (1-6) a final pass in sequence to 100 Nm (74 lb ft). 5. Install the automatic transmission. Refer to Transmission Replacement (See: Automatic Transmission/Transaxle/Service and Repair) for the 4L60-E. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Specifications Flywheel: Specifications NEW Flywheel Bolts First pass ........................................................................................................... ........................................................................................... 79 Nm (58 lb ft) Second pass .................. .............................................................................................................................................................. ........................... 60 degrees Final pass ............................................................................................. ............................................................................................ an additional 60 degrees Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Specifications > Page 8547 Flywheel: Service and Repair Engine Flywheel Replacement Special Tools * J 44643 Flywheel Holding Tool * J 45059 Angle Meter Removal Procedure 1. Remove the transmission. Refer to Transmission Replacement (See: Automatic Transmission/Transaxle/Service and Repair) for the 4L60-E /4L65-E/4L70-E transmission, Transmission Replacement (See: Automatic Transmission/Transaxle/Service and Repair) for the 4L50/4L80/4L90 transmission, or Transmission Replacement (See: Automatic Transmission/Transaxle/Service and Repair) for the Allison transmission. 2. Install J 44643 in order to hold the flywheel. Warning Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Specifications > Page 8548 When removing, handling or installing this component wear protective gloves. The sharp edges on the component may be very sharp and may cause injury. 3. Remove and discard the flywheel bolts. 4. Remove the flywheel washer and flywheel. Installation Procedure Warning When removing, handling or installing this component wear protective gloves. The sharp edges on the component may be very sharp and may cause injury. Note: When installing the flywheel, ensure that the tapered side of the teeth are facing the starter. 1. Install the flywheel. 2. Install the flywheel washer with the beveled side facing the engine. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Caution: This component uses bolts with a preapplied molybdenum disulfide coating for thread lubrication. Do not remove the coating or use any additional lubricant. Improperly lubricated threads will adversely affect the bolt torque and clamp load. Improper bolt torque and clamp load can lead to engine damage. 3. Install NEW flywheel bolts. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Specifications > Page 8549 4. Tighten the flywheel bolts in the proper sequence. 1. Tighten the bolts a first pass to 79 Nm (58 lb ft). 2. Tighten the bolts a second pass to 60 degrees using J 45059 . 3. Tighten the bolts a final pass an additional 60 degrees using J 45059 . 5. Remove J 44643 from the flywheel. 6. Install the transmission. Refer to Transmission Replacement (See: Automatic Transmission/Transaxle/Service and Repair) for the 4L60-E/4L65-E/4L70-E transmission, Transmission Replacement (See: Automatic Transmission/Transaxle/Service and Repair) for the 4L50/4L80/4L90 transmission, or Transmission Replacement (See: Automatic Transmission/Transaxle/Service and Repair) for the Allison transmission. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Bell Housing, M/T > Component Information > Service and Repair Bell Housing: Service and Repair Flywheel Housing Replacement Special Tools J 37228 Seal Cutter Removal Procedure 1. Drain the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair). 2. Remove the crankshaft rear oil seal. Refer to Crankshaft Rear Oil Seal Replacement (See: Engine, Cooling and Exhaust/Engine/Seals and Gaskets/Crankshaft Main Bearing Seal/Service and Repair). 3. Remove the turbocharger oil return pipe nuts from the top of the flywheel housing. 4. Remove the oil cooler adapter studs and nuts from the flywheel housing. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Bell Housing, M/T > Component Information > Service and Repair > Page 8554 5. Remove the upper oil pan. Refer to Upper Oil Pan Replacement (See: Engine, Cooling and Exhaust/Engine/Engine Lubrication/Oil Pan/Service and Repair/Upper Oil Pan Replacement). 6. Remove the oil filter. 7. Remove the flywheel housing bolts, denoted by the black circles. 8. Separate the flywheel from the cylinder block using J 37228 . 9. Remove the flywheel housing. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Bell Housing, M/T > Component Information > Service and Repair > Page 8555 10. Remove the turbocharger oil return pipe gasket from the flywheel housing. 11. Remove the oil cooler adapter bolts. 12. Remove the oil cooler adapter and gaskets. 13. If required, clean and inspect the flywheel housing. Refer to Flywheel Housing Cleaning and Inspection (See: Engine, Cooling and Exhaust/Engine/Service and Repair/Overhaul/96. Flywheel Housing Cleaning and Inspection). Installation Procedure 1. Install NEW O-ring seals to the flywheel housing, if necessary. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Bell Housing, M/T > Component Information > Service and Repair > Page 8556 2. Apply a 2 mm (1/8 in) wide bead of sealant (3) to the flywheel housing sealing surfaces. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Engine, Cooling and Exhaust/Engine/Specifications/Adhesives, Fluids, Lubricants, and Sealers) for the correct part number. 3. Install a NEW oil cooler adapter gasket. 4. Install a NEW oil cooler adapter to flywheel housing gasket. 5. Install the oil cooler adapter to the flywheel housing. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 6. Install the oil cooler adapter bolts. Tighten the bolts/nuts to 21 Nm (15 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Bell Housing, M/T > Component Information > Service and Repair > Page 8557 7. Install the flywheel housing bolts, denoted by the black circles. Tighten the bolts to 90 Nm (67 lb ft). 8. Install the oil cooler adapter studs and nuts to the flywheel housing. * Tighten the oil cooler adapter studs to 10 Nm (89 lb in). * Tighten the oil cooler adapter nuts to 25 Nm (18 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Bell Housing, M/T > Component Information > Service and Repair > Page 8558 9. Install the oil filter. 10. Install the upper oil pan. Refer to Upper Oil Pan Replacement (See: Engine, Cooling and Exhaust/Engine/Engine Lubrication/Oil Pan/Service and Repair/Upper Oil Pan Replacement). 11. Install a NEW gasket to the turbocharger oil return pipe. 12. Install the turbocharger oil return pipe to flywheel housing nuts. Tighten the nuts to 21 Nm (15 lb ft). 13. Install the crankshaft rear oil seal. Refer to Crankshaft Rear Oil Seal Replacement (See: Engine, Cooling and Exhaust/Engine/Seals and Gaskets/Crankshaft Main Bearing Seal/Service and Repair). 14. Fill the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Capacity Specifications Fluid - M/T: Capacity Specifications MANUAL TRANSMISSION FLUID CAPACITY TREMEC 5-SPEED (RPO M96) .......................................................................................................................................................... 3.5 liters (3.7 quarts) TREMEC 5-SPEED (RPO TZ0) .......................................................................................................................................................... 4.4 liters (4.6 quarts) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Capacity Specifications > Page 8563 Fluid - M/T: Fluid Type Specifications MANUAL TRANSMISSION FLUID TYPE TREMEC 5-SPEED (M96) ............................................................................................................................................. 5W-30 Synthetic Oil P/N ET-M99 TREMEC 5-SPEED (TZ0) .............................................................................................................................................. 1874 MTX Fluid 12550 ET-M81 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Service and Repair > Tremec 5-Speed (M96) - Manual Transmission Fluid - M/T: Service and Repair Tremec 5-Speed (M96) - Manual Transmission Transmission Fluid Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Place a suitable drain pan under the transmission in order to catch the drained transmission fluid. 3. Remove the oil fill plug (1). 4. Remove the oil drain plug (2). 5. Remove any old sealant from the transmission housing. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Service and Repair > Tremec 5-Speed (M96) - Manual Transmission > Page 8566 1. Apply a thin bead of sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the oil drain plug threads. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the oil drain plug (2). Tighten the plug to 37 Nm (27 lb ft). 3. Fill the transmission with the proper fluid to just below the bottom of the fill plug hole. 4. Apply a thin bead of sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the oil fill plug threads. 5. Install the oil fill plug (1). Tighten the plug to 37 Nm (27 lb ft). 6. Lower the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Service and Repair > Tremec 5-Speed (M96) - Manual Transmission > Page 8567 Fluid - M/T: Service and Repair Tremec 5-Speed (TZ0) - Manual Transmission Transmission Fluid Replacement Special Tools J 36511 Oil Fill/Drain Plug Hex Bit (17 mm) Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Using J 36511 remove the oil fill plug. 3. Place a suitable drain pan under the transmission in order to catch the drained transmission fluid. 4. Using J 36511 remove the oil drain plug. 5. Remove any old sealant from the transmission housing. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Service and Repair > Tremec 5-Speed (M96) - Manual Transmission > Page 8568 Installation Procedure 1. Apply sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the oil drain and fill plug threads. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Using J 36511 install the oil drain plug. Tighten the plug to 30 Nm (22 lb ft). 3. Remove and drain the drain pan used to catch the used transmission fluid. 4. Fill the transmission to just below the bottom of the fill plug hole. Refer to Lubrication Specifications (See: Specifications/Mechanical Specifications/Tremec 5-Speed (TZ0) - Manual Transmission/Lubrication Specifications). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Service and Repair > Tremec 5-Speed (M96) - Manual Transmission > Page 8569 5. Using J 36511 install the oil fill plug. Tighten the plug to 30 Nm (22 lb ft). 6. Lower the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Seals and Gaskets, M/T > System Information > Service and Repair Seals and Gaskets: Service and Repair Main Shaft Rear Seal Replacement Tools Required * J 23129 Universal Seal Remover * J 6125-1B Slide Hammer * J 36503 Extension Housing Seal Installer Removal Procedure 1. Remove the rear propeller shaft. Refer to One-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/One-Piece Propeller Shaft Replacement) or Two-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Two-Piece Propeller Shaft Replacement). 2. Remove the rear oil seal using J 6125-1B (1) and J 23129 (2). Installation Procedure 1. Using J 36503 install the NEW rear oil seal. 2. Install the rear propeller shaft. Refer to One-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/One-Piece Propeller Shaft Replacement) or Two-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Two-Piece Propeller Shaft Replacement). 3. Check to transmission fluid level. Add if necessary. 4. Lower the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches M/T > Clutch Pedal Position Sensor / Switch > Component Information > Testing and Inspection Clutch Pedal Position Sensor / Switch: Testing and Inspection Clutch Pedal Position Sensor Learn Important: The clutch pedal position (CPP) sensor learn procedure is required when the following service procedures have been performed regardless of whether DTC P080A is set: * An engine control module (ECM) replacement * A CPP sensor replacement * Any repairs which affect the CPP sensor relationship 1. Install a scan tool. 2. Monitor the ECM for DTCs with a scan tool. If other DTCs are set, except DTC P080A, refer to Diagnostic Trouble Code (DTC) List - Vehicle ( See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle) for the applicable DTC that set. 3. With a scan tool, select Clutch Pedal Position Learn under Module Setup in Manual Transmission, and perform the following instructions displayed on the scan tool screen. Important: The CPP sensor learn procedure cannot be performed more than once per ignition cycle. The clutch pedal needs to be fully depressed and held steady throughout this procedure in order to perform a correct learning. 4. The scan tool will display under CPP Learn Status: Not Learned, In Process, Complete, Fail Low Volt, Fail - High Volt, or Fail Moving. The scan tool will display under CPP Learn Status Complete if the process was successful. 5. If the scan tool indicates that DTC P080A ran and passed this ignition the CPP sensor learn procedure is complete. If the scan tool indicates DTC P080A failed or did not run this ignition, refer to DTC P080A (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P080A/Tremec 5-Speed (TZ0) - Manual Transmission). If any other DTC is set, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle) for the applicable DTC. 6. Turn OFF the ignition for 30 seconds after the learn procedure has successfully completed in order to store the CPP sensor variation values in ECM history. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches M/T > Clutch Pedal Position Sensor / Switch > Component Information > Testing and Inspection > Page 8577 Clutch Pedal Position Sensor / Switch: Service and Repair Clutch Pedal Engine Start Switch Replacement Removal Procedure 1. Disconnect the clutch pedal position switch electrical connector (1). 2. Remove the plastic retainer (1) tabs from the clutch pedal position switch (2). 3. Remove the clutch pedal position switch (2) from the pushrod. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches M/T > Clutch Pedal Position Sensor / Switch > Component Information > Testing and Inspection > Page 8578 1. Install the clutch pedal position switch (2) to the pushrod. 2. Install the plastic retainer (1) tabs to the clutch pedal position switch (2). 3. Connect the clutch pedal position switch electrical connector (1). Warning Replacement or reprogramming of the ECM, or replacement of the clutch pedal position sensor (CPPS) or clutch pedal requires that a CPPS learn procedure be performed. Failure to perform the CPPS learn procedure may result in personal injury or damage to the vehicle or its components if the vehicle is in gear and the starter motor is accidentally engaged. 4. Perform the clutch pedal position sensor learn procedure. Refer to DTC P080A (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P080A/Tremec 5-Speed (TZ0) - Manual Transmission) or Clutch Pedal Position Sensor Learn (See: Testing and Inspection/Component Tests and General Diagnostics). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Service and Repair > Tremec 5-Speed (M96) - Manual Transmission Shifter M/T: Service and Repair Tremec 5-Speed (M96) - Manual Transmission Transmission Control Replacement Transmission Control Replacement Transmission Control Lever Boot Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Service and Repair > Tremec 5-Speed (M96) - Manual Transmission > Page 8583 Transmission Control Lever Boot Replacement Removal Procedure 1. Remove the transmission control lever. Refer to Transmission Control Lever Knob Replacement (See: Transmission Control Lever Knob Replacement). 2. Lift and push the lower edge of the control lever boot as necessary in order to expose the retaining screws 3. Remove the 4 control lever boot retaining screws (2). 4. Carefully release the 4 plastic retainers (3) from the floor and remove the control lever boot retaining bezel (1), boot (4), and retainers (3) as an assembly. 5. Remove the 4 plastic retainers (3) in order to separate the control lever boot retaining bezel (1) from the boot (4). 6. Remove the control lever insulator (5) from the floor. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Service and Repair > Tremec 5-Speed (M96) - Manual Transmission > Page 8584 1. Install the control lever insulator (5) to the floor. 2. Assemble the control lever boot retaining bezel (1) to the boot (4) and insert the 4 plastic retainers (3). 3. Install the control lever boot retaining bezel (1), boot (4) and secure the 4 plastic retainers (3) to the floor. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Lift and push the lower edge of the control lever boot as necessary in order to install the 4 retaining screws (2). Tighten the screws to 1.6 Nm (14 lb in). 5. Install the transmission control lever. Refer to Transmission Control Lever Knob Replacement (See: Transmission Control Lever Knob Replacement). Transmission Control Lever Knob Replacement Transmission Control Lever Knob Replacement Removal Procedure 1. Remove the control lever boot from the control lever. Note: DO NOT move the shift lever assembly adjustment nut if replacing the control lever. 2. Remove the control lever. Installation Procedure 1. Install the control lever. 2. If alignment of the control lever is necessary, or if the shift lever assembly was replaced perform the following: 1. The nut must be seated at the bottom of the thread runout on the shift lever. 2. Seat the control lever against the shift lever assembly adjustment nut. 3. Back the control lever off the nut in order to align the index mark on the control lever perpendicular to the edge of the control lever boot retainer. 4. Ensure that the index mark is located on the passenger side and that the shift pattern is aligned parallel to the vehicle centerline or rotated no more than 6 degrees clockwise. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Hold the control lever and tighten the shift lever assembly nut against the control lever. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Service and Repair > Tremec 5-Speed (M96) - Manual Transmission > Page 8585 Tighten the nut to 37 Nm (27 lb in). 6. Install the control lever boot to the control lever. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Service and Repair > Tremec 5-Speed (M96) - Manual Transmission > Page 8586 Shifter M/T: Service and Repair Tremec 5-Speed (TZ0) - Manual Transmission Transmission Control Lever Boot Replacement Transmission Control Lever Boot Replacement Removal Procedure 1. Remove the transmission control lever. Refer to Transmission Control Lever Knob Replacement (See: Tremec 5-Speed (M96) - Manual Transmission/Transmission Control Lever Knob Replacement). 2. Lift and push the lower edge of the control lever boot as necessary in order to expose the retaining screws 3. Remove the 4 control lever boot retaining screws (2). 4. Carefully release the 4 plastic retainers (3) from the floor and remove the control lever boot retaining bezel (1), boot (4), and retainers (3) as an assembly. 5. Remove the 4 plastic retainers (3) in order to separate the control lever boot retaining bezel (1) from the boot (4). 6. Remove the control lever insulator (5) from the floor. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Service and Repair > Tremec 5-Speed (M96) - Manual Transmission > Page 8587 1. Install the control lever insulator (5) to the floor. 2. Assemble the control lever boot retaining bezel (1) to the boot (4) and insert the 4 plastic retainers (3). 3. Install the control lever boot retaining bezel (1), boot (4) and secure the 4 plastic retainers (3) to the floor. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Lift and push the lower edge of the control lever boot as necessary in order to install the 4 retaining screws (2). Tighten the screws to 1.6 Nm (14 lb in). 5. Install the transmission control lever. Refer to Transmission Control Lever Knob Replacement (See: Tremec 5-Speed (M96) - Manual Transmission/Transmission Control Lever Knob Replacement). Transmission Control Lever Knob Replacement Transmission Control Lever Knob Replacement Removal Procedure 1. Remove the control lever boot from the control lever. Note: DO NOT move the shift lever assembly adjustment nut if replacing the control lever. 2. Remove the control lever. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Service and Repair > Tremec 5-Speed (M96) - Manual Transmission > Page 8588 1. Install the control lever. 2. If alignment of the control lever is necessary, or if the shift lever assembly was replaced perform the following: 1. The nut must be seated at the bottom of the thread runout on the shift lever. 2. Seat the control lever against the shift lever assembly adjustment nut. 3. Back the control lever off the nut in order to align the index mark on the control lever perpendicular to the edge of the control lever boot retainer. 4. Ensure that the index mark is located on the passenger side and that the shift pattern is aligned parallel to the vehicle centerline or rotated no more than 6 degrees clockwise. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Hold the control lever and tighten the shift lever assembly nut against the control lever. Tighten the nut to 37 Nm (27 lb in). 6. Install the control lever boot to the control lever. Transmission Control Replacement Transmission Control Replacement Removal Procedure Note: * Ensure that the control lever is positioned into the mechanical third or fourth gear prior to removal of the shift lever from the transmission. The transmission must remain in this state when the shift lever is removed. * Do not disassemble the transmission shift lever. Internal parts for this shift lever are not available. Opening the shift lever voids the warranty. * When removing the shift lever from the transmission, use the exposed bolts on the base of the lever. 1. Remove the control lever and boot. Refer to Transmission Control Lever Boot Replacement (See: Tremec 5-Speed (M96) - Manual Transmission/Transmission Control Lever Boot Replacement). 2. Remove the boot. 3. Remove the shift lever bolts. 4. Remove the shift lever and seal. 5. Remove the shift lever insulator. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Service and Repair > Tremec 5-Speed (M96) - Manual Transmission > Page 8589 1. Install a NEW shift lever insulator. 2. Install the shift lever seal and lever. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the shift lever bolts. Tighten the bolts to 20 Nm (15 lb ft). 4. Install the boot. 5. Install the control lever and boot. Refer to Transmission Control Lever Boot Replacement (See: Tremec 5-Speed (M96) - Manual Transmission/Transmission Control Lever Boot Replacement). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Service and Repair Transmission Mount: Service and Repair Transmission Rear Mount Replacement Removal Procedure Caution: Broken or deteriorated mounts can cause misalignment and destruction of certain drive train components. When a single mount breaks, the remaining mounts are subjected to abnormally high stresses. 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the transmission mount to crossmember nut (1). 3. Remove the transmission mount to transmission bolts. 4. Raise the transmission just enough in order to permit removal of the mount using a suitable transmission jack. 5. Remove the transmission mount. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Service and Repair > Page 8593 1. Position the transmission mount. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the transmission mount to transmission bolts. Tighten the bolts to 50 Nm (37 lb ft). 3. Lower the transmission and remove the transmission jack. 4. Install the transmission mount to crossmember nut (1). Tighten the nut to 40 Nm (30 lb ft). 5. Lower the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Power Take-Off Relay > Component Information > Diagrams Power Take-Off Relay: Diagrams Component Connector End Views Power Take Off (PTO) Relay (PTO) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Power Take-Off Switch > Component Information > Diagrams Power Take-Off Switch: Diagrams Component Connector End Views Power Take-Off (PTO) Switch (PTO) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Relays and Modules - Power Take-Off > Power Take-Off Relay > Component Information > Diagrams Power Take-Off Relay: Diagrams Component Connector End Views Power Take Off (PTO) Relay (PTO) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Power Take-Off > Sensors and Switches - Power Take-Off > Power Take-Off Switch > Component Information > Diagrams Power Take-Off Switch: Diagrams Component Connector End Views Power Take-Off (PTO) Switch (PTO) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON Control Module: Customer Interest A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 8619 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 8620 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 8621 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON Control Module: All Technical Service Bulletins A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 8627 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 8628 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 8629 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 8630 Control Module: Locations Harness Routing Views Engine Chassis Harness Routing - Top Front (Diesel) 1 - Battery - Right 2 - Fuse Holder 3 - X127 4 - X108 5 - X107 6 - X123 (PTO) 7 - Fuse Block Underhood 8 - X109 9 - Battery - Left 10 - Engine Control Module (ECM) 11 - Transmission Control Module (TCM) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 8631 Control Module: Diagrams Component Connector End Views Transmission Control Module (TCM) (M30) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 8632 Transmission Control Module (TCM) (MW7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 8633 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 8634 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 8635 Control Module: Service and Repair Transmission Control Module Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Power Take-Off > Power Take-Off Relay > Component Information > Diagrams Power Take-Off Relay: Diagrams Component Connector End Views Power Take Off (PTO) Relay (PTO) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams Control Module: Diagrams Component Connector End Views Transfer Case Shift Control Module X1 (NQF or NQH) Transfer Case Shift Control Module X2 (NQF or NQH) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Page 8644 Transfer Case Shift Control Module X3 (NQF or NQH) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Page 8645 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case Control Module: Service and Repair MP 1625/1626-NQF - Transfer Case Transfer Case Shift Control Module Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case > Page 8648 Control Module: Service and Repair MP 3023/3024-NQH - Transfer Case Transfer Case Shift Control Module Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations Fluid Pressure Sensor/Switch: Locations Disassembled Views Control Valve Body Assembly 1 - Control Valve Body Assembly 2 - Shift Valve Body Assembly 3 - Separator Plate 4 - Main Valve Body Assembly 5 - Transmission Fluid Pressure (TFP) Switch 6 - Main Valve Body Assembly Bolt, M6 x 10 x 50, Flanged Head (23) 7 - Reverse Signal Pipe 8 - Reverse Signal Pipe Bolt, M6 x 10 x 50, Flanged Head 9 - Retaining Clip 10 - Modulated Main Valve Body 11 - Bolt, M6 x 10 x 65 12 Bolt, M6 x 10 x 50 13 - O-Rings 14 - Modulated Main Pressure (MAIN MOD) Solenoid 15 - 6 Speed Pipe Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 8654 Fluid Pressure Sensor/Switch: Diagrams Component Connector End Views Pressure Switch Manifold (PSM) (MW7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 8655 Fluid Pressure Sensor/Switch: Service and Repair Pressure Switch Manifold Replacement Removal Procedure Note: Individual pressure switches cannot be replaced. When any pressure switch needs replacing, the entire assembly must be replaced. Note: The modulated main pressure (MAIN MOD) solenoid has been removed for clarity. 1. Remove the oil pan and transmission internal oil filter. Refer to Oil Pan Replacement (See: Automatic Transmission/Transaxle/Fluid Pan/Service and Repair). Warning: Refer to Battery Disconnect Warning (See: Starting and Charging/Battery/Service Precautions). 2. Disconnect the internal wiring harness connector from the transmission fluid pressure (TFP) switch (2). 3. Remove six bolts (1). Remove the TFP switch (2). Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 8656 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Place the new TFP manifold assembly (2) in position and install one bolt (1) in a recessed location to hold in position. Start the remaining five bolts (1) in recessed locations and tighten the bolts by hand. Torque the bolts to 12 Nm (108 lb in). 2. Connect the internal wiring harness connector to the TFP switch. 3. Install the oil pan and transmission internal oil filter. Refer to Oil Pan Replacement (See: Automatic Transmission/Transaxle/Fluid Pan/Service and Repair). Note: The FastLearn, adapt, procedure must be performed. This can be done in 1 step using a scan tool. If this procedure is not done, the TCM adaptive values will be at the settings that it learned for the old components and will be in slow adaptive mode. Under these conditions, it will take an unacceptably long time for the adaptive values to converge to levels suitable for the new transmission. 4. Perform the FastLearn procedure. Refer to FastLearn Procedure (See: Automatic Transmission/Transaxle/Testing and Inspection/Programming and Relearning). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON Transmission Mode Switch: Customer Interest A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 8665 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 8666 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 8667 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON Transmission Mode Switch: All Technical Service Bulletins A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 8673 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 8674 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 8675 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > Page 8676 Transmission Mode Switch: Diagrams Component Connector End Views Automatic Transmission Internal Mode Switch (MW7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > Page 8677 Transmission Mode Switch: Service and Repair Transmission Internal Mode Switch Replacement Important: The Internal Mode Switch (IMS) is mounted to the manual shift shaft detent lever as an assembly. The components of the detent lever/IMS assembly cannot be individually serviced. When the IMS needs replacing, the entire assembly must be replaced. Replace the IMS. Refer to Manual Shift Shaft, Detent Lever, and Position Switch Assembly Replacement (See: Transmission Position Switch/Sensor/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams Transmission Position Switch/Sensor: Diagrams Component Connector End Views Park/Neutral Position (PNP) Switch (M30) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 8681 Transmission Position Switch/Sensor: Service and Repair Manual Shift Shaft, Detent Lever, and Position Switch Assembly Replacement Removal Procedure 1. Remove the control valve assembly from the transmission. Refer to Control Valve Body Replacement (See: Automatic Transmission/Transaxle/Valve Body/Service and Repair). Note: The detent lever/IMS retaining bolt contains patch lock material on the threads. Do not reuse the retaining bolt. 2. Remove the detent lever/IMS retaining bolt (1) using a T27 TORX(R) bit and discard the retaining bolt. Caution: DO NOT mar the transmission case surface around the spherical pin when removing or installing the spherical pin. An unmarred surface is required to maintain the seal between the control valve assembly and the transmission case. Caution: DO NOT twist the spherical pin when removing the pin from the transmission case. Damage to the transmission case can occur. 3. Place a protective plate on the transmission case surface around the spherical pin (3). Remove the spherical pin (3) from the transmission case. 4. Slide the manual shift shaft (5) through the detent lever/IMS assembly (4) and through the manual shift shaft seal. 5. Rotate the detent lever/IMS assembly to disengage the park pawl apply assembly (2). Remove the detent lever/IMS assembly (4). Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 8682 1. Place the new detent lever/IMS assembly (4) in position in the transmission case. Rotate the detent lever/IMS assembly to engage the park pawl apply assembly (2). Reinstall the manual shift shaft (5) through the manual shift shaft seal and through the detent lever/IMS assembly (4). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Push the manual shift shaft (5) into the final position in the transmission case. 3. Install the spherical pin (3) into the transmission case that retains the manual shift shaft. 4. Install the detent lever/IMS retaining bolt (1) using a T27 TORX(R) bit. Tighten the bolt (1) to 10 Nm (92 lb in). 5. Install the control valve assembly. Refer to Control Valve Body Replacement (See: Automatic Transmission/Transaxle/Valve Body/Service and Repair). Note: The FastLearn, adapt, procedure must be performed. This can be done in 1 step using a scan tool. If this procedure is not done, the TCM adaptive values will be at the settings that it learned for the old components and will be in slow adaptive mode. Under these conditions, it will take an unacceptably long time for the adaptive values to converge to levels suitable for the new transmission. 6. Perform the FastLearn procedure. Refer to FastLearn Procedure (See: Automatic Transmission/Transaxle/Testing and Inspection/Programming and Relearning). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Component Locations Transmission Speed Sensor: Component Locations Disassembled Views Automatic Transmission Case 1 - Automatic Transmission Case 2 - Transmission Case Locating Pin 3 - Transmission Vent Assembly 4 - Transmission Vent Cap 5 - Transmission Vent 6 - Nameplate Rivet 7 - Nameplate 8 Vehicle Speed Sensor Bolt, M6 x 1.0 x 13 9 - Sensor Shipping Cover 10 - Turbine Speed Sensor 11 - Vehicle Speed Sensor O-Ring 12 - Power Take-Off (PTO) Cover Gasket (2) 13 - PTO Cover (2) 14 - PTO Cover Bolt, M10 x 1.5 x 20, Flanged Head, Coated (12) 16 - Manual Shift Shaft 17 Manual Shift Shaft Seal 18 - Manual Shift Shaft Pin 19 - Manual Shift Shaft Detent Lever/Internal Mode Switch (IMS) Assembly 20 - Park Pawl Assembly 21 - Control Valve Body Locating Pin 22 Detent Lever/IMS Bolt 23 - Connector Shipping Cover 24 - Control Valve Body Assembly 25 Control Valve Body Bolt, M6 x 1.0 x 50, Flanged Head (15) 26 - Manual Shift Shaft Detent Spring 27 - Manual Shift Shaft Detent Spring Bolt M6 x 1.0 x 12. Flanged Head (2) 28 - Transmission Wiring Harness Assembly Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Component Locations > Page 8687 Transmission Speed Sensor: Connector Locations Harness Routing Views Engine Chassis Harness Routing - Rear (Diesel) 1 - X300 2 - G300 3 - Automatic Transmission Turbine Speed Sensor (MW7) 4 - Automatic Transmission (MW7) 5 - Vehicle Speed Sensor (VSS) (MW7) 6 - X124 (PTO) 7 - Power Take Off (PTO) Module (PTO) 8 - X175 (MW7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 8688 Transmission Speed Sensor: Diagrams Component Connector End Views Automatic Transmission Input Shaft Speed (ISS) Sensor (M30) Automatic Transmission Turbine Speed Sensor (MW7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 8689 Output Speed Sensor (OSS) (M99) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 8690 Transmission Speed Sensor: Service and Repair Speed Sensor Replacement Removal Procedure Warning: Refer to Battery Disconnect Warning (See: Starting and Charging/Battery/Service Precautions). 1. Be sure the vehicle ignition is turned off. 2. Disconnect the external wiring harness from the speed sensor. 3. Remove the bolt (1) from the speed sensor and carefully remove the speed sensor (2). Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 8691 Note: Do not rotate the sensor in its retaining bracket. Changing the sensor/bracket orientation may cause improper operation. 1. Install a new a O-ring on the speed sensor (2). Lubricate the O-ring with clean transmission fluid. 2. Install the new speed sensor (2) into the speed sensor bore. Align the hole in the retaining bracket with the bolt hole in the speed sensor boss. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the speed sensor bolt (1). Tighten bolt to 12 Nm (108 lb in). 4. Reconnect the external wiring harness to the speed sensor. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams Transmission Temperature Sensor/Switch: Diagrams Component Connector End Views Automatic Transmission Fluid Temperature (TFT) Sensor (M30) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Clutch Pedal Position Sensor / Switch > Component Information > Testing and Inspection Clutch Pedal Position Sensor / Switch: Testing and Inspection Clutch Pedal Position Sensor Learn Important: The clutch pedal position (CPP) sensor learn procedure is required when the following service procedures have been performed regardless of whether DTC P080A is set: * An engine control module (ECM) replacement * A CPP sensor replacement * Any repairs which affect the CPP sensor relationship 1. Install a scan tool. 2. Monitor the ECM for DTCs with a scan tool. If other DTCs are set, except DTC P080A, refer to Diagnostic Trouble Code (DTC) List - Vehicle ( See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle) for the applicable DTC that set. 3. With a scan tool, select Clutch Pedal Position Learn under Module Setup in Manual Transmission, and perform the following instructions displayed on the scan tool screen. Important: The CPP sensor learn procedure cannot be performed more than once per ignition cycle. The clutch pedal needs to be fully depressed and held steady throughout this procedure in order to perform a correct learning. 4. The scan tool will display under CPP Learn Status: Not Learned, In Process, Complete, Fail Low Volt, Fail - High Volt, or Fail Moving. The scan tool will display under CPP Learn Status Complete if the process was successful. 5. If the scan tool indicates that DTC P080A ran and passed this ignition the CPP sensor learn procedure is complete. If the scan tool indicates DTC P080A failed or did not run this ignition, refer to DTC P080A (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P080A/Tremec 5-Speed (TZ0) - Manual Transmission). If any other DTC is set, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle) for the applicable DTC. 6. Turn OFF the ignition for 30 seconds after the learn procedure has successfully completed in order to store the CPP sensor variation values in ECM history. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Clutch Pedal Position Sensor / Switch > Component Information > Testing and Inspection > Page 8699 Clutch Pedal Position Sensor / Switch: Service and Repair Clutch Pedal Engine Start Switch Replacement Removal Procedure 1. Disconnect the clutch pedal position switch electrical connector (1). 2. Remove the plastic retainer (1) tabs from the clutch pedal position switch (2). 3. Remove the clutch pedal position switch (2) from the pushrod. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Clutch Pedal Position Sensor / Switch > Component Information > Testing and Inspection > Page 8700 1. Install the clutch pedal position switch (2) to the pushrod. 2. Install the plastic retainer (1) tabs to the clutch pedal position switch (2). 3. Connect the clutch pedal position switch electrical connector (1). Warning Replacement or reprogramming of the ECM, or replacement of the clutch pedal position sensor (CPPS) or clutch pedal requires that a CPPS learn procedure be performed. Failure to perform the CPPS learn procedure may result in personal injury or damage to the vehicle or its components if the vehicle is in gear and the starter motor is accidentally engaged. 4. Perform the clutch pedal position sensor learn procedure. Refer to DTC P080A (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P080A/Tremec 5-Speed (TZ0) - Manual Transmission) or Clutch Pedal Position Sensor Learn (See: Manual Transmission/Transaxle/Testing and Inspection/Component Tests and General Diagnostics). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Power Take-Off > Power Take-Off Switch > Component Information > Diagrams Power Take-Off Switch: Diagrams Component Connector End Views Power Take-Off (PTO) Switch (PTO) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations Four Wheel Drive Selector Switch: Locations Harness Routing Views Engine Harness Routing - Rear (4.8L/5.3L/6.0L/6.2L except LFA/HP2) 1 - Dash Panel 2 - Transmission 3 - X175 (M30) 4 - Transfer Case Shift Control Switch (NQG) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 8709 Four Wheel Drive Selector Switch: Diagrams Component Connector End Views Transfer Case Shift Control Switch (NQF or NQH) Transfer Case Shift Control Switch (NQG) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 8710 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case Four Wheel Drive Selector Switch: Service and Repair MP 1625/1626-NQF - Transfer Case Transfer Case Shift Control Switch Replacement (Without SLT) Transfer Case Shift Control Switch Replacement (Without SLT) Transfer Case Shift Control Switch Replacement (With SLT) Transfer Case Shift Control Switch Replacement (With SLT) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case > Page 8713 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case > Page 8714 Four Wheel Drive Selector Switch: Service and Repair MP 3023/3024-NQH - Transfer Case Transfer Case Shift Control Switch Replacement (With SLT) Transfer Case Shift Control Switch Replacement (With SLT) Transfer Case Shift Control Switch Replacement (Without SLT) Transfer Case Shift Control Switch Replacement (Without SLT) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case > Page 8715 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams Gear Sensor/Switch: Diagrams Component Connector End Views Transfer Case 2/4 Wheel Drive Actuator Position Sensor (NQH) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair Speed Sensor: Service and Repair Transfer Case Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the speed sensor electrical connector (4). 3. Remove the speed sensor and O-ring. 4. Discard the O-ring. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Page 8722 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the speed sensor with a NEW O-ring. Tighten the sensor to 17 Nm (13 lb ft). 2. Connect the speed sensor electrical connector (4). 3. Lower the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams Transfer Case Actuator: Diagrams Component Connector End Views Transfer Case Encoder Motor (NQF or NQH) Front Drive Axle Actuator (NQF, NQG or NQH) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Page 8728 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case Transfer Case Actuator: Service and Repair MP 1625/1626-NQF - Transfer Case Transfer Case Two/Four Wheel Drive Actuator Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case > Page 8731 Transfer Case Actuator: Service and Repair MP 3023/3024-NQH - Transfer Case Transfer Case Two/Four Wheel Drive Actuator Position Sensor Replacement Transfer Case Two/Four Wheel Drive Actuator Position Sensor Replacement Transfer Case Two/Four Wheel Drive Actuator Replacement Transfer Case Two/Four Wheel Drive Actuator Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case > Page 8732 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Case Adapter, Transfer Case > Component Information > Service and Repair > BW 4485-NR3 - Transfer Case Case Adapter: Service and Repair BW 4485-NR3 - Transfer Case Transfer Case Adapter Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Case Adapter, Transfer Case > Component Information > Service and Repair > BW 4485-NR3 - Transfer Case > Page 8737 Case Adapter: Service and Repair MP 1222/1225/1226-NQG - Transfer Case Transfer Case Adapter Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Case Adapter, Transfer Case > Component Information > Service and Repair > BW 4485-NR3 - Transfer Case > Page 8738 Case Adapter: Service and Repair MP 1625/1626-NQF - Transfer Case Transfer Case Adapter Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Case Adapter, Transfer Case > Component Information > Service and Repair > BW 4485-NR3 - Transfer Case > Page 8739 Case Adapter: Service and Repair MP 3023/3024-NQH - Transfer Case Transfer Case Adapter Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Diagrams Control Module: Diagrams Component Connector End Views Transfer Case Shift Control Module X1 (NQF or NQH) Transfer Case Shift Control Module X2 (NQF or NQH) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Page 8743 Transfer Case Shift Control Module X3 (NQF or NQH) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Page 8744 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case Control Module: Service and Repair MP 1625/1626-NQF - Transfer Case Transfer Case Shift Control Module Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case > Page 8747 Control Module: Service and Repair MP 3023/3024-NQH - Transfer Case Transfer Case Shift Control Module Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications Fluid - Transfer Case: Capacity Specifications TRANSFER CASE FLUID BW 4485-NR3 ..................................................................................................................................... ...................................... Fill to bottom of drain hole. MP 1222/1225/1226-NQG ................................................................................................................... ............................................... 1.6 quarts (1.5 liters) MP 1625/1626-NQF ............................................................................................................................ ................................................ 1.6 quarts (1.5 liters) MP 3023/3024-NQH ............................................................................................................................ ............................................... 1.6 quarts (1.5 liters) NOTE: All capacities are approximate. When adding, be sure to fill to the approximate level. Recheck fluid level after filling. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications > Page 8752 Fluid - Transfer Case: Fluid Type Specifications TRANSFER CASE FLUID DEXRON-VI Automatic Transmission Fluid. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Service and Repair > BW 4485-NR3 - Transfer Case Fluid - Transfer Case: Service and Repair BW 4485-NR3 - Transfer Case Transfer Case Fluid Replacement Removal Procedure Note: When performing the following procedure, use only hand tools to remove and install the drain and fill plugs. 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the transfer case shield, if equipped. Refer to Transfer Case Shield Replacement (See: Service and Repair/Removal and Replacement/BW 4485-NR3 - Transfer Case/Transfer Case Shield Replacement). 3. Remove the fill plug. 4. Remove the drain plug. Note: Ensure that an approved drain pan is used when draining the transfer case. 5. Allow the transfer case to drain completely. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Service and Repair > BW 4485-NR3 - Transfer Case > Page 8755 Note: Use only drain and fill plugs that are made from aluminum. Steel or brass plugs are not compatible with the magnesium case. 1. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent, to the threads of the drain and fill plugs. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the drain plug. Tighten the plug to 25 Nm (18 lb ft). 3. Fill the transfer case to the bottom of the fill plug hole with the recommended fluid. 4. Install the fill plug. Tighten the plug to 25 Nm (18 lb ft). 5. Install the transfer case shield, if equipped. Refer to Transfer Case Shield Replacement (See: Service and Repair/Removal and Replacement/BW 4485-NR3 - Transfer Case/Transfer Case Shield Replacement). 6. Lower the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Service and Repair > BW 4485-NR3 - Transfer Case > Page 8756 Fluid - Transfer Case: Service and Repair MP 1222/1225/1226-NQG - Transfer Case Transfer Case Fluid Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Service and Repair > BW 4485-NR3 - Transfer Case > Page 8757 Fluid - Transfer Case: Service and Repair MP 1625/1626-NQF - Transfer Case Transfer Case Fluid Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Service and Repair > BW 4485-NR3 - Transfer Case > Page 8758 Fluid - Transfer Case: Service and Repair MP 3023/3024-NQH - Transfer Case Transfer Case Fluid Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations Four Wheel Drive Selector Switch: Locations Harness Routing Views Engine Harness Routing - Rear (4.8L/5.3L/6.0L/6.2L except LFA/HP2) 1 - Dash Panel 2 - Transmission 3 - X175 (M30) 4 - Transfer Case Shift Control Switch (NQG) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 8762 Four Wheel Drive Selector Switch: Diagrams Component Connector End Views Transfer Case Shift Control Switch (NQF or NQH) Transfer Case Shift Control Switch (NQG) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 8763 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case Four Wheel Drive Selector Switch: Service and Repair MP 1625/1626-NQF - Transfer Case Transfer Case Shift Control Switch Replacement (Without SLT) Transfer Case Shift Control Switch Replacement (Without SLT) Transfer Case Shift Control Switch Replacement (With SLT) Transfer Case Shift Control Switch Replacement (With SLT) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case > Page 8766 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case > Page 8767 Four Wheel Drive Selector Switch: Service and Repair MP 3023/3024-NQH - Transfer Case Transfer Case Shift Control Switch Replacement (With SLT) Transfer Case Shift Control Switch Replacement (With SLT) Transfer Case Shift Control Switch Replacement (Without SLT) Transfer Case Shift Control Switch Replacement (Without SLT) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case > Page 8768 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams Gear Sensor/Switch: Diagrams Component Connector End Views Transfer Case 2/4 Wheel Drive Actuator Position Sensor (NQH) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams Control Module: Diagrams Component Connector End Views Transfer Case Shift Control Module X1 (NQF or NQH) Transfer Case Shift Control Module X2 (NQF or NQH) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Page 8776 Transfer Case Shift Control Module X3 (NQF or NQH) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Page 8777 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case Control Module: Service and Repair MP 1625/1626-NQF - Transfer Case Transfer Case Shift Control Module Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case > Page 8780 Control Module: Service and Repair MP 3023/3024-NQH - Transfer Case Transfer Case Shift Control Module Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > BW 4485-NR3 - Transfer Case Seals and Gaskets: Service and Repair BW 4485-NR3 - Transfer Case Front Output Shaft Seal Replacement Front Output Shaft Seal Replacement Tools Required * J 8092 Driver Handle * J 43484 Output Shaft Seal Installer Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the transfer case shield, if equipped. Refer to Transfer Case Shield Replacement (See: Service and Repair/Removal and Replacement/BW 4485-NR3 - Transfer Case/Transfer Case Shield Replacement). 3. Remove the front propeller shaft. Refer to Front Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Front Propeller Shaft Replacement). Important: The front output shaft seal is a two piece internal seal. The inner seal race is a force fit on the front output shaft. 4. Remove the front output shaft seal by inserting a flat-tipped screwdriver behind the inner race of the seal. 5. Pry the inner seal race forward. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > BW 4485-NR3 - Transfer Case > Page 8785 6. Using a small pry bar, move the inner seal race forward on the front output shaft. 7. Remove the inner seal race from the front output shaft. 8. Insert a flat-tipped screwdriver or small pry bar into the space between the lip of the outer race of the seal and the transfer case. 9. Remove the remaining part of the output shaft seal from the transfer case. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > BW 4485-NR3 - Transfer Case > Page 8786 1. Install the J 43484 (2) to the J 8092 (1). 2. Install a NEW seal onto J 43484 . 3. Using J 43484 (2), and J 8092 (1), install the seal. 4. Install the front propeller shaft. Refer to Front Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Front Propeller Shaft Replacement). 5. Check the fluid level. Add fluid, if necessary. 6. Install the transfer case shield, if equipped. Refer to Transfer Case Shield Replacement (See: Service and Repair/Removal and Replacement/BW 4485-NR3 - Transfer Case/Transfer Case Shield Replacement). 7. Lower the vehicle. Rear Output Shaft Seal Replacement Rear Output Shaft Seal Replacement Tools Required J 45756 Output Shaft Seal Installer Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > BW 4485-NR3 - Transfer Case > Page 8787 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the transfer case shield, if equipped. Refer to Transfer Case Shield Replacement (See: Service and Repair/Removal and Replacement/BW 4485-NR3 - Transfer Case/Transfer Case Shield Replacement). 3. Remove the rear propeller shaft. Refer to One-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/One-Piece Propeller Shaft Replacement) or Two-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Two-Piece Propeller Shaft Replacement). 4. Remove the rear output shaft seal by prying it out with a flat tipped screwdriver. Installation Procedure 1. Using the J 45756 , install a NEW front output shaft seal. 2. Install the rear propeller shaft. Refer to One-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/One-Piece Propeller Shaft Replacement) or Two-Piece Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Two-Piece Propeller Shaft Replacement). 3. Check the fluid level. Add fluid, if necessary. 4. Install the transfer case shield, if equipped. Refer to Transfer Case Shield Replacement (See: Service and Repair/Removal and Replacement/BW 4485-NR3 - Transfer Case/Transfer Case Shield Replacement). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > BW 4485-NR3 - Transfer Case > Page 8788 5. Lower the vehicle. Input Shaft Seal Replacement Input Shaft Seal Replacement Tools Required * J 36825 Output Shaft Oil Seal Remover * J 23907 Slide Hammer with Bearing Adapter * J 42738 Front Output Shaft Seal Installer Removal Procedure 1. Remove the transfer case. Refer to Transfer Case Assembly Replacement (See: Service and Repair/Removal and Replacement/BW 4485-NR3 - Transfer Case/Transfer Case Assembly Replacement). Important: It may be necessary to use a sharp punch in order to poke a hole into the seal prior to inserting J 36825 . 2. Using the J 23907 (1), and J 36825 (2), remove the input seal. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > BW 4485-NR3 - Transfer Case > Page 8789 1. Using the J 42738 , install the input shaft seal. 2. Install the transfer case. Refer to Transfer Case Assembly Replacement (See: Service and Repair/Removal and Replacement/BW 4485-NR3 Transfer Case/Transfer Case Assembly Replacement). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > BW 4485-NR3 - Transfer Case > Page 8790 Seals and Gaskets: Service and Repair MP 1222/1225/1226-NQG - Transfer Case Front Output Shaft Seal Replacement Front Output Shaft Seal Replacement Rear Output Shaft Seal Replacement Rear Output Shaft Seal Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > BW 4485-NR3 - Transfer Case > Page 8791 Input Shaft Seal Replacement Input Shaft Seal Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > BW 4485-NR3 - Transfer Case > Page 8792 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > BW 4485-NR3 - Transfer Case > Page 8793 Seals and Gaskets: Service and Repair MP 1625/1626-NQF - Transfer Case Front Output Shaft Seal Replacement Front Output Shaft Seal Replacement Rear Output Shaft Seal Replacement Rear Output Shaft Seal Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > BW 4485-NR3 - Transfer Case > Page 8794 Input Shaft Seal Replacement Input Shaft Seal Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > BW 4485-NR3 - Transfer Case > Page 8795 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > BW 4485-NR3 - Transfer Case > Page 8796 Seals and Gaskets: Service and Repair MP 3023/3024-NQH - Transfer Case Front Output Shaft Seal Replacement Front Output Shaft Seal Replacement Rear Output Shaft Seal Replacement Rear Output Shaft Seal Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > BW 4485-NR3 - Transfer Case > Page 8797 Input Shaft Seal Replacement Input Shaft Seal Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > BW 4485-NR3 - Transfer Case > Page 8798 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations Four Wheel Drive Selector Switch: Locations Harness Routing Views Engine Harness Routing - Rear (4.8L/5.3L/6.0L/6.2L except LFA/HP2) 1 - Dash Panel 2 - Transmission 3 - X175 (M30) 4 - Transfer Case Shift Control Switch (NQG) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 8803 Four Wheel Drive Selector Switch: Diagrams Component Connector End Views Transfer Case Shift Control Switch (NQF or NQH) Transfer Case Shift Control Switch (NQG) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 8804 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case Four Wheel Drive Selector Switch: Service and Repair MP 1625/1626-NQF - Transfer Case Transfer Case Shift Control Switch Replacement (Without SLT) Transfer Case Shift Control Switch Replacement (Without SLT) Transfer Case Shift Control Switch Replacement (With SLT) Transfer Case Shift Control Switch Replacement (With SLT) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case > Page 8807 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case > Page 8808 Four Wheel Drive Selector Switch: Service and Repair MP 3023/3024-NQH - Transfer Case Transfer Case Shift Control Switch Replacement (With SLT) Transfer Case Shift Control Switch Replacement (With SLT) Transfer Case Shift Control Switch Replacement (Without SLT) Transfer Case Shift Control Switch Replacement (Without SLT) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case > Page 8809 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams Gear Sensor/Switch: Diagrams Component Connector End Views Transfer Case 2/4 Wheel Drive Actuator Position Sensor (NQH) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair Speed Sensor: Service and Repair Transfer Case Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the speed sensor electrical connector (4). 3. Remove the speed sensor and O-ring. 4. Discard the O-ring. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Page 8816 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the speed sensor with a NEW O-ring. Tighten the sensor to 17 Nm (13 lb ft). 2. Connect the speed sensor electrical connector (4). 3. Lower the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Shift Fork, Transfer Case > Component Information > Technical Service Bulletins > Drivetrain - Magna Transfer Case Service Parts Info. Shift Fork: Technical Service Bulletins Drivetrain - Magna Transfer Case Service Parts Info. INFORMATION Bulletin No.: 09-04-21-006 Date: October 29, 2009 Subject: Information on Magna Transfer Case Service Parts for Control Actuator Levers Models: 2007-2010 Cadillac Escalade Hybrid 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2010 GMC Sierra, Yukon, Yukon XL All Equipped with Magna MP3023 Two-Speed Active Transfer Case (RPO NQH) or MP3010 Single-Speed Active Transfer Case (RPO NQH and NP0) Note Heavy duty (HD) components are the only parts available for service. The purpose of this bulletin is to provide information regarding the servicing of the Light Duty (LD) transfer cases. LD Transfer cases are built with LD control actuator levers (3 and 6) and are used with 13 mm (0.52 in) diameter control actuator lever balls (5). Heavy Duty (HD) components can be identified as using 10 mm (0.39 in) control actuator lever balls. Note Light Duty (LD) 2007-2010 MP3023-NQH and 2010 MP3010-NP0 transfer cases are built with LD control actuator levers (3 and 6) and are used with 13 mm (0.52 in) diameter control actuator lever balls (5). Heavy Duty (HD) components can be identified as using 10 mm (0.39 in) control actuator lever balls. Additional component dimensional information can be obtained within the applicable Transfer Case Description and Operation/Build Variations section of SI. When replacement of one or both of the LD control actuator levers is required, it is necessary to replace both of the levers and all three balls with the HD components as a set. It is also necessary to re-measure and adjust clutch pack clearances as required and to perform the Transfer Case High/Low Clutch Reset. Refer to Measuring/Adjusting Clutch Assembly Height in Transfer Case Assemble, Transfer Case Description and Operation and Transfer Case High/Low Clutch Reset. Refer to the table below for information regarding the HD design part numbers. Parts Information Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Shifter Transfer Case > Component Information > Service and Repair Shifter Transfer Case: Service and Repair Transfer Case Control Lever Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Shift Linkage, Transfer Case > Component Information > Service and Repair Shift Linkage: Service and Repair Transfer Case Control Rod Replacement Removal Procedure Note: Before beginning the following service procedure, place the transmission into the PARK position. Then place the transfer case in the 2 HI position. 1. Remove the transfer case shield, if equipped. Refer to Transfer Case Shield Replacement (See: Service and Repair/Removal and Replacement/BW 4485-NR3 - Transfer Case/Transfer Case Shield Replacement). 2. Remove the front propeller shaft. Refer to Front Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Front Propeller Shaft Replacement). Note: When performing this service procedure, use a small pocket screwdriver in order to release the retaining clip on the ends of the control rod. 3. Remove the control rod from the control lever. 4. Remove the control rod from the shift lever. 5. Remove the control rod. Installation Procedure Note: * Before installing a NEW control rod, loosen the adjusting bolt on the control rod so it slides with slight resistance. * When installing the control rod on the control levers, a snapping sound should be heard or felt upon installation. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Shift Linkage, Transfer Case > Component Information > Service and Repair > Page 8827 1. Install the control rod onto the control lever first. 2. Slide the control rod forward. 3. Install the control rod onto the shift control lever. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Tighten the control rod adjusting bolt. Tighten the bolt to 15 Nm (11 lb ft). 5. Install the front propeller shaft. Refer to Front Propeller Shaft Replacement (See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Front Propeller Shaft Replacement). 6. Install the transfer case shield, if equipped. Refer to Transfer Case Shield Replacement (See: Service and Repair/Removal and Replacement/BW 4485-NR3 - Transfer Case/Transfer Case Shield Replacement). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair Speed Sensor: Service and Repair Transfer Case Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the speed sensor electrical connector (4). 3. Remove the speed sensor and O-ring. 4. Discard the O-ring. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Page 8831 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the speed sensor with a NEW O-ring. Tighten the sensor to 17 Nm (13 lb ft). 2. Connect the speed sensor electrical connector (4). 3. Lower the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Diagrams Transfer Case Actuator: Diagrams Component Connector End Views Transfer Case Encoder Motor (NQF or NQH) Front Drive Axle Actuator (NQF, NQG or NQH) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Page 8835 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case Transfer Case Actuator: Service and Repair MP 1625/1626-NQF - Transfer Case Transfer Case Two/Four Wheel Drive Actuator Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case > Page 8838 Transfer Case Actuator: Service and Repair MP 3023/3024-NQH - Transfer Case Transfer Case Two/Four Wheel Drive Actuator Position Sensor Replacement Transfer Case Two/Four Wheel Drive Actuator Position Sensor Replacement Transfer Case Two/Four Wheel Drive Actuator Replacement Transfer Case Two/Four Wheel Drive Actuator Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case > Page 8839 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams Pressure Regulating Solenoid: Diagrams Component Connector End Views Pressure Control (PC) Solenoid Valve (M30) Pressure Control (PC) Solenoid Valve 1 (MW7) Pressure Control (PC) Solenoid Valve 2 (MW7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 8846 Modulated Main Pressure Control (PC) Solenoid Valve (MW7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Service and Repair Shift Interlock Solenoid: Service and Repair Automatic Transmission Shift Lock Control Actuator Replacement Removal Procedure 1. Disable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair). 2. Remove the knee bolster. Refer to Knee Bolster Replacement (With SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (With SLT))Knee Bolster Replacement (Without SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (Without SLT)). 3. Put the shift lever clevis into the neutral position. 4. Disconnect the electrical connector. 5. Using a small screwdriver, pry the automatic transmission shift lock control actuator away from the steering column jacket and the cable shift cam. 6. Remove the shift lock control actuator. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Service and Repair > Page 8850 1. Firmly install the shift lock control actuator onto the steering column jacket and the cable shift cam. 2. Connect the electrical connector. 3. Adjust the shift lock control actuator (with the shift lever clevis in the neutral position) in the following way: 1. Pull out the tab (1) on the adjuster block side (2) of the shift lock control actuator. 2. Press on the adjuster block (2) to compress the internal adjuster spring which disengages the adjuster teeth. Slide the adjuster block (2) as far away from the actuator as possible. 3. Lock the adjuster block (2) in place by pushing in on the tab (1). 4. Inspect the shift lock control actuator for the following items: 1. The shift lock control actuator must lock the shift lever clevis when the shift lever clevis is put into the park position. 2. Depress the brake pedal to move the shift lever out of the park position. 3. The actuator will be energized. 4. Readjust the shift lock control actuator if needed. 5. Install the knee bolster. Refer to Knee Bolster Replacement (With SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (With SLT))Knee Bolster Replacement (Without SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (Without SLT)). 6. Enable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations Shift Solenoid: Locations Disassembled Views Main Valve Body Assembly 1 - Main Valve Body Assembly 2 - Retaining Clip 3 - Exhaust Pressure Regulator Valve Spring 4 Exhaust Pressure Regulator Valve 5 - Retaining Clip 6 - Control Relief Spring 7 - Control Relief Valve 8 - Main Valve Body 9 - Locating Pin (4) 10 - Locating Pin 11 - Pressure Control Solenoid 1 (PCS1) Spring 12 - PCS1 Valve 13 - PCS1 Spring 14 - Trim Gain Valve 15 - PCS1 16 - PCS1 O-Ring 17 - PCS2 Spring 18 - PCS2 Valve 19 - Trim Gain Valve 20 - PCS2 21 - PCS2 O-Ring 22 Shift Solenoid (SS) 3 23 - SS3 O-Ring 24 - SS3 O-Ring 25 - SS2 26 - SS2 O-Ring 27 - SS2 O-Ring Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Page 8854 28 - Torque Converter Clutch Pressure Control Solenoid (TCC PCS) Spring 29 - TCC PCS Valve 31 - TCC PCS 32 - TCC PCS O-Ring 33 - TCC PCS O-Ring 34 - TCC PCS Retaining Bracket 35 - SS2 and SS3 Retainers (2) 36 - Accumulator Plug (2) 37 - Accumulator Spring (2) 38 - PCS1 and PCS2 Retaining Bracket Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Shift Solenoid: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Schematic Symbols Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8857 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8858 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8859 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8860 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8861 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8862 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8863 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8864 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8865 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8866 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8867 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8868 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8869 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8870 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8871 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8872 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8873 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8874 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8875 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8876 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8877 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8878 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8879 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8880 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8881 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8882 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8883 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8884 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8885 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8886 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8887 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8888 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8889 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8890 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8891 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8892 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8893 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8894 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8895 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8896 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8897 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8898 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8899 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8900 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8901 Shift Solenoid: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed with Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8902 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8903 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Connector Test Adapters) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8904 Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Test Lamp) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Fused Jumper Wires) * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage Drop) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Frequency) * Testing Ground and Low Reference Circuits (See: Testing and Inspection/Component Tests and General Diagnostics/Testing Ground and Low Reference Circuits) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fuses) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Circuit Breakers) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fusible Links) Troubleshooting with a Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Testing for a Short to Voltage Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8905 Testing for a Short to Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure tests for a short to voltage in a circuit. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the Digital Multimeter (DMM) to the V (DC) position. 4. Connect the positive lead of the DMM to one end of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. Turn ON the ignition and operate all accessories. 7. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Special Tools J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure). Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents). Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8906 The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the frequency of a signal. Note: Connecting the Digital Multimeter (DMM) to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Set to Hz on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8907 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the Digital Multimeter (DMM). 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the difference in voltage potential between 2 points. 1. Set the Digital Multimeter (DMM) to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8908 Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Backprobe Note: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8909 (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for Continuity Testing for Continuity Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures verify good continuity in a circuit. With a Digital Multimeter (DMM) 1. Set the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Select the MIN MAX function on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8910 Testing for Electrical Intermittents Testing for Electrical Intermittents Special Tools J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. Note: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions). 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8911 visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing for Terminal Fretting Some intermittent conditions can be caused by wire terminal fretting corrosion. Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can pile up enough at the electrical contact spots that the electrical resistance across the connection increases. Movement between the contacting surfaces as small as 10 to 100 microns can cause fretting. To put this in perspective, a sheet of paper is about 100 microns thick, so fretting motion is small and hard to see. Vibration and thermal expansion/contraction are the main sources that create fretting motion. Since vehicles vibrate and can experience large temperature swings, they are a good source for fretting motion. Tin, copper, nickel, and iron surfaces are all susceptible to fretting corrosion. Fretting corrosion can be difficult to see but it looks like small, dark smudges on the terminals contact surface. To correct a fretting condition disconnect the suspect connector and add Nyogel lubricant 760G (dielectric grease) to both sides of the connector terminals. Then reconnect the connector and wipe away any excess lubricant. This will correct the additional terminal contact resistance due to the terminal fretting corrosion. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8912 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics). * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Ground Distribution Schematics). Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Checking Aftermarket Accessories). * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8913 Note: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures test for a short to ground in a circuit. With a Digital Multimeter (DMM) 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohms position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Danger: High voltage circuits should only be tested using a digital multimeter (DMM) and test leads with at least a CAT III rating, such as the J 39200-A Digital Multimeter. Failure to follow the procedures exactly as written may result in serious injury or death. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Digital Multimeter (DMM) Basic Requirements Service information is validated using digital multimeters that meet or exceed the following requirements. Using a multimeter that does not meet these basic requirements may give inaccurate readings which could lead to an incorrect diagnosis. Display and Settings 1. Four digits displayed 2. Voltage, amperage, resistance, frequency, diode test settings, and min-max function 3. Display positive and negative values Voltage 1. Have at least 10 M ohm input impedance Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8914 2. Test a DC voltage range of 0.1-1000 V. 3. Test an AC voltage range of 0.1-1000 V. Amperage 1. Test a DC amperage range of 0.1µA-10 A. 2. Test an AC amperage range of 0.1µA-10 A. Resistance Test a resistance range of 0.1 ohm-40 Mohm and displays infinite for a value greater than 40 M ohm (O.L. (Over-load)) Frequency Test for a frequency range of 0.5 HZ-199 K HZ Diode Test 1. Apply at least 1 mA when performing the diode bias test 2. Display the break over voltage drop (0-3 V) of a forward biased diode 3. Display infinite (O.L. (Over-load)) when a diode is reverse biased Min-Max Readings 1. Can update at a 1 ms sample rate 2. Saves and displays minimum and maximum values Note: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Probe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors). * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the EL-38125-580 GM Approved Terminal Release Tool Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the EL-38125-580 GM Approved Terminal Release Tool Kit , ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the EL-38125-580 GM Approved Terminal Release Tool Kit label on the inside of the EL-38125-580 GM Approved Terminal Release Tool Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8915 Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/EPC Connectors AFL/EPC Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8916 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 3. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8917 View showing depressing of the lever lock release tab. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8918 6. Release the rear lower half of the wiredress cover. 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8919 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8920 Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Bosch Connectors (ECM) Bosch Connectors (ECM) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8921 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. 2. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8922 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-bladed tool to release the locking tabs and remove the dress cover. 4. The terminal positive assurance (TPA) is located in the front of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8923 5. Use a small flat-blade tool to remove TPA from the connector. 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8924 Note: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8925 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8926 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Terminal Replacement Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8927 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8928 5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Position Assurance Locks) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Terminal Position Assurance Locks) * AFL/EPC Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/AFL/EPC Connectors) * Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (BSK))Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (0.64))Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (2.8 JPT))Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (ECM)) * Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Weather Pack))Delphi Connectors (Push To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Push to Seat))Delphi Connectors Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8929 (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Pull to Seat))Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro-Pack 100W))Delphi Connectors (Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro .64))Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (12-Way)) * FCI Connectors (Lever Lock) (See: General Electrical Diagnostic Procedures/Connector Repairs/FCI Connectors (Lever Lock)) * JST Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/JST Connectors) * Kostal Connectors (Glow Plug Control Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Glow Plug Control Module))Kostal Connectors (Transmission) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Transmission)) * Molex Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Molex Connectors) * Sumitomo Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Sumitomo Connectors) * Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (CM 42-Way))Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Sensor))Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (0.25 Cap))Tyco/AMP Connectors (43-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (43-Way))Tyco/AMP Connectors (Door Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Door Module))Tyco/AMP Connectors (102-Way Inline) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (102-Way Inline))Tyco/AMP Connectors (Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Seat))Tyco/AMP Connectors (SIR) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (SIR)) * Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (2-Way))Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (16-Way)) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8930 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8931 * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8932 * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8933 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8934 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8935 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Push to Seat) Delphi Connectors (Push To Seat) Special Tools J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8936 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs). 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Terminated Lead Repair 1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice sleeves depending on the gauge size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Delphi Connectors (Pull to Seat) Delphi Connectors (Pull To Seat) Special Tools Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8937 J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Note: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8938 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. View of a typical Micro 64 connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8939 Depress the lock and pull the lever over and past the lock. View of the connector when released from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8940 View of another type of Micro 64 connector. Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8941 View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8942 Note: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8943 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8944 Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Note: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8945 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8946 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8947 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8948 1. Cut the wire as close to the terminal as possible. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8949 Terminal Replacement Procedure After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Special Tools J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Note: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals). 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12-Way) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8950 Delphi Connectors (12-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8951 4. Release the lower wire dress cover locking tab. 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8952 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8953 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors (Lever Lock) FCI Connectors (Lever Lock) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8954 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. The release tab is located on the top of the wiredress cover. 3. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8955 6. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8956 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8957 1. While depressing the lock, remove the connector from the component. 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8958 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. 4. View of the TPA when removed from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8959 5. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Glow Plug Control Module) Kostal Connectors (Glow Plug Control Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8960 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8961 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8962 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. Note: The front TPA cannot be removed from the connector. Only move it to the preset position. 6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm). 7. Use a small flat-blade tool to completely remove the rear TPA from the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8963 8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Transmission) Kostal Connectors (Transmission) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8964 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8965 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Terminal Replacement Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8966 After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8967 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8968 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8969 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8970 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8971 3. To assemble the connector, reverse the connector disassembly procedure. Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8972 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8973 7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8974 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8975 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8976 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8977 Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8978 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8979 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8980 6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (102-Way Inline) Tyco/AMP Connectors (102-Way Inline) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8981 View of a typical connector in the assembled position. 1. Pull the locking lever to the 90 degree position from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8982 2. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal. 3. Slide the male connector body out away from the guide plates. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8983 Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 4. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. 5. Using terminal release tool J 38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8984 6. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 7. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8985 8. The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool J-38125-11A or equivalent to release the locking tab and slide the connector off the female body. 9. Move the locking lever 180 degrees from the connected position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8986 10. With the locking lever in the 180 degree position the guide plates can be removed from the connector body. Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 11. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8987 12. Using terminal release tool J 38125-216, lift the terminal plate past the terminals and out of the connector body cavity. 13. Terminal plate will bind slightly on each corner. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8988 14. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 15. Using terminal release tool J 38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8989 16. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 17. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8990 18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever. 19. Slide the male connector body back inward toward the guide plates. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8991 20. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly. 21. Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Seat) Tyco/AMP Connectors (Seat) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8992 Removal Procedure 1. Grasp the locking slide lever and pull outward from the end of the connector. 2. As the slide lever is pulled out the mating connector is lifted from the seated position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8993 Note: TPA is keyed and can only be inserted in one direction. 3. Using terminal release tool J 38125-11A or equivalent, push the TPA tabs into the connector body. 4. Pull the TPA from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8994 5. Using terminal release tool J 38125-11A or equivalent, release the connector wire dress cover locking tab. 6. With the lock tab released, lift the connector wire dress cover from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8995 7. Using terminal release tool J 38125-212, press the prongs into the holes each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 8. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8996 9. Using terminal release tool J 38125-556, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (SIR) Tyco/AMP Connectors (SIR) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8997 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8998 3. Using terminal tool J-38125-11A or equivalent, release the wire dress cover locking tabs. 4. Pivot connector wire dress cover while removing from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 8999 5. Using terminal tool J-38125-11A or equivalent, remove the TPA by lifting straight off the connector body. 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals Repairing Connector Terminals Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9000 Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gauge size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9001 2. Disconnect the connector from the component. 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9002 4. Relieve the tension on the nose piece retainers by inserting J 38125-12A into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. 5. Once the nose piece retainers are relaxed, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9003 6. On the opposite side of the nose piece, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9004 8. Insert the J 38125-553 tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9005 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. If the TPA is removed, be sure to reinstall it before reconnecting the connector. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9006 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Special Tools Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9007 J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Note: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9008 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9009 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9010 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9011 1. While depressing the lock, pull the two connector halves apart. Note: The TPA is fragile and may break if not done carefully. 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. 3. View of the male half of the connector with female terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9012 4. View of the female half of the connector with male terminals. 5. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. View of the female half of the connector with male terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9013 7. View of the male half of the connector with female terminals. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9014 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are a one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine if the element in the fuse is broken (2). If not broken (1), also check for continuity using a Digital Multimeter (DMM) or a continuity tester. If the element is broken or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a Digital Multimeter (DMM) at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gauge size. Repairing a Fusible Link Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9015 Flat Wire Repairs The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Special Tools J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool * J 38125-5 Ultra Torch Special Tool The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Note: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation). GMLAN Connector Terminal Repair Note: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) for the appropriate connector repair procedure. GMLAN Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9016 Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9017 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Special Tools J-38125 Terminal Repair Kit Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9018 repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs High Temperature Wiring Repairs Special Tools J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gauge size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9019 splice. Note: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9020 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9021 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the wire insulation has been chafed, or broken, enough to show the conductive portion of the wire, and the wire is not damaged, determine the length of insulation that needs to be repaired. If the repair is less than 280 mm (11 in), cut the wire within the damaged area. Then slide the appropriate heat shrink tubing (listed below) over the wire, and repair the wire by splicing the wires together. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Once the wire is spliced together slide heat shrink tubing over the damaged area and apply heat to seal the repaired wire. If the wire is damaged, or the damaged area is larger than 280 mm (11 in), then replace the damaged wire by splicing in a new section of wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9022 SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Special Tools J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9023 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9024 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9025 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Special Tools J-38125 Terminal Repair Kit Note: Use only DuraSeal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use DuraSeal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use DuraSeal splice sleeves where there are special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9026 * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9027 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9028 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the instructions for Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Staggering the splices by 65 mm (2.5 in) is recommended. Note: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product AL-36FR to replace the damaged mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Flat Wire Repairs) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/GMLAN Wiring Repairs) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Heated Oxygen Sensor Wiring Repairs) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves) * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Twisted or Shielded Cable) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Inline Harness Diodes) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/SIR/SRS Wiring Repairs) US English/Metric Conversion US English/Metric Conversion Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9029 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9030 Testing Ground and Low Reference Circuits Testing Ground and Low Reference Circuits Because a test lamp can light with up to 200 ohm in a ground or low reference circuit they are not recommended to be used for this type of test. A low impedance test lamp can light and indicate the circuit is good when there is as much as 20-30 ohm present, while a high impedance test lamp can light with up to 200 ohm present in the circuit. This is why the Digital Multi-Meter (DMM) is used when validating a ground or low reference circuit continuity. When using the DMM there are many vehicle conditions that can affect the ground and low reference continuity testing. If these conditions are not met, a ground or low reference circuit test can fail on a good circuit. This may cause longer diagnosis time and incorrect component replacement. Any current flow through a ground or low reference circuit, while being tested, will skew the DMM continuity reading, or display a reading higher than when there is no current flowing. Performing a ground or low reference circuit continuity test, in reference to the vehicles battery negative terminal, will have the highest risk of failing a good ground or low reference circuit test than any other ground reference point. The best ground test points would be a control module housing (if the control modules housing is metal and grounded), door jamb striker (if attached to metal), under dash metal frame work, engine block, or body ground studs (other than where the negative battery cable is attached). A typical DMM ground or low reference circuit continuity reading can be as high as 100 ohm with the ignition ON, and drop to 15-25 ohm after the ignition is turned OFF. The reading will drop below 10 ohm after 30-40 seconds, then below 5 ohm after 60 seconds. Once the vehicle completely goes to sleep (generally 3-10 minutes) the reading will drop below 0.3 ohm. The following list of conditions may need to be met to ensure a valid continuity reading on a ground or low reference circuit: * Ignition OFF * Key out of the ignition switch (when not equipped with keyless entry and remote start) * Retained Accessory Power (RAP) OFF (open and close the driver door after ignition OFF) * Battery charger set at a 2 A or less charge rate * Scan tool not communicating with any vehicle control module (in some cases it may need to be disconnected from the DLC) * All entry doors closed * Headlamps OFF (auto headlamps disabled) * Any delay lighting OFF * HVAC after blow OFF * Any accessory that can work when the ignition is OFF * Wait up to 60 seconds (after all other listed conditions are met) Activating the DOOR LOCK function with a key fob can greatly reduce the time to achieve a valid ground or low reference continuity test result. Terminal Removal Terminal Removal Special Tools * EL-38125-580 - Terminal Release Tool Kit * EL-35616 - Connector Test Adapter Kit For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repair procedures. 1. Find the appropriate connector end view within the connector end view section. The connector end view has the following information: Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9031 * Diagnostic probe tool * Terminal release tool * Terminal/terminated lead part numbers Note: Not using the proper test kit probe may cause damage to the terminal(s) that are probed. 2. Determine if a terminal is damaged. * Locate the diagnostic probe tool from the connector end view. The connector end view describes the color and part number to help the technician find and use the correct tool. * Connect the probe tool to the Digital Multimeter. * Insert the probe tool into the cavity and follow the procedures from the Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter). 3. Disconnect the connector body to perform the repair. 4. Use the following procedure to remove the terminal from the connector body. Note: Several procedures for specific connector bodies are called out in the Wiring Repairs section. * The terminal position assurance (TPA) and connector position assurance (CPA) should be removed before releasing the terminal for the connector body. * Look at the connector end view to locate the cavity of the damaged terminal and find the proper terminal release tool from the terminal release tool kit. Note: Using the incorrect terminal release tool can damage the connector body. * Insert the terminal release tool into the cavity. Note: Some terminals have a lever that must be disengaged before the terminal can be released. 5. Gently pull the wire out of the back of the connector. 6. Repair the terminal by following the Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) procedure. 7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminated Lead Repair Terminated Lead Repair Special Tools * J-38125-8 - Splice Sleeve Crimp Tool Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9032 * J-38125-5 - Ultra Torch For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) procedures. Terminated leads are terminals that are crimped onto wires. The terminated lead can be used throughout the vehicle since it is designed for temperatures up to 150°C. The length of the wire is 450 mm. The DuraSeal splice sleeve has the following 2 critical features: * A special heat shrink tubing that environmentally seals the splice. The shrink tubing contains a sealing adhesive inside the shrink tubing. * A cross hatched (knurled) core crimp that provides the necessary contact integrity for sensitive low energy circuits. 1. Use the connector end view to identify the correct terminated lead. 2. The terminated lead package should include a DuraSeal splice sleeve. If not, use the chart to identify the correct part. 3. Open the harness by removing any tape: Use a sewing seam ripper, or a comparable tool, to cut open the harness, to avoid wire insulation damage. 4. Depending on how many terminals need repairs, cut the terminal and wire back at least 40 mm. Try to keep the harness wire length the same. If more than one terminated lead is required, stagger the lengths by 40 mm. This helps reduce the bundle size of the wire harness. 5. Use the EL-38125-10 - tool in order to position the DuraSeal splice sleeve in the proper color nest of the splice sleeve crimp tool. The crimp tool has four nests, one for each color. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9033 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the J-38125-5 - ultra torch , apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9034 Shift Solenoid: Connector Views Component Connector End Views Control Solenoid Valve Assembly X1 (MYC, MYD or M99) Control Solenoid Valve Assembly X2 (MYC, MYD or M99) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9035 Control Solenoid Valve Assembly X3 (MYC, MYD or M99) 1-2 Shift Solenoid (SS) Valve (M30) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9036 2-3 Shift Solenoid (SS) Valve (M30) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9037 Shift Solenoid (SS) Valve 1 (MW7) Shift Solenoid (SS) Valve 2 (MW7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9038 Shift Solenoid (SS) Valve 3 (MW7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > Control Valve Solenoid Replacement (PCS1 and PCS2) Shift Solenoid: Service and Repair Control Valve Solenoid Replacement (PCS1 and PCS2) Control Valve Solenoid Replacement (PCS1 and PCS2) Removal Procedure 1. Remove the oil pan and transmission internal oil filter. Refer to Oil Pan Replacement (See: Automatic Transmission/Transaxle/Fluid Pan/Service and Repair). 2. Disconnect the internal wiring harness from the solenoid being changed. 3. Remove the 2 bolts that fasten reverse signal pipe (1) to the control valve assembly. Remove the reverse signal pipe. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > Control Valve Solenoid Replacement (PCS1 and PCS2) > Page 9041 Note: * When the pressure control valve retaining bracket (5) is removed, there are 2 sets of accumulators (3) and springs (6) which may fall from the bores. Be sure to catch the accumulators and springs so as to prevent damage to these parts. * The pressure control valve retaining bracket (5) must not be modified. Note that the angle between the 2 bracket surfaces is less than 90 degrees. Replace the bracket if the angle is 90 degrees or more. 4. To remove the pressure control solenoid 1 (PCS1) or PCS2, remove three bolts (4) and the pressure control valve retaining bracket (5). Remove accumulators (3) and springs (6) if they do not fall out when the bracket (5) is removed. 5. Note the position of the solenoid connector and pull the solenoid (1) or (8) out of the bore in the control valve assembly. The O-ring on the solenoid provides the resistance felt during removal. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > Control Valve Solenoid Replacement (PCS1 and PCS2) > Page 9042 1. Obtain the new solenoid (1) or (8). Lubricate new O-ring (2) or (7) with clean transmission fluid. Install the O-ring and push the new solenoid into the control valve body bore with the wiring harness connector in the correct position. 2. Install the 2 accumulators (3) and springs (6) before installing the pressure control valve retaining bracket (5). The valve (3) goes in the bore first with the hollow end facing outward, followed by the spring (6) which goes inside the hollow portion of the valve. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the pressure control valve retaining bracket (5), and install the 3 bolts (4). Tighten the bolts to 12 Nm (108 lb in). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > Control Valve Solenoid Replacement (PCS1 and PCS2) > Page 9043 4. Install the reverse signal pipe (1). Install the 2 bolts that fasten reverse signal pipe to the control valve assembly. Tighten the bolts to 12 Nm (108 lb in). 5. Reconnect the internal wiring harness to the solenoid. 6. Install the oil pan and transmission internal oil filter. Refer to Oil Pan Replacement (See: Automatic Transmission/Transaxle/Fluid Pan/Service and Repair). Note: The FastLearn, adapt, procedure must be performed. This can be done in 1 step using a scan tool. If this procedure is not done, the TCM adaptive values will be at the settings that it learned for the old components and will be in slow adaptive mode. Under these conditions, it will take an unacceptably long time for the adaptive values to converge to levels suitable for the new transmission. 7. Perform the FastLearn procedure. Refer to FastLearn Procedure (See: Automatic Transmission/Transaxle/Testing and Inspection/Programming and Relearning). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > Control Valve Solenoid Replacement (PCS1 and PCS2) > Page 9044 Shift Solenoid: Service and Repair Control Valve Solenoid Replacement (SS1, SS2, SS3, TCC, and MAIN MOD) Control Valve Solenoid Replacement (SS1, SS2, SS3, TCC, and MAIN MOD) Removal Procedure 1. Remove the oil pan and the transmission internal oil filter. Refer to Oil Pan Replacement (See: Automatic Transmission/Transaxle/Fluid Pan/Service and Repair). 2. Disconnect the internal wiring harness from the solenoid being changed. 3. Remove the solenoid retainer (2) for shift solenoid 1 (SS1) (5). Note the position of the solenoid connector and pull the solenoid (5) out of the bore in the control valve assembly (1). The O-rings (3 and 4) provide the resistance felt during removal. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > Control Valve Solenoid Replacement (PCS1 and PCS2) > Page 9045 4. Remove the solenoid retainer (6) for shift solenoid 2 (SS2) (1) or shift solenoid 3 (SS3) (4), whichever is being replaced. 5. Note the position of the solenoid connector and pull the solenoid out of the bore in the control valve assembly. The O-rings (2 and 3) provide the resistance felt during removal. Note: The TCC pressure control solenoid (PCS) retaining bracket must not be modified. Note that the angle between the 2 bracket surfaces is less than 90 degrees. Replace the bracket if the angle is 90 degrees or greater. 6. Remove the TCC PCS retaining bolt and retaining bracket. 7. Remove the TCC PCS (7). Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > Control Valve Solenoid Replacement (PCS1 and PCS2) > Page 9046 1. Obtain a new SS 2 (1), SS 3 (4), TCC PCS (7), or modulated main pressure solenoid. Install O-rings (2 and 3) and lubricate with clean transmission fluid. Push the new solenoid into the control valve assembly (5) with the wiring harness connector in the correct position. 2. Install the solenoid retainer (6). Connect the internal wiring harness to the solenoids replaced. 3. For a new TCC PCS (7), install O-rings and lubricate with clean transmission fluid. Push the new TCC PCS (7) into the control valve assembly with the wiring harness connector in the correct position. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the TCC PCS retainer and bolt. Tighten the bolt to 12 Nm (108 lb in). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > Control Valve Solenoid Replacement (PCS1 and PCS2) > Page 9047 5. For a new SS 1 (5), install O-rings (3 and 4) and lubricate with clean transmission fluid. Push the new SS 1 (5) into the control valve assembly with the wiring harness connector in the correct position. Install the solenoid retainer (2). 6. Install the oil pan and transmission internal oil filter. Refer to Oil Pan Replacement (See: Automatic Transmission/Transaxle/Fluid Pan/Service and Repair). Note: The FastLearn, adapt, procedure must be performed. This can be done in 1 step using a scan tool. If this procedure is not done, the TCM adaptive values will be at the settings that it learned for the old components and will be in slow adaptive mode. Under these conditions, it will take an unacceptably long time for the adaptive values to converge to levels suitable for the new transmission. 7. Perform the FastLearn procedure. Refer to FastLearn Procedure (See: Automatic Transmission/Transaxle/Testing and Inspection/Programming and Relearning). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions Torque Converter Clutch Solenoid: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Schematic Symbols Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9052 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9053 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9054 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9055 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9056 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9057 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9058 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9059 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9060 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9061 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9062 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9063 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9064 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9065 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9066 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9067 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9068 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9069 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9070 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9071 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9072 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9073 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9074 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9075 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9076 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9077 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9078 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9079 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9080 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9081 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9082 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9083 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9084 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9085 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9086 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9087 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9088 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9089 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9090 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9091 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9092 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9093 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9094 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9095 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9096 Torque Converter Clutch Solenoid: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed with Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9097 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9098 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Connector Test Adapters) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9099 Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Test Lamp) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Fused Jumper Wires) * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage Drop) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Frequency) * Testing Ground and Low Reference Circuits (See: Testing and Inspection/Component Tests and General Diagnostics/Testing Ground and Low Reference Circuits) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fuses) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Circuit Breakers) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fusible Links) Troubleshooting with a Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Testing for a Short to Voltage Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9100 Testing for a Short to Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure tests for a short to voltage in a circuit. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the Digital Multimeter (DMM) to the V (DC) position. 4. Connect the positive lead of the DMM to one end of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. Turn ON the ignition and operate all accessories. 7. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Special Tools J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure). Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents). Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9101 The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the frequency of a signal. Note: Connecting the Digital Multimeter (DMM) to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Set to Hz on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9102 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the Digital Multimeter (DMM). 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the difference in voltage potential between 2 points. 1. Set the Digital Multimeter (DMM) to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9103 Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Backprobe Note: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9104 (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for Continuity Testing for Continuity Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures verify good continuity in a circuit. With a Digital Multimeter (DMM) 1. Set the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Select the MIN MAX function on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9105 Testing for Electrical Intermittents Testing for Electrical Intermittents Special Tools J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. Note: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions). 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9106 visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing for Terminal Fretting Some intermittent conditions can be caused by wire terminal fretting corrosion. Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can pile up enough at the electrical contact spots that the electrical resistance across the connection increases. Movement between the contacting surfaces as small as 10 to 100 microns can cause fretting. To put this in perspective, a sheet of paper is about 100 microns thick, so fretting motion is small and hard to see. Vibration and thermal expansion/contraction are the main sources that create fretting motion. Since vehicles vibrate and can experience large temperature swings, they are a good source for fretting motion. Tin, copper, nickel, and iron surfaces are all susceptible to fretting corrosion. Fretting corrosion can be difficult to see but it looks like small, dark smudges on the terminals contact surface. To correct a fretting condition disconnect the suspect connector and add Nyogel lubricant 760G (dielectric grease) to both sides of the connector terminals. Then reconnect the connector and wipe away any excess lubricant. This will correct the additional terminal contact resistance due to the terminal fretting corrosion. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9107 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics). * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Ground Distribution Schematics). Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Checking Aftermarket Accessories). * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9108 Note: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures test for a short to ground in a circuit. With a Digital Multimeter (DMM) 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohms position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Danger: High voltage circuits should only be tested using a digital multimeter (DMM) and test leads with at least a CAT III rating, such as the J 39200-A Digital Multimeter. Failure to follow the procedures exactly as written may result in serious injury or death. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Digital Multimeter (DMM) Basic Requirements Service information is validated using digital multimeters that meet or exceed the following requirements. Using a multimeter that does not meet these basic requirements may give inaccurate readings which could lead to an incorrect diagnosis. Display and Settings 1. Four digits displayed 2. Voltage, amperage, resistance, frequency, diode test settings, and min-max function 3. Display positive and negative values Voltage 1. Have at least 10 M ohm input impedance Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9109 2. Test a DC voltage range of 0.1-1000 V. 3. Test an AC voltage range of 0.1-1000 V. Amperage 1. Test a DC amperage range of 0.1µA-10 A. 2. Test an AC amperage range of 0.1µA-10 A. Resistance Test a resistance range of 0.1 ohm-40 Mohm and displays infinite for a value greater than 40 M ohm (O.L. (Over-load)) Frequency Test for a frequency range of 0.5 HZ-199 K HZ Diode Test 1. Apply at least 1 mA when performing the diode bias test 2. Display the break over voltage drop (0-3 V) of a forward biased diode 3. Display infinite (O.L. (Over-load)) when a diode is reverse biased Min-Max Readings 1. Can update at a 1 ms sample rate 2. Saves and displays minimum and maximum values Note: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Probe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors). * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the EL-38125-580 GM Approved Terminal Release Tool Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the EL-38125-580 GM Approved Terminal Release Tool Kit , ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the EL-38125-580 GM Approved Terminal Release Tool Kit label on the inside of the EL-38125-580 GM Approved Terminal Release Tool Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9110 Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/EPC Connectors AFL/EPC Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9111 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 3. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9112 View showing depressing of the lever lock release tab. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9113 6. Release the rear lower half of the wiredress cover. 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9114 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9115 Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Bosch Connectors (ECM) Bosch Connectors (ECM) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9116 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. 2. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9117 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-bladed tool to release the locking tabs and remove the dress cover. 4. The terminal positive assurance (TPA) is located in the front of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9118 5. Use a small flat-blade tool to remove TPA from the connector. 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9119 Note: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9120 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9121 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Terminal Replacement Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9122 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9123 5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Position Assurance Locks) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Terminal Position Assurance Locks) * AFL/EPC Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/AFL/EPC Connectors) * Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (BSK))Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (0.64))Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (2.8 JPT))Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (ECM)) * Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Weather Pack))Delphi Connectors (Push To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Push to Seat))Delphi Connectors Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9124 (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Pull to Seat))Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro-Pack 100W))Delphi Connectors (Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro .64))Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (12-Way)) * FCI Connectors (Lever Lock) (See: General Electrical Diagnostic Procedures/Connector Repairs/FCI Connectors (Lever Lock)) * JST Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/JST Connectors) * Kostal Connectors (Glow Plug Control Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Glow Plug Control Module))Kostal Connectors (Transmission) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Transmission)) * Molex Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Molex Connectors) * Sumitomo Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Sumitomo Connectors) * Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (CM 42-Way))Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Sensor))Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (0.25 Cap))Tyco/AMP Connectors (43-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (43-Way))Tyco/AMP Connectors (Door Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Door Module))Tyco/AMP Connectors (102-Way Inline) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (102-Way Inline))Tyco/AMP Connectors (Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Seat))Tyco/AMP Connectors (SIR) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (SIR)) * Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (2-Way))Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (16-Way)) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9125 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9126 * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9127 * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9128 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9129 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9130 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Push to Seat) Delphi Connectors (Push To Seat) Special Tools J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9131 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs). 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Terminated Lead Repair 1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice sleeves depending on the gauge size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Delphi Connectors (Pull to Seat) Delphi Connectors (Pull To Seat) Special Tools Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9132 J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Note: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9133 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. View of a typical Micro 64 connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9134 Depress the lock and pull the lever over and past the lock. View of the connector when released from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9135 View of another type of Micro 64 connector. Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9136 View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9137 Note: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9138 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9139 Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Note: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9140 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9141 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9142 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9143 1. Cut the wire as close to the terminal as possible. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9144 Terminal Replacement Procedure After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Special Tools J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Note: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals). 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12-Way) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9145 Delphi Connectors (12-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9146 4. Release the lower wire dress cover locking tab. 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9147 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9148 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors (Lever Lock) FCI Connectors (Lever Lock) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9149 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. The release tab is located on the top of the wiredress cover. 3. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9150 6. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9151 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9152 1. While depressing the lock, remove the connector from the component. 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9153 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. 4. View of the TPA when removed from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9154 5. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Glow Plug Control Module) Kostal Connectors (Glow Plug Control Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9155 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9156 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9157 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. Note: The front TPA cannot be removed from the connector. Only move it to the preset position. 6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm). 7. Use a small flat-blade tool to completely remove the rear TPA from the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9158 8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Transmission) Kostal Connectors (Transmission) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9159 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9160 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Terminal Replacement Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9161 After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9162 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9163 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9164 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9165 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9166 3. To assemble the connector, reverse the connector disassembly procedure. Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9167 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9168 7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9169 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9170 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9171 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9172 Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9173 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9174 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9175 6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (102-Way Inline) Tyco/AMP Connectors (102-Way Inline) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9176 View of a typical connector in the assembled position. 1. Pull the locking lever to the 90 degree position from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9177 2. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal. 3. Slide the male connector body out away from the guide plates. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9178 Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 4. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. 5. Using terminal release tool J 38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9179 6. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 7. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9180 8. The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool J-38125-11A or equivalent to release the locking tab and slide the connector off the female body. 9. Move the locking lever 180 degrees from the connected position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9181 10. With the locking lever in the 180 degree position the guide plates can be removed from the connector body. Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 11. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9182 12. Using terminal release tool J 38125-216, lift the terminal plate past the terminals and out of the connector body cavity. 13. Terminal plate will bind slightly on each corner. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9183 14. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 15. Using terminal release tool J 38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9184 16. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 17. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9185 18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever. 19. Slide the male connector body back inward toward the guide plates. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9186 20. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly. 21. Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Seat) Tyco/AMP Connectors (Seat) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9187 Removal Procedure 1. Grasp the locking slide lever and pull outward from the end of the connector. 2. As the slide lever is pulled out the mating connector is lifted from the seated position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9188 Note: TPA is keyed and can only be inserted in one direction. 3. Using terminal release tool J 38125-11A or equivalent, push the TPA tabs into the connector body. 4. Pull the TPA from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9189 5. Using terminal release tool J 38125-11A or equivalent, release the connector wire dress cover locking tab. 6. With the lock tab released, lift the connector wire dress cover from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9190 7. Using terminal release tool J 38125-212, press the prongs into the holes each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 8. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9191 9. Using terminal release tool J 38125-556, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (SIR) Tyco/AMP Connectors (SIR) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9192 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9193 3. Using terminal tool J-38125-11A or equivalent, release the wire dress cover locking tabs. 4. Pivot connector wire dress cover while removing from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9194 5. Using terminal tool J-38125-11A or equivalent, remove the TPA by lifting straight off the connector body. 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals Repairing Connector Terminals Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9195 Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gauge size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9196 2. Disconnect the connector from the component. 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9197 4. Relieve the tension on the nose piece retainers by inserting J 38125-12A into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. 5. Once the nose piece retainers are relaxed, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9198 6. On the opposite side of the nose piece, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9199 8. Insert the J 38125-553 tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9200 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. If the TPA is removed, be sure to reinstall it before reconnecting the connector. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9201 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Special Tools Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9202 J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Note: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9203 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9204 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9205 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9206 1. While depressing the lock, pull the two connector halves apart. Note: The TPA is fragile and may break if not done carefully. 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. 3. View of the male half of the connector with female terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9207 4. View of the female half of the connector with male terminals. 5. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. View of the female half of the connector with male terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9208 7. View of the male half of the connector with female terminals. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9209 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are a one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine if the element in the fuse is broken (2). If not broken (1), also check for continuity using a Digital Multimeter (DMM) or a continuity tester. If the element is broken or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a Digital Multimeter (DMM) at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gauge size. Repairing a Fusible Link Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9210 Flat Wire Repairs The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Special Tools J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool * J 38125-5 Ultra Torch Special Tool The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Note: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation). GMLAN Connector Terminal Repair Note: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) for the appropriate connector repair procedure. GMLAN Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9211 Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9212 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Special Tools J-38125 Terminal Repair Kit Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9213 repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs High Temperature Wiring Repairs Special Tools J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gauge size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9214 splice. Note: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9215 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9216 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the wire insulation has been chafed, or broken, enough to show the conductive portion of the wire, and the wire is not damaged, determine the length of insulation that needs to be repaired. If the repair is less than 280 mm (11 in), cut the wire within the damaged area. Then slide the appropriate heat shrink tubing (listed below) over the wire, and repair the wire by splicing the wires together. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Once the wire is spliced together slide heat shrink tubing over the damaged area and apply heat to seal the repaired wire. If the wire is damaged, or the damaged area is larger than 280 mm (11 in), then replace the damaged wire by splicing in a new section of wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9217 SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Special Tools J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9218 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9219 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9220 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Special Tools J-38125 Terminal Repair Kit Note: Use only DuraSeal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use DuraSeal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use DuraSeal splice sleeves where there are special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9221 * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9222 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9223 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the instructions for Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Staggering the splices by 65 mm (2.5 in) is recommended. Note: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product AL-36FR to replace the damaged mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Flat Wire Repairs) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/GMLAN Wiring Repairs) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Heated Oxygen Sensor Wiring Repairs) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves) * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Twisted or Shielded Cable) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Inline Harness Diodes) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/SIR/SRS Wiring Repairs) US English/Metric Conversion US English/Metric Conversion Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9224 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9225 Testing Ground and Low Reference Circuits Testing Ground and Low Reference Circuits Because a test lamp can light with up to 200 ohm in a ground or low reference circuit they are not recommended to be used for this type of test. A low impedance test lamp can light and indicate the circuit is good when there is as much as 20-30 ohm present, while a high impedance test lamp can light with up to 200 ohm present in the circuit. This is why the Digital Multi-Meter (DMM) is used when validating a ground or low reference circuit continuity. When using the DMM there are many vehicle conditions that can affect the ground and low reference continuity testing. If these conditions are not met, a ground or low reference circuit test can fail on a good circuit. This may cause longer diagnosis time and incorrect component replacement. Any current flow through a ground or low reference circuit, while being tested, will skew the DMM continuity reading, or display a reading higher than when there is no current flowing. Performing a ground or low reference circuit continuity test, in reference to the vehicles battery negative terminal, will have the highest risk of failing a good ground or low reference circuit test than any other ground reference point. The best ground test points would be a control module housing (if the control modules housing is metal and grounded), door jamb striker (if attached to metal), under dash metal frame work, engine block, or body ground studs (other than where the negative battery cable is attached). A typical DMM ground or low reference circuit continuity reading can be as high as 100 ohm with the ignition ON, and drop to 15-25 ohm after the ignition is turned OFF. The reading will drop below 10 ohm after 30-40 seconds, then below 5 ohm after 60 seconds. Once the vehicle completely goes to sleep (generally 3-10 minutes) the reading will drop below 0.3 ohm. The following list of conditions may need to be met to ensure a valid continuity reading on a ground or low reference circuit: * Ignition OFF * Key out of the ignition switch (when not equipped with keyless entry and remote start) * Retained Accessory Power (RAP) OFF (open and close the driver door after ignition OFF) * Battery charger set at a 2 A or less charge rate * Scan tool not communicating with any vehicle control module (in some cases it may need to be disconnected from the DLC) * All entry doors closed * Headlamps OFF (auto headlamps disabled) * Any delay lighting OFF * HVAC after blow OFF * Any accessory that can work when the ignition is OFF * Wait up to 60 seconds (after all other listed conditions are met) Activating the DOOR LOCK function with a key fob can greatly reduce the time to achieve a valid ground or low reference continuity test result. Terminal Removal Terminal Removal Special Tools * EL-38125-580 - Terminal Release Tool Kit * EL-35616 - Connector Test Adapter Kit For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repair procedures. 1. Find the appropriate connector end view within the connector end view section. The connector end view has the following information: Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9226 * Diagnostic probe tool * Terminal release tool * Terminal/terminated lead part numbers Note: Not using the proper test kit probe may cause damage to the terminal(s) that are probed. 2. Determine if a terminal is damaged. * Locate the diagnostic probe tool from the connector end view. The connector end view describes the color and part number to help the technician find and use the correct tool. * Connect the probe tool to the Digital Multimeter. * Insert the probe tool into the cavity and follow the procedures from the Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter). 3. Disconnect the connector body to perform the repair. 4. Use the following procedure to remove the terminal from the connector body. Note: Several procedures for specific connector bodies are called out in the Wiring Repairs section. * The terminal position assurance (TPA) and connector position assurance (CPA) should be removed before releasing the terminal for the connector body. * Look at the connector end view to locate the cavity of the damaged terminal and find the proper terminal release tool from the terminal release tool kit. Note: Using the incorrect terminal release tool can damage the connector body. * Insert the terminal release tool into the cavity. Note: Some terminals have a lever that must be disengaged before the terminal can be released. 5. Gently pull the wire out of the back of the connector. 6. Repair the terminal by following the Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) procedure. 7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminated Lead Repair Terminated Lead Repair Special Tools * J-38125-8 - Splice Sleeve Crimp Tool Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9227 * J-38125-5 - Ultra Torch For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) procedures. Terminated leads are terminals that are crimped onto wires. The terminated lead can be used throughout the vehicle since it is designed for temperatures up to 150°C. The length of the wire is 450 mm. The DuraSeal splice sleeve has the following 2 critical features: * A special heat shrink tubing that environmentally seals the splice. The shrink tubing contains a sealing adhesive inside the shrink tubing. * A cross hatched (knurled) core crimp that provides the necessary contact integrity for sensitive low energy circuits. 1. Use the connector end view to identify the correct terminated lead. 2. The terminated lead package should include a DuraSeal splice sleeve. If not, use the chart to identify the correct part. 3. Open the harness by removing any tape: Use a sewing seam ripper, or a comparable tool, to cut open the harness, to avoid wire insulation damage. 4. Depending on how many terminals need repairs, cut the terminal and wire back at least 40 mm. Try to keep the harness wire length the same. If more than one terminated lead is required, stagger the lengths by 40 mm. This helps reduce the bundle size of the wire harness. 5. Use the EL-38125-10 - tool in order to position the DuraSeal splice sleeve in the proper color nest of the splice sleeve crimp tool. The crimp tool has four nests, one for each color. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9228 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the J-38125-5 - ultra torch , apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9229 Torque Converter Clutch Solenoid: Connector Views Component Connector End Views Torque Converter Clutch (TCC) Pressure Control (PC) Solenoid Valve (MW7) Torque Converter Clutch (TCC) Pulse Width Modulated (PWM) Solenoid Valve (M30) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 9230 Torque Converter Clutch (TCC) Solenoid Valve (M30) Wiring Diagram Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Differential > Actuator, Differential Lock > Component Information > Service and Repair Actuator: Service and Repair Front Drive Axle Actuator Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the engine shield, if equipped. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement). 3. Disconnect the electrical connector from the actuator. 4. Remove the actuator (1) for the 8.25 inch axle (2) or (3) for the 9.5 inch axle (4) by turning the actuator counterclockwise. Installation Procedure 1. Apply sealant to the threads of the actuator (1) for the 8.25 inch axle (2) or (3) for the 9.25 inch axle (4). Use the correct sealant. Refer to Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Differential > Actuator, Differential Lock > Component Information > Service and Repair > Page 9235 Adhesives, Fluids, Lubricants, and Sealers (See: Differential Assembly/Fluid Differential/Specifications/Fluid Type Specifications). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the actuator (1 or 3). Tighten the actuator to 20 Nm (15 lb ft). 3. Connect the electrical connector to the actuator. 4. Install the engine shield, if equipped. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement). 5. Lower the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams Transfer Case Actuator: Diagrams Component Connector End Views Transfer Case Encoder Motor (NQF or NQH) Front Drive Axle Actuator (NQF, NQG or NQH) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Page 9240 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case Transfer Case Actuator: Service and Repair MP 1625/1626-NQF - Transfer Case Transfer Case Two/Four Wheel Drive Actuator Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case > Page 9243 Transfer Case Actuator: Service and Repair MP 3023/3024-NQH - Transfer Case Transfer Case Two/Four Wheel Drive Actuator Position Sensor Replacement Transfer Case Two/Four Wheel Drive Actuator Position Sensor Replacement Transfer Case Two/Four Wheel Drive Actuator Replacement Transfer Case Two/Four Wheel Drive Actuator Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case > Page 9244 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON Control Module: All Technical Service Bulletins A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 9255 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 9256 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 9257 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON Control Module: Customer Interest A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 9263 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 9264 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 9265 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 9266 Control Module: Locations Harness Routing Views Engine Chassis Harness Routing - Top Front (Diesel) 1 - Battery - Right 2 - Fuse Holder 3 - X127 4 - X108 5 - X107 6 - X123 (PTO) 7 - Fuse Block Underhood 8 - X109 9 - Battery - Left 10 - Engine Control Module (ECM) 11 - Transmission Control Module (TCM) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 9267 Control Module: Diagrams Component Connector End Views Transmission Control Module (TCM) (M30) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 9268 Transmission Control Module (TCM) (MW7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 9269 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 9270 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 9271 Control Module: Service and Repair Transmission Control Module Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Power Take-Off > Power Take-Off Relay > Component Information > Diagrams Power Take-Off Relay: Diagrams Component Connector End Views Power Take Off (PTO) Relay (PTO) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams Control Module: Diagrams Component Connector End Views Transfer Case Shift Control Module X1 (NQF or NQH) Transfer Case Shift Control Module X2 (NQF or NQH) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Page 9280 Transfer Case Shift Control Module X3 (NQF or NQH) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Page 9281 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case Control Module: Service and Repair MP 1625/1626-NQF - Transfer Case Transfer Case Shift Control Module Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case > Page 9284 Control Module: Service and Repair MP 3023/3024-NQH - Transfer Case Transfer Case Shift Control Module Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations Fluid Pressure Sensor/Switch: Locations Disassembled Views Control Valve Body Assembly 1 - Control Valve Body Assembly 2 - Shift Valve Body Assembly 3 - Separator Plate 4 - Main Valve Body Assembly 5 - Transmission Fluid Pressure (TFP) Switch 6 - Main Valve Body Assembly Bolt, M6 x 10 x 50, Flanged Head (23) 7 - Reverse Signal Pipe 8 - Reverse Signal Pipe Bolt, M6 x 10 x 50, Flanged Head 9 - Retaining Clip 10 - Modulated Main Valve Body 11 - Bolt, M6 x 10 x 65 12 Bolt, M6 x 10 x 50 13 - O-Rings 14 - Modulated Main Pressure (MAIN MOD) Solenoid 15 - 6 Speed Pipe Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 9290 Fluid Pressure Sensor/Switch: Diagrams Component Connector End Views Pressure Switch Manifold (PSM) (MW7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 9291 Fluid Pressure Sensor/Switch: Service and Repair Pressure Switch Manifold Replacement Removal Procedure Note: Individual pressure switches cannot be replaced. When any pressure switch needs replacing, the entire assembly must be replaced. Note: The modulated main pressure (MAIN MOD) solenoid has been removed for clarity. 1. Remove the oil pan and transmission internal oil filter. Refer to Oil Pan Replacement (See: Automatic Transmission/Transaxle/Fluid Pan/Service and Repair). Warning: Refer to Battery Disconnect Warning (See: Starting and Charging/Battery/Service Precautions). 2. Disconnect the internal wiring harness connector from the transmission fluid pressure (TFP) switch (2). 3. Remove six bolts (1). Remove the TFP switch (2). Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 9292 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Place the new TFP manifold assembly (2) in position and install one bolt (1) in a recessed location to hold in position. Start the remaining five bolts (1) in recessed locations and tighten the bolts by hand. Torque the bolts to 12 Nm (108 lb in). 2. Connect the internal wiring harness connector to the TFP switch. 3. Install the oil pan and transmission internal oil filter. Refer to Oil Pan Replacement (See: Automatic Transmission/Transaxle/Fluid Pan/Service and Repair). Note: The FastLearn, adapt, procedure must be performed. This can be done in 1 step using a scan tool. If this procedure is not done, the TCM adaptive values will be at the settings that it learned for the old components and will be in slow adaptive mode. Under these conditions, it will take an unacceptably long time for the adaptive values to converge to levels suitable for the new transmission. 4. Perform the FastLearn procedure. Refer to FastLearn Procedure (See: Automatic Transmission/Transaxle/Testing and Inspection/Programming and Relearning). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON Transmission Mode Switch: Customer Interest A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 9301 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 9302 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 9303 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON Transmission Mode Switch: All Technical Service Bulletins A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 9309 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 9310 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Mode Switch: > 08-07-30-020E > Mar > 10 > A/T Controls - DTC P1825/P182E or P1915/MIL ON > Page 9311 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > Page 9312 Transmission Mode Switch: Diagrams Component Connector End Views Automatic Transmission Internal Mode Switch (MW7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Technical Service Bulletins > Page 9313 Transmission Mode Switch: Service and Repair Transmission Internal Mode Switch Replacement Important: The Internal Mode Switch (IMS) is mounted to the manual shift shaft detent lever as an assembly. The components of the detent lever/IMS assembly cannot be individually serviced. When the IMS needs replacing, the entire assembly must be replaced. Replace the IMS. Refer to Manual Shift Shaft, Detent Lever, and Position Switch Assembly Replacement (See: Transmission Position Switch/Sensor/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams Transmission Position Switch/Sensor: Diagrams Component Connector End Views Park/Neutral Position (PNP) Switch (M30) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 9317 Transmission Position Switch/Sensor: Service and Repair Manual Shift Shaft, Detent Lever, and Position Switch Assembly Replacement Removal Procedure 1. Remove the control valve assembly from the transmission. Refer to Control Valve Body Replacement (See: Automatic Transmission/Transaxle/Valve Body/Service and Repair). Note: The detent lever/IMS retaining bolt contains patch lock material on the threads. Do not reuse the retaining bolt. 2. Remove the detent lever/IMS retaining bolt (1) using a T27 TORX(R) bit and discard the retaining bolt. Caution: DO NOT mar the transmission case surface around the spherical pin when removing or installing the spherical pin. An unmarred surface is required to maintain the seal between the control valve assembly and the transmission case. Caution: DO NOT twist the spherical pin when removing the pin from the transmission case. Damage to the transmission case can occur. 3. Place a protective plate on the transmission case surface around the spherical pin (3). Remove the spherical pin (3) from the transmission case. 4. Slide the manual shift shaft (5) through the detent lever/IMS assembly (4) and through the manual shift shaft seal. 5. Rotate the detent lever/IMS assembly to disengage the park pawl apply assembly (2). Remove the detent lever/IMS assembly (4). Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 9318 1. Place the new detent lever/IMS assembly (4) in position in the transmission case. Rotate the detent lever/IMS assembly to engage the park pawl apply assembly (2). Reinstall the manual shift shaft (5) through the manual shift shaft seal and through the detent lever/IMS assembly (4). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Push the manual shift shaft (5) into the final position in the transmission case. 3. Install the spherical pin (3) into the transmission case that retains the manual shift shaft. 4. Install the detent lever/IMS retaining bolt (1) using a T27 TORX(R) bit. Tighten the bolt (1) to 10 Nm (92 lb in). 5. Install the control valve assembly. Refer to Control Valve Body Replacement (See: Automatic Transmission/Transaxle/Valve Body/Service and Repair). Note: The FastLearn, adapt, procedure must be performed. This can be done in 1 step using a scan tool. If this procedure is not done, the TCM adaptive values will be at the settings that it learned for the old components and will be in slow adaptive mode. Under these conditions, it will take an unacceptably long time for the adaptive values to converge to levels suitable for the new transmission. 6. Perform the FastLearn procedure. Refer to FastLearn Procedure (See: Automatic Transmission/Transaxle/Testing and Inspection/Programming and Relearning). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Component Locations Transmission Speed Sensor: Component Locations Disassembled Views Automatic Transmission Case 1 - Automatic Transmission Case 2 - Transmission Case Locating Pin 3 - Transmission Vent Assembly 4 - Transmission Vent Cap 5 - Transmission Vent 6 - Nameplate Rivet 7 - Nameplate 8 Vehicle Speed Sensor Bolt, M6 x 1.0 x 13 9 - Sensor Shipping Cover 10 - Turbine Speed Sensor 11 - Vehicle Speed Sensor O-Ring 12 - Power Take-Off (PTO) Cover Gasket (2) 13 - PTO Cover (2) 14 - PTO Cover Bolt, M10 x 1.5 x 20, Flanged Head, Coated (12) 16 - Manual Shift Shaft 17 Manual Shift Shaft Seal 18 - Manual Shift Shaft Pin 19 - Manual Shift Shaft Detent Lever/Internal Mode Switch (IMS) Assembly 20 - Park Pawl Assembly 21 - Control Valve Body Locating Pin 22 Detent Lever/IMS Bolt 23 - Connector Shipping Cover 24 - Control Valve Body Assembly 25 Control Valve Body Bolt, M6 x 1.0 x 50, Flanged Head (15) 26 - Manual Shift Shaft Detent Spring 27 - Manual Shift Shaft Detent Spring Bolt M6 x 1.0 x 12. Flanged Head (2) 28 - Transmission Wiring Harness Assembly Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Component Locations > Page 9323 Transmission Speed Sensor: Connector Locations Harness Routing Views Engine Chassis Harness Routing - Rear (Diesel) 1 - X300 2 - G300 3 - Automatic Transmission Turbine Speed Sensor (MW7) 4 - Automatic Transmission (MW7) 5 - Vehicle Speed Sensor (VSS) (MW7) 6 - X124 (PTO) 7 - Power Take Off (PTO) Module (PTO) 8 - X175 (MW7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 9324 Transmission Speed Sensor: Diagrams Component Connector End Views Automatic Transmission Input Shaft Speed (ISS) Sensor (M30) Automatic Transmission Turbine Speed Sensor (MW7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 9325 Output Speed Sensor (OSS) (M99) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 9326 Transmission Speed Sensor: Service and Repair Speed Sensor Replacement Removal Procedure Warning: Refer to Battery Disconnect Warning (See: Starting and Charging/Battery/Service Precautions). 1. Be sure the vehicle ignition is turned off. 2. Disconnect the external wiring harness from the speed sensor. 3. Remove the bolt (1) from the speed sensor and carefully remove the speed sensor (2). Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 9327 Note: Do not rotate the sensor in its retaining bracket. Changing the sensor/bracket orientation may cause improper operation. 1. Install a new a O-ring on the speed sensor (2). Lubricate the O-ring with clean transmission fluid. 2. Install the new speed sensor (2) into the speed sensor bore. Align the hole in the retaining bracket with the bolt hole in the speed sensor boss. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the speed sensor bolt (1). Tighten bolt to 12 Nm (108 lb in). 4. Reconnect the external wiring harness to the speed sensor. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams Transmission Temperature Sensor/Switch: Diagrams Component Connector End Views Automatic Transmission Fluid Temperature (TFT) Sensor (M30) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Clutch Pedal Position Sensor / Switch > Component Information > Testing and Inspection Clutch Pedal Position Sensor / Switch: Testing and Inspection Clutch Pedal Position Sensor Learn Important: The clutch pedal position (CPP) sensor learn procedure is required when the following service procedures have been performed regardless of whether DTC P080A is set: * An engine control module (ECM) replacement * A CPP sensor replacement * Any repairs which affect the CPP sensor relationship 1. Install a scan tool. 2. Monitor the ECM for DTCs with a scan tool. If other DTCs are set, except DTC P080A, refer to Diagnostic Trouble Code (DTC) List - Vehicle ( See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle) for the applicable DTC that set. 3. With a scan tool, select Clutch Pedal Position Learn under Module Setup in Manual Transmission, and perform the following instructions displayed on the scan tool screen. Important: The CPP sensor learn procedure cannot be performed more than once per ignition cycle. The clutch pedal needs to be fully depressed and held steady throughout this procedure in order to perform a correct learning. 4. The scan tool will display under CPP Learn Status: Not Learned, In Process, Complete, Fail Low Volt, Fail - High Volt, or Fail Moving. The scan tool will display under CPP Learn Status Complete if the process was successful. 5. If the scan tool indicates that DTC P080A ran and passed this ignition the CPP sensor learn procedure is complete. If the scan tool indicates DTC P080A failed or did not run this ignition, refer to DTC P080A (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P080A/Tremec 5-Speed (TZ0) - Manual Transmission). If any other DTC is set, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle) for the applicable DTC. 6. Turn OFF the ignition for 30 seconds after the learn procedure has successfully completed in order to store the CPP sensor variation values in ECM history. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Clutch Pedal Position Sensor / Switch > Component Information > Testing and Inspection > Page 9335 Clutch Pedal Position Sensor / Switch: Service and Repair Clutch Pedal Engine Start Switch Replacement Removal Procedure 1. Disconnect the clutch pedal position switch electrical connector (1). 2. Remove the plastic retainer (1) tabs from the clutch pedal position switch (2). 3. Remove the clutch pedal position switch (2) from the pushrod. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Clutch Pedal Position Sensor / Switch > Component Information > Testing and Inspection > Page 9336 1. Install the clutch pedal position switch (2) to the pushrod. 2. Install the plastic retainer (1) tabs to the clutch pedal position switch (2). 3. Connect the clutch pedal position switch electrical connector (1). Warning Replacement or reprogramming of the ECM, or replacement of the clutch pedal position sensor (CPPS) or clutch pedal requires that a CPPS learn procedure be performed. Failure to perform the CPPS learn procedure may result in personal injury or damage to the vehicle or its components if the vehicle is in gear and the starter motor is accidentally engaged. 4. Perform the clutch pedal position sensor learn procedure. Refer to DTC P080A (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P080A/Tremec 5-Speed (TZ0) - Manual Transmission) or Clutch Pedal Position Sensor Learn (See: Manual Transmission/Transaxle/Testing and Inspection/Component Tests and General Diagnostics). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Power Take-Off > Power Take-Off Switch > Component Information > Diagrams Power Take-Off Switch: Diagrams Component Connector End Views Power Take-Off (PTO) Switch (PTO) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations Four Wheel Drive Selector Switch: Locations Harness Routing Views Engine Harness Routing - Rear (4.8L/5.3L/6.0L/6.2L except LFA/HP2) 1 - Dash Panel 2 - Transmission 3 - X175 (M30) 4 - Transfer Case Shift Control Switch (NQG) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 9345 Four Wheel Drive Selector Switch: Diagrams Component Connector End Views Transfer Case Shift Control Switch (NQF or NQH) Transfer Case Shift Control Switch (NQG) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 9346 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case Four Wheel Drive Selector Switch: Service and Repair MP 1625/1626-NQF - Transfer Case Transfer Case Shift Control Switch Replacement (Without SLT) Transfer Case Shift Control Switch Replacement (Without SLT) Transfer Case Shift Control Switch Replacement (With SLT) Transfer Case Shift Control Switch Replacement (With SLT) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case > Page 9349 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case > Page 9350 Four Wheel Drive Selector Switch: Service and Repair MP 3023/3024-NQH - Transfer Case Transfer Case Shift Control Switch Replacement (With SLT) Transfer Case Shift Control Switch Replacement (With SLT) Transfer Case Shift Control Switch Replacement (Without SLT) Transfer Case Shift Control Switch Replacement (Without SLT) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Service and Repair > MP 1625/1626-NQF - Transfer Case > Page 9351 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams Gear Sensor/Switch: Diagrams Component Connector End Views Transfer Case 2/4 Wheel Drive Actuator Position Sensor (NQH) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair Speed Sensor: Service and Repair Transfer Case Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the speed sensor electrical connector (4). 3. Remove the speed sensor and O-ring. 4. Discard the O-ring. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Service and Repair > Page 9358 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the speed sensor with a NEW O-ring. Tighten the sensor to 17 Nm (13 lb ft). 2. Connect the speed sensor electrical connector (4). 3. Lower the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Braking Sensor/Switch > Component Information > Service and Repair Braking Sensor/Switch: Service and Repair Brake Master Cylinder Primary Piston Position Sensor Replacement Removal Procedure Note: The ignition must be in the OFF position, without pausing at ACCESSORY, and without applying the brake pedal to ensure the brake modulator and high pressure accumulator (HPA) pressure relief occurs. This process will take approximately 1 to 3 minutes. 1. Turn the ignition to OFF, without pausing at ACCESSORY, and without applying the brake pedal. Remove the ignition key. 2. Wait approximately 1 to 3 minutes until the brake modulator and HPA pressure relief is complete. 3. Disconnect the brake master cylinder (BMC) primary piston position sensor electrical connector. 4. Remove the 2 BMC primary piston position sensor screws (1). 5. Remove the primary piston position sensor (2). Tilt the rear of the position sensor downward and remove the sensor. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Braking Sensor/Switch > Component Information > Service and Repair > Page 9364 1. Install the BMC primary piston position sensor (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the 2 BMC primary piston position sensor screws (1) and tighten to 10 Nm (89 lb in). 3. Connect the primary piston position sensor electrical connector. 4. Inspect the battery state of charge. Refer to Battery Inspection/Test (See: Starting and Charging/Testing and Inspection/Component Tests and General Diagnostics). 5. If necessary, connect a battery charger to the 12V battery. Refer to Battery Charging (See: Starting and Charging/Battery/Service and Repair/Procedures) 6. Install a scan tool to the vehicle. Note: The ignition switch must remain in the ON position with the engine OFF during this procedure. 7. Turn the ignition ON with the engine OFF. 8. Using the scan tool, perform the following steps: 1. Select Diagnostics 2. Select the appropriate vehicle information 3. Select Chassis 4. Select Electronic Brake Control Module (EBCM) 5. Select Module Setup 6. Select BMC Primary Piston Position Relearn and follow the instructions on the scan tool Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Diagrams Electronic Brake Control Module: Diagrams Component Connector End Views Electronic Brake Control Module (EBCM) (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Diagrams > Page 9368 Electronic Brake Control Module (EBCM) (JF3 or JF7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Diagrams > Page 9369 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Diagrams > Page 9370 Electronic Brake Control Module (EBCM) (JH6 or JH7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Diagrams > Page 9371 Electronic Brake Control Module (EBCM) (JL4 except 10 Series) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Diagrams > Page 9372 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Diagrams > Page 9373 Electronic Brake Control Module (EBCM) (JL4 with 10 Series) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Diagrams > Page 9374 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Diagrams > Page 9375 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Service and Repair > Non-Hybrid Less than 3900 kg (8600 lb) GVW Electronic Brake Control Module: Service and Repair Non-Hybrid Less than 3900 kg (8600 lb) GVW Electronic Brake Control Module Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Service and Repair > Non-Hybrid Less than 3900 kg (8600 lb) GVW > Page 9378 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Service and Repair > Non-Hybrid Less than 3900 kg (8600 lb) GVW > Page 9379 Electronic Brake Control Module: Service and Repair Non-Hybrid Greater than/Equal to 3900 kg (8600 lb) GVW Electronic Brake Control Module Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Non-Hybrid Less than 3900 kg (8600 lb) GVW Hydraulic Control Assembly - Antilock Brakes: Service and Repair Non-Hybrid Less than 3900 kg (8600 lb) GVW Brake Pressure Modulator Valve Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Non-Hybrid Less than 3900 kg (8600 lb) GVW > Page 9384 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Non-Hybrid Less than 3900 kg (8600 lb) GVW > Page 9385 Hydraulic Control Assembly - Antilock Brakes: Service and Repair Non-Hybrid Greater than/Equal to 3900 kg (8600 lb) GVW Brake Pressure Modulator Valve Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Non-Hybrid Less than 3900 kg (8600 lb) GVW > Page 9386 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Lateral Accelerometer > Component Information > Diagrams Lateral Accelerometer: Diagrams Component Connector End Views Yaw and Lateral Accelerometer Sensor (HP2) Yaw and Lateral Accelerometer Sensor (JL4 except 10 Series) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Lateral Accelerometer > Component Information > Diagrams > Page 9390 Yaw and Lateral Accelerometer Sensor (JL4 with 10 Series) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Lateral Accelerometer > Component Information > Diagrams > Page 9391 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams Wheel Speed Sensor: Diagrams Component Connector End Views Wheel Speed Sensor (WSS) - Left Front (10 Series) Wheel Speed Sensor (WSS) - Left Front (except 10 Series) Wheel Speed Sensor (WSS) - Left Rear (JL4 or HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Page 9395 Wheel Speed Sensor (WSS) - Right Front (10 Series) Wheel Speed Sensor (WSS) - Right Front (except 10 Series) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Page 9396 Wheel Speed Sensor (WSS) - Right Rear (JL4 or HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement Wheel Speed Sensor: Service and Repair Front Wheel Speed Sensor Replacement Non-Hybrid Less than 3900 kg (8600 lb) GVW Front Wheel Speed Sensor Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 9399 Non-Hybrid Greater than/Equal to 3900 kg (8600 lb) GVW Front Wheel Speed Sensor Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 9400 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 9401 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 9402 Wheel Speed Sensor: Service and Repair Rear Wheel Speed Sensor Replacement Non-Hybrid Less than 3900 kg (8600 lb) GVW Rear Wheel Speed Sensor Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 9403 Non-Hybrid Greater than/Equal to 3900 kg (8600 lb) GVW Rear Wheel Speed Sensor Replacement Removal Procedure Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 9404 2. Disconnect the wheel speed sensor electrical connector (1). 3. Release the wheel speed sensor electrical connector and sensor harness clips (2) from the inboard frame rail. 4. Remove the wheel speed sensor bolt (1). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 9405 5. Remove the wheel speed sensor (1) from the rear axle. Installation Procedure 1. Install the wheel speed sensor (1) to the rear axle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 9406 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the wheel speed sensor bolt (1) and tighten to 9 Nm (80 lb in). 3. Connect the wheel speed sensor electrical connector (1). 4. Install the wheel speed sensor electrical connector and sensor harness clips (2) to the inboard frame rail. 5. Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 9407 Wheel Speed Sensor: Service and Repair Rear Wheel Speed Sensor Ring Replacement Non-Hybrid Less than 3900 kg (8600 lb) GVW Rear Wheel Speed Sensor Ring Replacement Special Tools * J-8092 - Driver Handle * J-21128 - Axle Pinion Oil Seal Installer * J-23690 - Bearing Installer * J-2619-01 - Slide Hammer * J-45857 - Tone Wheel and/or Bearing Remover * J-45860 - Tone Ring Installer Removal Procedure 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair ). 3. Remove the rear wheel speed sensor. Refer to Rear Wheel Speed Sensor Replacement (See: Rear Wheel Speed Sensor Replacement/Non-Hybrid Less than 3900 kg (8600 lb) GVW). 4. Remove the rear axle housing cover. Refer to Rear Axle Housing Cover and Gasket Replacement (8.6, 9.5 Inch Axles) ()Rear Axle Housing Cover and Gasket Replacement (10.5/11.5 Inch Axle) (). 5. Remove the axle shaft. Refer to Rear Axle Shaft Replacement (See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft Assembly/Axle Shaft/Service and Repair). 6. Remove the axle shaft seal, the bearing and the wheel speed sensor ring from the axle housing using the J-2619-01 - Slide Hammer (1) and the J-45857 - Tone Wheel and/or Bearing Remover (2). Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 9408 1. Install the wheel speed sensor ring using the J-45860 - Tone Ring Installer (1) and the J-8092 Driver Handle (2). 2. Drive the wheel speed sensor ring into the axle housing until the tool bottoms against the tube. 3. Install the axle shaft bearing using the J-23690 - Bearing Installer (1) and the J-8092 - Driver Handle (2). 4. Drive the axle shaft bearing into the axle housing until the tool bottoms against the tube. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 9409 5. Install the axle shaft seal using the J-21128 - Axle Pinion Oil Seal Installer. 6. Drive the tool into the bore until the axle shaft seal bottoms flush with the tube. 7. Install the axle shaft. Refer to Rear Axle Shaft Replacement (See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft Assembly/Axle Shaft/Service and Repair). 8. Install the rear axle housing cover. Refer to Rear Axle Housing Cover and Gasket Replacement (8.6, 9.5 Inch Axles) ()Rear Axle Housing Cover and Gasket Replacement (10.5/11.5 Inch Axle) (). 9. Install the rear wheel speed sensor. Refer to Rear Wheel Speed Sensor Replacement (See: Rear Wheel Speed Sensor Replacement/Non-Hybrid Less than 3900 kg (8600 lb) GVW). 10. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 11. Fill the rear axle. Refer to Differential Oil Replacement (10.5 Inch Axle) (See: Maintenance/Fluids/Fluid - Differential/Service and Repair/Removal and Replacement)Differential Oil Replacement (11.5 Inch Axle) (See: Maintenance/Fluids/Fluid - Differential/Service and Repair/Removal and Replacement)Differential Oil Replacement (8.6 Inch Axle) (See: Maintenance/Fluids/Fluid - Differential/Service and Repair/Removal and Replacement)Differential Oil Replacement (9.5LD Inch Axle) (See: Maintenance/Fluids/Fluid - Differential/Service and Repair/Removal and Replacement). 12. Lower the vehicle. Non-Hybrid Greater than/Equal to 3900 kg (8600 lb) GVW Rear Wheel Speed Sensor Ring Replacement Removal Procedure Note: The wheel speed sensor ring is integral to the wheel hub and must be replaced as an assembly. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair ). 3. Remove the rear brake rotor. Refer to Rear Brake Rotor Replacement (JD9) (See: Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JD9))Rear Brake Rotor Replacement (JH6) (See: Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JH6))Rear Brake Rotor Replacement (JH7) (See: Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JH7)). 4. Remove the rear axle hub. Refer to Rear Axle Hub, Bearing, Cup, and/or Seal Replacement (See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Bearing/Service and Repair/Rear Axle Hub, Bearing, Cup, and/or Seal Replacement). Installation Procedure 1. Install the rear axle hub. Refer to Rear Axle Hub, Bearing, Cup, and/or Seal Replacement (See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Bearing/Service and Repair/Rear Axle Hub, Bearing, Cup, and/or Seal Replacement). 2. Install the rear brake rotor. Refer to Rear Brake Rotor Replacement (JD9) (See: Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JD9))Rear Brake Rotor Replacement (JH6) (See: Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JH6))Rear Brake Rotor Replacement (JH7) (See: Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 9410 Brake Rotor Replacement (JH7)). 3. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Yaw Rate Sensor > Component Information > Diagrams Yaw Rate Sensor: Diagrams Component Connector End Views Yaw and Lateral Accelerometer Sensor (HP2) Yaw and Lateral Accelerometer Sensor (JL4 except 10 Series) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Yaw Rate Sensor > Component Information > Diagrams > Page 9414 Yaw and Lateral Accelerometer Sensor (JL4 with 10 Series) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Yaw Rate Sensor > Component Information > Diagrams > Page 9415 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Yaw Rate Sensor > Component Information > Service and Repair > Non-Hybrid Less than 3900 kg (8600 lb) GVW Yaw Rate Sensor: Service and Repair Non-Hybrid Less than 3900 kg (8600 lb) GVW Vehicle Yaw Sensor with Vehicle Lateral Accelerometer Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Yaw Rate Sensor > Component Information > Service and Repair > Non-Hybrid Less than 3900 kg (8600 lb) GVW > Page 9418 Yaw Rate Sensor: Service and Repair Non-Hybrid Greater than/Equal to 3900 kg (8600 lb) GVW Vehicle Yaw Sensor with Vehicle Lateral Accelerometer Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Antilock Brake Automated Bleed Procedure Brake Bleeding: Service and Repair Antilock Brake Automated Bleed Procedure Less Than 3900 KG (8600 Lb) GVW Antilock Brake System Automated Bleed Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings). Note: The base hydraulic brake system must be bled before performing this automated bleeding procedure. If you have not yet performed the base hydraulic brake system bleeding procedure, refer to Hydraulic Brake System Bleeding (Manual) (See: )Hydraulic Brake System Bleeding (Pressure) ( See: )Hydraulic Brake System Bleeding (Two-mode Hybrid) (See: ) before proceeding. 1. Install a scan tool to the vehicle. 2. Start the engine and allow the engine to idle. 3. Using the scan tool, begin the automated bleed procedure. 4. Follow the instructions on the scan tool to complete the automated bleed procedure. Apply the brake pedal when instructed by the scan tool. 5. Turn the ignition OFF. 6. Remove the scan tool from the vehicle. 7. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 8. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) (See: )Hydraulic Brake System Bleeding (Pressure) ( See: )Hydraulic Brake System Bleeding (Two-mode Hybrid) (See: ). 9. With the ignition OFF, apply the brakes 3-5 times, or until the brake pedal becomes firm, in order to deplete the brake booster power reserve. 10. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 11. If the brake pedal feels spongy, repeat the automated bleeding procedure. If the brake pedal still feels spongy after repeating the automated bleeding procedure inspect the brake system for external leaks. Refer to Brake System External Leak Inspection (See: Hydraulic System/Testing and Inspection/Component Tests and General Diagnostics/Brake System External Leak Inspection). 12. Turn the ignition key ON, with the engine OFF; check to see if the brake system warning lamp remains illuminated. 13. If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. Refer to Symptoms - Hydraulic Brakes (See: Hydraulic System/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Hydraulic Brakes). 14. Drive the vehicle to exceed 13 km/h (8 mph) to allow ABS initialization to occur. Observe brake pedal feel. 15. If the brake pedal feels spongy, repeat the automated bleeding procedure until a firm brake pedal is obtained. Greater Than/Equal to 3900 KG (8600 Lb) GVW Antilock Brake System Automated Bleed Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings). Note: * Before performing the ABS Automated Bleed Procedure, first perform a manual or pressure bleed of the base hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) (See: )Hydraulic Brake System Bleeding (Pressure) (See: )Hydraulic Brake System Bleeding (Two-mode Hybrid) (See: ). * The automated bleed procedure must be performed when a new brake pressure modulator valve (BPMV) is installed, because the secondary circuits of the new BPMV are not prefilled with brake fluid. * The automated bleed procedure is recommended when one of the following conditions exist: * Base brake system bleeding does not achieve the desired pedal height or feel * Extreme loss of brake fluid has occurred * Air ingestion is suspected in the secondary circuits of the brake modulator assembly The ABS Automated Bleed Procedure uses a scan tool to cycle the system solenoid valves and run the pump in order to purge any air from the secondary circuits. These circuits are normally closed off, and are only opened during system initialization at vehicle start up and during ABS operation. The automated bleed procedure opens these secondary circuits and allows any air trapped in these circuits to flow out away from the brake modulator assembly, which is then forced out at the brake corners by the pressure bleeder. Automated Bleed Procedure Caution: The Auto Bleed Procedure may be terminated at any time during the process by pressing the EXIT button. No further Scan Tool prompts pertaining to the Auto Bleed procedure will be given. After exiting the bleed procedure, relieve bleed pressure and disconnect bleed Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Antilock Brake Automated Bleed Procedure > Page 9423 equipment per manufacturers instructions. Failure to properly relieve pressure may result in spilled brake fluid causing damage to components and painted surfaces. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 3. Inspect the brake system for leaks and visual damage. Refer to Symptoms - Hydraulic Brakes (See: Hydraulic System/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Hydraulic Brakes). Repair or replace components as needed. 4. Lower the vehicle. 5. Prepare the brake bleeding equipment and the vehicle for a pressure bleed of the base hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) (See: )Hydraulic Brake System Bleeding (Pressure) (See: )Hydraulic Brake System Bleeding (Two-mode Hybrid) (See: ). 6. Inspect the battery state of charge. Refer to Battery Inspection/Test (See: Starting and Charging/Testing and Inspection/Component Tests and General Diagnostics). 7. Install a scan tool. 8. Turn the ignition ON, with the engine OFF. 9. With the scan tool, perform the following steps: 1. Select Diagnostics 2. Select the appropriate vehicle information 3. Select Chassis 4. Select Electronic Brake Control Module (EBCM) 5. Select Special Functions 6. Select Automated Bleed 10. With an assistant ready, raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). Note: * Apply the brake pedal when instructed, using moderate effort. * Ensure the pedal remains applied until instructed to release by the scan tool. * Do not exceed the time period allowed by the scan tool for having the bleeder valves open. * The bleed sequence for each corner is as follows: - Left front - Right front - Right rear - Left rear 11. Perform the automated bleed procedure as instructed by the scan tool. 12. If the automated bleed procedure is aborted, a malfunction exists. If a DTC is detected, refer to Diagnostic Trouble Code (DTC) List - Vehicle ( See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle) to diagnose the DTC. 13. After completion of the automated bleed procedure, press and hold the brake pedal to inspect for pedal firmness. 14. If the brake pedal feels spongy, repeat the bleed procedure completely. 15. Remove the scan tool. 16. Install the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair ). 17. Lower the vehicle. 18. Adjust the brake fluid level. Refer to Master Cylinder Reservoir Filling (Non-Hybrid) (See: Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Reservoir Filling)Master Cylinder Reservoir Filling (Two-mode Hybrid) (See: Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Reservoir Filling). 19. Road test the vehicle while confirming the brake pedal remains high and firm. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Antilock Brake Automated Bleed Procedure > Page 9424 Brake Bleeding: Service and Repair Hydraulic Brake Bleeding (Manual) Hydraulic Brake System Bleeding (Manual) Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings). 1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort increases significantly, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add GM approved brake fluid from a clean, sealed brake fluid container. Refer to Fluid and Lubricant Recommendations (USA and Canada) (See: Maintenance). If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. 2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 4. Reconnect the brake pipe to the master cylinder port and tighten securely. 5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the master cylinder. 9. With the front brake pipe installed securely to the master cylinder, after all air has been purged from the front port of the master cylinder, loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8. 10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 4. Fill the brake master cylinder reservoir with GM approved brake fluid from a clean, sealed brake fluid container. Refer to Master Cylinder Reservoir Filling (Non-Hybrid) (See: Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Reservoir Filling)Master Cylinder Reservoir Filling (Two-mode Hybrid) (See: Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Reservoir Filling). Ensure that the brake master cylinder reservoir remains at least half-full during this bleeding procedure. Add fluid as needed to maintain the proper level. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 6. Install a transparent hose over the end of the bleeder valve. 7. Submerge the open end of the transparent hose into a transparent container partially filled with GM approved brake fluid from a clean, sealed brake fluid container. Refer to Fluid and Lubricant Recommendations (USA and Canada) (See: Maintenance). 8. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 9. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. 10. Tighten the bleeder valve, then have the assistant slowly release the brake pedal. 11. Wait 15 seconds, then repeat steps 8-10 until all air is purged from the same wheel hydraulic circuit. 12. With the right rear wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the right rear hydraulic circuit install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 13. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 14. With the left rear wheel hydraulic circuit bleeder valve tightened securely, after all air purged from the left rear hydraulic circuit, install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve. 15. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 16. With the right front wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the right front hydraulic circuit, install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 17. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 18. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. 19. Fill the brake master cylinder reservoir to the maximum-fill level with GM approved brake fluid from a clean, sealed brake fluid container. Refer to Master Cylinder Reservoir Filling (Non-Hybrid) (See: Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Reservoir Filling)Master Cylinder Reservoir Filling (Two-mode Hybrid) (See: Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Reservoir Filling). 20. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 21. If the brake pedal feels spongy, repeat the bleeding procedure again. If the brake pedal still feels spongy after repeating the bleeding procedure, perform the following steps: 1. Inspect the brake system for external leaks. Refer to Brake System External Leak Inspection (See: Hydraulic System/Testing and Inspection/Component Tests and General Diagnostics/Brake System External Leak Inspection). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Antilock Brake Automated Bleed Procedure > Page 9425 2. Pressure bleed the hydraulic brake system in order to purge any air that may still be trapped in the system. 22. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. Note: If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. 23. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic Brakes (See: Hydraulic System/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Hydraulic Brakes). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Antilock Brake Automated Bleed Procedure > Page 9426 Brake Bleeding: Service and Repair Hydraulic Brake Bleeding (Pressure) Hydraulic Brake System Bleeding (Pressure) Special Tools * J-29532 - Diaphragm Pressure Bleeder, or equivalent * J-35589-A - Brake Pressure Bleeder Adapter Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings). Caution: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort increases significantly, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. 2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 4. Reconnect the brake pipe to the master cylinder port and tighten securely. 5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the master cylinder. 9. With the front brake pipe installed securely to the master cylinder, after all air has been purged from the front port of the master cylinder, loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8. 10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 4. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Install the J-35589-A - Brake Pressure Bleeder Adapter to the brake master cylinder reservoir. 6. Check the brake fluid level in the J-29532 - Diaphragm Pressure Bleeder, or equivalent. Add Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container as necessary to bring the level to approximately the half-full point. 7. Connect the J-29532 - Diaphragm Pressure Bleeder, or equivalent , to the J-35589-A - Brake Pressure Bleeder Adapter. 8. Charge the J-29532 - Diaphragm Pressure Bleeder, or equivalent , air tank to 175-205 kPa (25-30 psi). 9. Open the J-29532 - Diaphragm Pressure Bleeder, or equivalent , fluid tank valve to allow pressurized brake fluid to enter the brake system. 10. Wait approximately 30 seconds, then inspect the entire hydraulic brake system in order to ensure that there are no existing external brake fluid leaks. Any brake fluid leaks identified require repair prior to completing this procedure. 11. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 12. Install a transparent hose over the end of the bleeder valve. 13. Submerge the open end of the transparent hose into a transparent container partially filled with Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 14. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. Allow fluid to flow until air bubbles stop flowing from the bleeder, then tighten the bleeder valve. 15. With the right rear wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the right rear hydraulic circuit, install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 16. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 17. With the left rear wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the left rear hydraulic circuit, install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve. 18. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 19. With the right front wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the right front hydraulic circuit, Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Antilock Brake Automated Bleed Procedure > Page 9427 install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 20. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 21. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. 22. Close the J-29532 - Diaphragm Pressure Bleeder, or equivalent , fluid tank valve, then disconnect the J-29532 - Diaphragm Pressure Bleeder, or equivalent , from the J-35589-A - Brake Pressure Bleeder Adapter. 23. Remove the J-35589-A - Brake Pressure Bleeder Adapter from the brake master cylinder reservoir. 24. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 25. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 26. If the brake pedal feels spongy perform the following steps: 1. Inspect the brake system for external leaks. Refer to Brake System External Leak Inspection (See: Hydraulic System/Testing and Inspection/Component Tests and General Diagnostics/Brake System External Leak Inspection). 2. Using a scan tool, perform the antilock brake system automated bleeding procedure to remove any air that may have been trapped in the brake pressure modulator valve (BPMV). Refer to the following procedures, as appropriate: * Antilock Brake System Automated Bleed (See: )for Two-mode Hybrid vehicles * Antilock Brake System Automated Bleed (See: )for non-hybrid vehicles less than 3900 kg (8600 lb) GVW * Antilock Brake System Automated Bleed (See: )for non-hybrid vehicles greater than/equal to 3900 kg (8600 lb) GVW 27. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. Note: If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. 28. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic Brakes (See: Hydraulic System/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Hydraulic Brakes). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Antilock Brake Automated Bleed Procedure > Page 9428 Brake Bleeding: Service and Repair Hydraulic Brake Flushing Hydraulic Brake System Flushing Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings). Caution: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Inspect the brake fluid for the following conditions, indicating brake fluid contamination: * Fluid separation, indicating two types of fluid are present; a substance other than the recommended brake fluid has been introduced into the brake hydraulic system - Swirled appearance - oil-based substance - Layered appearance - silicone-based substance * Fluid discoloration, indicating the presence of moisture or particles that have been introduced into the brake hydraulic system - Cloudy appearance - moisture - Dark appearance/suspended particles in fluid - dirt, rust, corrosion, brake dust 2. Inspect the master cylinder reservoir cap diaphragm and the reservoir-to-master cylinder grommets for swelling, indicating brake fluid contamination. 3. If the brake fluid WAS contaminated with an oil-based or a silicone-based substance, indicated by fluid separation and/or a swollen master cylinder reservoir cap diaphragm and/or swollen reservoir-to-master cylinder grommets, perform the following: 1. Remove ALL of the following components listed from the vehicle. Each component contains internal rubber seals/linings which have been contaminated by the contaminated brake fluid in the brake hydraulic system. Refer to the procedures indicated: * Master Cylinder Replacement (Vacuum Assist) (See: Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Replacement)Master Cylinder Replacement (Two-Mode Hybrid) (See: Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Replacement)Master Cylinder Replacement (Hydraulic Assist) ( See: Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Replacement) * Front Brake Hose Replacement (JH6, JH7) (See: Hydraulic System/Brake Hose/Line/Service and Repair/Front Brake Hose Replacement (JH6, JH7))Front Brake Hose Replacement (JD9, JF3, JF7, JG4) (See: Hydraulic System/Brake Hose/Line/Service and Repair/Front Brake Hose Replacement (JD9, JF3, JF7, JG4)) * Rear Brake Hose Replacement (To Axle - JF3 without JL4, JF7, JG4) (See: Hydraulic System/Brake Hose/Line/Service and Repair/Rear Brake Hose Replacement (To Axle - JF3 without JL4, JF7, JG4))Rear Brake Hose Replacement (To Axle - JD9, JF3 with JL4) (See: Hydraulic System/Brake Hose/Line/Service and Repair/Rear Brake Hose Replacement (To Axle - JD9, JF3 with JL4))Rear Brake Hose Replacement (Frame to Axle - JH6, JH7) (See: Hydraulic System/Brake Hose/Line/Service and Repair/Rear Brake Hose Replacement (Frame to Axle - JH6, JH7))Rear Brake Hose Replacement (To Caliper - JD9) (See: Hydraulic System/Brake Hose/Line/Service and Repair/Rear Brake Hose Replacement (To Caliper - JD9))Rear Brake Hose Replacement (Caliper - JH6, JH7) (See: Hydraulic System/Brake Hose/Line/Service and Repair/Rear Brake Hose Replacement (Caliper - JH6, JH7)) * Front Brake Caliper Replacement (JD9, JF3, JF7, JG4) (See: Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Front Brake Caliper Replacement (JD9, JF3, JF7, JG4))Front Brake Caliper Replacement (JH6, JH7) (See: Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Front Brake Caliper Replacement (JH6, JH7)) * Rear Brake Caliper Replacement (JD9) (See: Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Rear Brake Caliper Replacement (JD9))Rear Brake Caliper Replacement (JH6, JH7) (See: Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Rear Brake Caliper Replacement (JH6, JH7)) * Brake Pressure Modulator Valve Replacement (See: Antilock Brakes / Traction Control Systems/Hydraulic Control Assembly - Antilock Brakes/Service and Repair) * Brake Pressure Modulator Valve Replacement (See: Antilock Brakes / Traction Control Systems/Hydraulic Control Assembly - Antilock Brakes/Service and Repair/Non-Hybrid Less than 3900 kg (8600 lb) GVW) * Brake Pressure Modulator Valve Replacement (See: Antilock Brakes / Traction Control Systems/Hydraulic Control Assembly - Antilock Brakes/Service and Repair/Non-Hybrid Greater than/Equal to 3900 kg (8600 lb) GVW) 2. Clean out all the hydraulic brake pipes using denatured alcohol, or equivalent. 3. Dry the brake pipes using non-lubricated, filtered air. 4. Repair or replace ALL of the following components listed and install them to the vehicle. Each component contains internal rubber seals/linings which have been contaminated by the contaminated brake fluid in the brake hydraulic system. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Antilock Brake Automated Bleed Procedure > Page 9429 Refer to the procedures indicated: * Master Cylinder Replacement (Vacuum Assist) (See: Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Replacement)Master Cylinder Replacement (Two-Mode Hybrid) (See: Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Replacement)Master Cylinder Replacement (Hydraulic Assist) ( See: Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Replacement) ; also perform the following: Clean the brake master cylinder reservoir using denatured alcohol, or equivalent, then dry the reservoir using non-lubricated, filtered air. Inspect the reservoir for cracks and/or damage and replace if necessary. Refer to Master Cylinder Reservoir Replacement (Vacuum Assist) (See: Hydraulic System/Brake Fluid Reservoir/Service and Repair/Master Cylinder Reservoir Replacement (Vacuum Assist))Master Cylinder Reservoir Replacement (Hydraulic Assist) (See: Hydraulic System/Brake Fluid Reservoir/Service and Repair/Master Cylinder Reservoir Replacement (Hydraulic Assist))Master Cylinder Reservoir Replacement (Two-mode Hybrid) (). Replace the brake master cylinder reservoir cap diaphragm. * Front Brake Hose Replacement (JH6, JH7) (See: Hydraulic System/Brake Hose/Line/Service and Repair/Front Brake Hose Replacement (JH6, JH7))Front Brake Hose Replacement (JD9, JF3, JF7, JG4) (See: Hydraulic System/Brake Hose/Line/Service and Repair/Front Brake Hose Replacement (JD9, JF3, JF7, JG4)) * Rear Brake Hose Replacement (To Axle - JF3 without JL4, JF7, JG4) (See: Hydraulic System/Brake Hose/Line/Service and Repair/Rear Brake Hose Replacement (To Axle - JF3 without JL4, JF7, JG4))Rear Brake Hose Replacement (To Axle - JD9, JF3 with JL4) (See: Hydraulic System/Brake Hose/Line/Service and Repair/Rear Brake Hose Replacement (To Axle - JD9, JF3 with JL4))Rear Brake Hose Replacement (Frame to Axle - JH6, JH7) (See: Hydraulic System/Brake Hose/Line/Service and Repair/Rear Brake Hose Replacement (Frame to Axle - JH6, JH7))Rear Brake Hose Replacement (To Caliper - JD9) (See: Hydraulic System/Brake Hose/Line/Service and Repair/Rear Brake Hose Replacement (To Caliper - JD9))Rear Brake Hose Replacement (Caliper - JH6, JH7) (See: Hydraulic System/Brake Hose/Line/Service and Repair/Rear Brake Hose Replacement (Caliper - JH6, JH7)) * Front Brake Caliper Overhaul (JH6, JH7) (See: Disc Brake System/Brake Caliper/Service and Repair/Overhaul/Front Brake Caliper Overhaul (JH6, JH7)) or Front Brake Caliper Replacement (JD9, JF3, JF7, JG4) (See: Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Front Brake Caliper Replacement (JD9, JF3, JF7, JG4))Front Brake Caliper Replacement (JH6, JH7) ( See: Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Front Brake Caliper Replacement (JH6, JH7)) * Rear Brake Caliper Overhaul (JH6, JH7) (See: Disc Brake System/Brake Caliper/Service and Repair/Overhaul/Rear Brake Caliper Overhaul (JH6, JH7)) or Rear Brake Caliper Replacement (JD9) (See: Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Rear Brake Caliper Replacement (JD9))Rear Brake Caliper Replacement (JH6, JH7) (See: Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Rear Brake Caliper Replacement (JH6, JH7)) * Brake Pressure Modulator Valve Replacement (See: Antilock Brakes / Traction Control Systems/Hydraulic Control Assembly - Antilock Brakes/Service and Repair) * Brake Pressure Modulator Valve Replacement (See: Antilock Brakes / Traction Control Systems/Hydraulic Control Assembly - Antilock Brakes/Service and Repair/Non-Hybrid Less than 3900 kg (8600 lb) GVW) * Brake Pressure Modulator Valve Replacement (See: Antilock Brakes / Traction Control Systems/Hydraulic Control Assembly - Antilock Brakes/Service and Repair/Non-Hybrid Greater than/Equal to 3900 kg (8600 lb) GVW) 4. If the brake fluid was NOT contaminated with an oil-based or a silicone-based substance, but WAS contaminated with water or dirt, rust, corrosion, and/or brake dust, replace the brake master cylinder reservoir cap diaphragm. The diaphragm may have allowed the moisture or particles to enter the hydraulic system. 5. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11(R), GM P/N 12377967 (Canada P/N 992667) or equivalent, DOT-3 brake fluid from a clean, sealed brake fluid container. 6. Pressure bleed the hydraulic brake system. Begin the procedure with the pressure bleeder reservoir filled to the maximum-fill level with the correct brake fluid as indicated. Refer to Hydraulic Brake System Bleeding (Manual) (See: )Hydraulic Brake System Bleeding (Pressure) (See: )Hydraulic Brake System Bleeding (Two-mode Hybrid) (See: ). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair Brake Pedal Assy: Service and Repair Brake Pedal Assembly Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > Page 9433 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Testing and Inspection Brake Caliper: Testing and Inspection Brake Caliper Inspection Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). 1. Inspect the brake caliper housing (1) for cracks, excess wear, and/or damage. If any of these conditions are present, the brake caliper requires replacement. 2. Inspect the caliper piston dust boot seal (2) for cracks, tears, cuts, deterioration and/or improper seating in the caliper body. If any of these conditions are present, the brake caliper requires overhaul or replacement. 3. Inspect for brake fluid leakage around the caliper piston dust boot seal (2) and on the disc brake pads. If there is any evidence of brake fluid leakage, the brake caliper requires overhaul or replacement. 4. Inspect for smooth and complete travel of the caliper pistons into the caliper bores: The movement of the caliper pistons into the caliper bores should be smooth and even. If the caliper piston is frozen or difficult to bottom, the caliper requires overhaul or replacement. * For single piston caliper applications, insert a discarded inner brake pad (2) or block of wood in front of the piston. Using a large C-clamp (1) installed over the body of the caliper (3) and against the brake pad or block of wood, slowly bottom the piston in the bore. * For dual piston caliper applications, insert a discarded inner brake pad (2) or block of wood in front of the pistons. Using 2 large C-clamps (1) installed over the body of the caliper (3) and against the brake pad or block of wood, slowly bottom the pistons evenly into the bores. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement Brake Caliper: Removal and Replacement Front Brake Caliper Replacement (JD9, JF3, JF7, JG4) Front Brake Caliper Replacement (JD9, JF3, JF7, JG4) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 9440 Front Brake Caliper Replacement (JH6, JH7) Front Brake Caliper Replacement (JH6, JH7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 9441 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 9442 Rear Brake Caliper Replacement (JD9) Rear Brake Caliper Replacement (JD9) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 9443 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 9444 Rear Brake Caliper Replacement (JH6, JH7) Rear Brake Caliper Replacement (JH6, JH7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 9445 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 9446 Front Brake Caliper Hardware Replacement (JD9, JF3, JF7, JG4) Front Brake Caliper Hardware Replacement (JD9, JF3, JF7, JG4) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 9447 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 9448 Front Brake Caliper Hardware Replacement (JH6, JH7) Front Brake Caliper Hardware Replacement (JH6, JH7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 9449 Rear Brake Caliper Hardware Replacement (JD9) Rear Brake Caliper Hardware Replacement (JD9) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 9450 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 9451 Rear Brake Caliper Hardware Replacement (JH6, JH7) Rear Brake Caliper Hardware Replacement (JH6, JH7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 9452 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 9453 Front Brake Caliper Bracket Replacement (JD9, JF3, JF7, JG4) Front Brake Caliper Bracket Replacement (JD9, JF3, JF7, JG4) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 9454 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 9455 Front Brake Caliper Bracket Replacement (JH6, JH7) Front Brake Caliper Bracket Replacement (JH6, JH7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 9456 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 9457 Rear Brake Caliper Bracket Replacement (JD9) Rear Brake Caliper Bracket Replacement (JD9) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 9458 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 9459 Rear Brake Caliper Bracket Replacement (JH6, JH7) Rear Brake Caliper Bracket Replacement (JH6, JH7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 9460 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 9461 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 9462 Brake Caliper: Overhaul Front Brake Caliper Overhaul (JH6, JH7) Front Brake Caliper Overhaul (JH6, JH7) Disassembly Procedure Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). 1. Remove the brake caliper. Refer to Front Brake Caliper Replacement (JD9, JF3, JF7, JG4) (See: Removal and Replacement/Front Brake Caliper Replacement (JD9, JF3, JF7, JG4))Front Brake Caliper Replacement (JH6, JH7) (See: Removal and Replacement/Front Brake Caliper Replacement (JH6, JH7)). 2. Drain all the brake fluid from the caliper. Note: The brake calipers use phenolic pistons that have stainless steel caps which contact the brake pads. Use compressed air to remove the piston from the brake caliper. 3. Secure the brake caliper in a suitable holding device. 4. Insert a piece of wood in the brake caliper between the pistons and the outer bridge. 5. Cover the brake caliper with a shop towel. 6. Apply filtered, non-lubricated compressed air into the brake hose inlet fitting port of the brake caliper. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 9463 7. If one of the pistons fails to be removed from the brake caliper, perform the following steps. 1. Reposition the piston that has been removed back into the brake caliper. 2. Using a small block of wood and a C-clamp, slowly tighten the C-clamp until the piston is half way into the brake caliper. It does not have to be fully seated. 3. Position a second block of wood in front of the piston that remains in the brake caliper. 4. Cover the brake caliper with a shop towel. 5. Apply filtered, non-lubricated compressed air into the brake hose inlet fitting port of the brake caliper. 8. Remove the pistons (3) from the caliper bores. 9. Remove the boots (4) from the caliper bores. Do not scratch the caliper bores. 10. Remove the piston seals (2) from the caliper bores. Do not use a metal tool. 11. Remove the bleeder valve cap (5). 12. Remove the bleeder valve (6) from the caliper housing (1). 13. Clean the bleeder valve, the caliper bores, the caliper passages and the pistons with denatured alcohol. Dry the parts and blow out the brake fluid passages using filtered, non-lubricated compressed air. 14. Replace the pistons or the caliper if any of the following conditions exist: Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 9464 * Scoring in the caliper bores * Corrosion in the caliper bores * Pitting in the caliper bores * Damage to the pistons (phenolic) 15. Clean the brake caliper assembly with denatured alcohol. 16. Dry with filtered , non-lubricated compressed air. Assembly Procedure Note: When applying the clean brake fluid to the piston bores, piston seals and pistons, only apply the brake fluid to one bore at a time. This is done to ensure that the brake caliper, seals and pistons DO NOT become contaminated with dirt or other foreign material. 1. Apply a small amount of clean DOT-3 brake fluid to the piston, piston seal, and piston bore. 2. Install the square-cut piston seal in the brake caliper bore groove. 3. Ensure that the square-cut piston seal is not twisted. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 9465 4. Install the boot over the end of the piston so that the fold will face toward the brake caliper housing piston bore opening. Note: Position the piston in the bore so that it is straight and level. 5. Position the piston to the brake caliper bore and seat the boot into the brake caliper bore groove. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 9466 6. Position a piece of wood across the piston to be installed. 7. Applying equal pressure by hand while pushing down, install the piston in the bore. 8. Remove the piece of wood. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 9. Install the bleeder valve in the brake caliper housing. Tighten the bleeder valve to 12 Nm (106 lb in). 10. Install the bleeder valve cap. 11. Install the brake caliper. Refer to Front Brake Caliper Replacement (JD9, JF3, JF7, JG4) (See: Removal and Replacement/Front Brake Caliper Replacement (JD9, JF3, JF7, JG4))Front Brake Caliper Replacement (JH6, JH7) (See: Removal and Replacement/Front Brake Caliper Replacement (JH6, JH7)). Rear Brake Caliper Overhaul (JH6, JH7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 9467 Rear Brake Caliper Overhaul (JH6, JH7) Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Disassembly Procedure 1. Remove the brake caliper. Refer to Rear Brake Caliper Replacement (JD9) (See: Removal and Replacement/Rear Brake Caliper Replacement (JD9))Rear Brake Caliper Replacement (JH6, JH7) (See: Removal and Replacement/Rear Brake Caliper Replacement (JH6, JH7)). 2. Drain all the brake fluid from the caliper. Note: The brake calipers use phenolic pistons with stainless steel caps which contact the brake pads. Use compressed air to remove the piston from the brake caliper. 3. Secure the brake caliper in a suitable holding device. 4. Insert a piece of wood in the brake caliper between the pistons and the outer bridge. 5. Cover the brake caliper with a shop towel. 6. Apply filtered, non-lubricated compressed air into the brake hose inlet fitting port of the brake caliper. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 9468 7. If one of the pistons fails to be removed from the brake caliper, perform the following steps. 1. Reposition the piston that has been removed back into the brake caliper. 2. Using a small block of wood and a C-clamp, slowly tighten the C-clamp until the piston is half way into the brake caliper. It does not have to be fully seated. 3. Position a second block of wood in front of the piston that remains in the brake caliper. 4. Cover the brake caliper with a shop towel. 5. Apply filtered, non-lubricated compressed air into the brake hose inlet fitting port of the brake caliper. 8. Remove the pistons (3) from the caliper bores. 9. Remove the boots (4) from the caliper bores. Do not scratch the caliper bores. 10. Remove the piston seals (2) from the caliper bores. Do not use a metal tool. 11. Remove the bleeder valve cap (5). 12. Remove the bleeder valve (6) from the caliper housing (1). 13. Clean the bleeder valve, the caliper bores, the caliper passages and the pistons with denatured alcohol. Dry the parts and blow out the brake fluid passages using filtered, non-lubricated compressed air. 14. Replace the pistons or the caliper if any of the following conditions exist: Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 9469 * Scoring in the caliper bores * Corrosion in the caliper bores * Pitting in the caliper bores * Damage to the pistons (phenolic) 15. Clean the brake caliper assembly with denatured alcohol. 16. Dry with filtered , non-lubricated compressed air. Assembly Procedure Note: When applying the clean brake fluid to the piston bores, piston seals and pistons, only apply the brake fluid to one bore at a time. This is done to ensure the brake caliper, seals and pistons DO NOT become contaminated with dirt or other foreign material. 1. Apply a small amount of clean DOT-3 brake fluid to the piston, piston seal, and piston bore. 2. Install the square-cut piston seal in the brake caliper bore groove. 3. Ensure the square-cut piston seal is not twisted. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 9470 4. Install the boot over the end of the piston so the fold will face toward the brake caliper housing piston bore opening. Note: Position the piston in the bore so that it is straight and level. 5. Position the piston to the brake caliper bore and seat the boot into the brake caliper bore groove. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 9471 6. Position a piece of wood across the piston to be installed. 7. Applying equal pressure by hand while pushing down, install the piston in the bore. 8. Remove the piece of wood. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 9. Install the bleeder valve in the brake caliper housing. Tighten the bleeder valve to 12 Nm (106 lb in). 10. Install the bleeder valve cap. 11. Install the brake caliper. Refer to Rear Brake Caliper Replacement (JD9) (See: Removal and Replacement/Rear Brake Caliper Replacement (JD9))Rear Brake Caliper Replacement (JH6, JH7) (See: Removal and Replacement/Rear Brake Caliper Replacement (JH6, JH7)). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications Brake Pad: Specifications Replace the disc brake pads when the friction surface (3) is worn to within 0.76 mm (0.030 in) of the mounting plates. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications > Page 9475 Brake Pad: Testing and Inspection Brake Pad Inspection Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). 1. Inspect the disc brake pads at regular intervals, or whenever the tire and wheel assemblies are removed from the vehicle. 2. If replacement is necessary, always replace disc brake pads in axle sets. 3. Inspect both edges of the disc brake pad friction surfaces (3). The highest rate of wear normally occurs at the trailing edge of the disc brake pads. 4. Inspect the thickness of the disc brake pads (3) in order to ensure that they have not worn prematurely. The disc brake pad wear should be approximately even per axle set. 5. Both front and rear disc brake pads have integral, audible wear sensors (1). When the disc brake pad wear reaches the minimum allowable thickness, the wear sensor contacts the disc brake rotor (2). The wear indicator will then produce an audible, high-pitched warning noise during wheel rotation. 6. Replace the disc brake pads when the friction surface (3) is worn to within 0.76 mm (0.030 in) of the mounting plates. 7. Remove the brake calipers and inspect the friction surfaces of the inner and outer disc brake pads to ensure that they are level. Place the disc brake pad friction surfaces together and measure the gap between the surfaces. If more than 0.13 mm (0.005 in) gap exists midway between the length of the disc brake pads, replace the disc brake pads. 8. Verify that any disc brake pad shims that may be required are in place and not damaged or excessively corroded. Replace any missing or damaged shims in order to preserve proper disc brake performance. 9. Replace the disc brake pads if any have separated from the mounting plates. 10. Inspect the disc brake pads friction surfaces for cracks, fractures, or damage which may cause noise or otherwise impair disc brake performance. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Procedures Brake Pad: Procedures Brake Pad and Rotor Burnishing Warning Road test a vehicle under safe conditions and while obeying all traffic laws. Do not attempt any maneuvers that could jeopardize vehicle control. Failure to adhere to these precautions could lead to serious personal injury and vehicle damage. Burnishing the brake pads and brake rotors is necessary in order to ensure that the braking surfaces are properly prepared after service has been performed on the disc brake system. This procedure should be performed whenever the disc brake rotors have been refinished or replaced, and/or whenever the disc brake pads have been replaced. 1. Select a smooth road with little or no traffic. 2. Accelerate the vehicle to 48 km/h (30 mph). Note: Use care to avoid overheating the brakes while performing this step. 3. Using moderate to firm pressure, apply the brakes to bring the vehicle to a stop. Do not allow the brakes to lock. 4. Repeat steps 2 and 3 until approximately 20 stops have been completed. Allow sufficient cooling periods between stops in order to properly burnish the brake pads and rotors. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Procedures > Page 9478 Brake Pad: Removal and Replacement Front Disc Brake Pads Replacement (JD9, JF3, JF7, JG4) Front Disc Brake Pads Replacement (JD9, JF3, JF7, JG4) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Procedures > Page 9479 Front Disc Brake Pads Replacement (JH6, JH7) Front Disc Brake Pads Replacement (JH6, JH7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Procedures > Page 9480 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Procedures > Page 9481 Rear Disc Brake Pads Replacement (JD9) Rear Disc Brake Pads Replacement (JD9) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Procedures > Page 9482 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Procedures > Page 9483 Rear Disc Brake Pads Replacement (JH6, JH7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Procedures > Page 9484 Rear Disc Brake Pads Replacement (JH6, JH7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Procedures > Page 9485 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures Technical Service Bulletin # 00-05-22-002L Date: 090326 Brakes- Disc Brake Warranty Service And Procedures INFORMATION Bulletin No.: 00-05-22-002L Date: March 26, 2009 Subject: Disc Brake Warranty Service and Procedures Models: 1999-2010 GM Passenger Cars and Light Duty Trucks 2003-2010 HUMMER H2 2006-2010 HUMMER H3 1999-2004 Isuzu Light Duty Trucks (Canada Only) 2005-2009 Saab 9-7X (Canada Only) 1999-2010 Saturn Vehicles (Canada Only) EXCLUDING 2009-2010 Chevrolet Corvette ZR1 Supercede: This bulletin is being revised to inform you that due to improvements in vehicle brake corner and wheel design, assembly plant build processes and dealership required tools like the On-Car Lathe, measuring for Lateral Run Out (LRO) is no longer a required step when performing base brake service. Due to this change, you are no longer required to enter the LRO measurement on the repair order or in the warranty system failure code section. The bulletin information below and the base brake labor operations have been updated accordingly. Due to this change it is more important than ever to properly maintain your brake lathe (per the Brake Lathe Calibration Procedure in this bulletin). Please discard Corporate Bulletin Number 00-05-22-002K (Section 05 Brakes). For your convenience, this bulletin updates and centralizes all GM's Standard Brake Service Procedures and Policy Guidelines for brake rotor and brake pad service and wear. For additional information, the Service Technical College lists a complete index of available Brake courses. This information can be accessed at www.gmtraining.com > resources > training materials > brakes courseware index. In Canada, refer to Service Know How course 55040.00V and Hydraulic Brake Certification program 15003.16H. Important PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM BRAKE SERVICE. The following four (4) key steps are a summary of this bulletin and are REQUIRED in completing a successful brake service. 1. Measure and Document Pre-Service Rotor Thickness* (REQUIRED on Repair Order) determine rotor clean-up/refinish/replace 2. Properly clean ALL brake corner mating surfaces - hub, rotor and wheel 3. Properly clean-up/refinish rotor, measure and document post-service rotor thickness (REQUIRED on Repair Order) Important If it is determined the rotor needs to be refinished, verify lathe equipment is properly calibrated. 4. Properly reassemble the brake corner using proper torque tools, torque specification and torque sequence - wheel lug nuts. * The bulletin refers to Minimum Thickness specification as the minimum allowable thickness after refinish. Always refer to SI to verify the spec stamped on the rotor is the minimum thickness spec after refinish and not the discard spec. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 9490 Bulletin Format ***REPAIR ORDER REQUIRED DOCUMENTATION Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 9491 Important When using any one of the brake labor operations listed in this bulletin (except for H9709 - Brake Burnish), the following two rotor measurements (1. Original Rotor Thickness, 2. Refinished Rotor Thickness are required and MUST be written/documented on the repair order, or for your convenience, complete the form (GM Brake Service Repair Order Documentation for Required Measurements) shown above and attach it to the repair order. If the Warranty Parts Center generates a request, this Documentation/Form must be attached to the repair order that is sent back. Important Documentation of brake lathe maintenance and calibration as recommended by the lathe manufacturer must be available for review upon request. Repair Order Documentation - Rotor Original And Refinished Thickness - REQUIRED When resurfacing a brake rotor or drum, the ORIGINAL thickness (measured thickness before refinish) and REFINISHED thickness (measured thickness after refinish) MUST be written/documented on the repair order hard copy for each rotor serviced. If a rotor replacement is necessary, only the original thickness measurement needs to be recorded. Repair Order Documentation - Explanation of Part Replacement - REQUIRED If replacement of a brake component is necessary, proper documentation on the repair order is required. See the following examples: ^ Brake rotor replacement - Customer comment was brake pulsation. Rotor was refinished on a prior brake service. After rotor measurement, it was determined that refinishing the rotor again would take it under the Minimum Thickness specification. ^ Brake pad replacement - Customer comment was brake squeak noise. On inspection, found pads contaminated by fluid leak at caliper. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 9492 TOOL INFORMATION CORRECTION PLATE PART INFORMATION Refer to TSB 01-05-23-001 for the Brake Align(R) application chart. For vehicles repaired under warranty, Brake Align(R) Run-Out Correction Plates should be submitted in the Net Amount at cost plus 40%. Brake Align(R) Run-Out Correction Plates are available through the following suppliers: - Dealer Equipment and Services - Brake Align(R) LLC (U.S. Dealers Only) * We believe this source and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such items, which may be available from other sources. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 9493 WARRANTY INFORMATION Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 9494 WORKSHEET - BRAKE LATHE CALIBRATION Important Brake lathe calibration should be performed and recorded monthly or if you are consistently measuring high LRO after rotor refinishing. Disclaimer GM Brake Service Procedure GM BRAKE SERVICE PROCEDURE 1. Remove the wheel and caliper. 2. Measure rotor thickness. In order to determine if the rotor can be refinished, do the following steps: Important Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 9495 If performing routine Brake Service for worn pads only, and the rotors are not damaged and measure within specification - DO NOT REFINISH ROTORS. 1. Remove the rotor(s). 2. Measure the rotor for original thickness using a brake micrometer. Multiple measure points should be taken and the lowest measurement should be recorded. 3. Reference the Minimum Thickness specification stamped on the backside of the rotor or SI for Minimum Thickness specification/other. In most cases, the rotor should be refinished unless the measurement taken makes it obvious that refinishing the rotor would take the measurement under the Minimum Thickness specification (then replacement is necessary). DO NOT use any other manufacturers rotor specifications. 3. ***Record the lowest ORIGINAL rotor thickness measurement on the repair order hard copy as noted in the "Repair Order Documentation - Rotor Refinish" section of this bulletin. 4. Clean all of the mating surfaces between the hub, the rotor and the wheel using the J 42450A Wheel Hub Cleaning Kit and J 41013 - Whiz Wheel(R). If rotors are not to be refinished - Go To Step 8. Important Cleaning all mating surfaces and making them free of corrosion, burrs and other debris (which includes removal of Hubless rotors) is critical and MUST be performed whether using an On-Car or Bench Lathe Refinish Procedure. 5. Be sure to follow the appropriate refinishing procedure listed below for the type of lathe you are using. Important Only replace the rotors if they do not meet the Minimum Thickness specification. Important DO NOT REFINISH NEW ROTORS. Important Only remove the necessary amount of material from each side of the rotor and note that equal amounts of material do not have to be removed from both sides on any brake system using a floating caliper. Important Prior to making the cut, install the recommended clip-on style disc silencer supplied with the lathe. Use of this silencer is critical to prevent chatter from occurring during the cut. Bench Type Lathe 1. Refinish the existing rotor on an approved, well-maintained lathe to guarantee smooth, flat and parallel surfaces. 2. Check for clean and true lathe adapters and make sure the arbor shoulder is clean and free of debris or burrs. For more information, see the "Brake Lathe Calibration Procedure (Bench-Type)" section in this bulletin. 3. On the outboard area of the rotor, position the cutting tools one eighth of an inch into the brake pad area of the rotor. Feed the cutting tools into the rotor until they cut the rotor to new metal, a full 360 degrees. Zero each dial and back off a full turn 4. Move the cutting bits to the middle of the rotor and do the same procedure. If zero is passed during the process, reset zero. Back off a full turn. 5. Position the cutting bits one eighth of an inch inside the inboard (closest to the hub) edge of the brake pad contact area. Do the same procedure. If zero is passed during the process, reset zero. 6. Back off a full turn and position the cutting bits all the way inboard in preparation to refinish the full rotor surface. Advance both tool cutters to the zero setting plus just enough to clean up the entire rotor surface. 7. After completing the refinish, sand both sides of the rotor for approximately one minute per side using a sanding block and 130-150 grit sandpaper to obtain a non-directional finish. On-Car Type Lathe 1. Reinstall the rotor(s). Important Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 9496 When using the On-Car lathe on vehicles equipped with limited slip (or posi-trac) rear system, it is critical that the rear drive shaft is disconnected/disengaged prior to operation of the On-Car lathe. Remember to mark and re-index the drive shaft correctly on re-assembly to prevent creating driveline vibration. Whenever the lathe drive motor is being switched on, the operator MUST keep their body out of the wheel well area until the machine has reached its normal operating RPM. 2. Refinish the existing rotor on an approved, well-maintained lathe to guarantee smooth, flat and parallel surfaces. Important When raising the vehicle on the lift, be sure to have it at a good working height (waist high is average) to accommodate mounting the On-Car lathe. Optimally, the center piston on the lathe trolley will be mid-travel. If the lathe trolley center piston is completely compressed (bottoming out) or inversely fully extended and hanging off the vehicle hub, this could affect the calibration time of the lathe. 3. Select the correct adapter for the vehicle you're working on and mount it to the hub with the vehicle lug nuts. Hand tighten 34-41 Nm (25-30 lb ft) the nuts using equal torque. DO NOT use impact wrenches, excessive torque will damage the adapter. Important Ensure the adapter sits flush on the rotor hat surface. Be sure to remove any rust, rotor retaining clips, etc. that may preclude the adapter from sitting flat on the mounting surface. 4. Connect the lathe to the adapter, turn on the lathe and activate the computer to compensate for run-out in the hub. 5. Once the computer indicates the compensation process was successful, on the outboard area of the rotor, position the cutting tools one eighth of an inch into the brake pad area of the rotor. Feed the cutting tools into the rotor until they cut the rotor to new metal, a full 360 degrees. Zero each dial and back off a full turn. 6. Move the cutting bits to the middle of the rotor and do the same procedure. If zero is passed during the process, reset zero. Back off a full turn. 7. Position the cutting bits one eighth of an inch inside the inboard (closest to the hub) edge of the brake pad contact area. Do the same procedure. If zero is passed during the process, reset zero. 8. Back off a full turn and position the cutting bits all the way inboard in preparation to refinish the full rotor surface. Advance both tool cutters to the zero setting plus just enough to clean up the entire rotor surface. 9. After completing the refinish, sand both sides of the rotor for approximately one minute per side using a sanding block and 130-150 grit sandpaper to obtain a non-directional finish. 10. Dismount the lathe, but leave the lathe adapter attached to the vehicle. 6. Once the rotor has been properly machined, wash the rotor with soap and water (use a mild dish washing soap) or wipe it clean with GM approved brake cleaner, P/N 88862650 (Canadian P/N 88901247). Important Thoroughly cleaning the rotor will prevent the possible transfer of finite metal dust left as a by-product of machining to the pad material during the seating process, thus reducing the opportunity for squeaks or other noises to occur. 7. ***Record the REFINISHED rotor thickness measurement on the repair order hard copy. Refer to the "Repair Order Documentation - Rotor Refinish" section of this bulletin. 8. Setting up to measure for Lateral Run Out (LRO): Important Measuring for Lateral Run Out (LRO) (steps 8 - 15) is no longer required however, these steps are being left in the overall procedure as a good check to be performed in the case of a repeat pulsation complaint. If you are not checking for LRO, go to step 16. Bench-Type Lathe 1. Ensure that the mating surfaces of the rotor hat section and the hub mating surface are clean and free of debris. 2. Mount the new, original or refinished rotor onto the vehicle hub. Important Always hold the rotor on the bottom half so any debris that may be dislodged from the vents will fall out instead of falling into the mounting area. Any movement or jarring from the rotor falling over on the studs can release rust from the vents on the rotor. 3. Tilt the top of the rotor in towards the vehicle so you can see the studs and ease the rotor onto the studs. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 9497 4. Slide the rotor all the way to the hub and hold it in place until you have placed one of the conical washers (with the tapered hole side facing out) and run the first lug nut up tight by hand so the rotor doesn't move when you release it. 5. Place the conical washers on the rest of the studs (with the tapered hole side facing out), start and snug the lug nuts by hand. 6. Using the one half inch drive impact wrench and a torque stick (J 39544) or equivalent, start with the lug nut opposite of the one you first tightened by hand and tighten the lug nuts using a star pattern until they touch the hub but do not completely torque. Then again, starting with the first lug nut you tightened by hand, tighten all the lug nuts in a star pattern to the specific vehicle torque specification. 7. DO NOT reinstall the caliper or the wheel at this time. On-Car Type Lathe 1. Leave the On-Car adapter on the wheel. 2. Proceed to Step 9. 9. Fasten the dial indicator to the steering knuckle so that the indicator needle contacts the rotor outboard friction surface approximately 6.35 mm (0.25 in) from the rotor's outer edge. The stylus should be perpendicular to the friction surface of the rotor. Important Make sure the dial indicator needle tip is screwed tight, a loose tip could cause false readings. 10. Measure for LRO. Follow the procedure below to determine if the LRO is within specification (0.050 mm (0.002 in) or LESS). 1. Rotate the rotor and locate the point on the rotor where the lowest dial indicator reading is indicated and set the dial indicator to zero. 2. Rotate the rotor from the low point and locate the point with the highest dial indicator reading (rotor "high spot"). Note the amount and mark the location of the "high spot" on the rotor and mark the closest wheel stud relative to this location. If the high point falls between two studs, mark both studs. In instances where the vehicle has "capped lug nuts" you should mark the hub. 11. If the Lateral Run Out (LRO) measurement is 0.050 mm (0.002 in) or LESS, no correction is necessary. Go to Step 15 if this is the first rotor completed. Go to Step 16 if this is the second rotor completed. If the LRO is GREATER than 0.050 mm (0.002 in), go to Step 12. 12. If the LRO measurement is greater than 0.050 mm (0.002 in), use the following procedure to correct for LRO: Important If the LRO measurement is over 0.279 mm (0.011 in), determine the source or cause of the LRO and correct it (i.e. verify drive axle nut torque specification, refinished rotor is source of LRO due to a lathe qualification issue - see "Brake Lathe Calibration Procedure"). Hubless Rotor 1. Remove the rotor and using the Brake Align(R) application chart (found in TSB 01-05-23-001B), choose the correct plate to bring the rotor LRO to 0.050 mm (0.002 in) or less. The plates come in 0.0762 mm (0.003 in), 0.1524 mm (0.006 in) and 0.2286 (0.009 in) compensation. For more information on proper plate selection, see the instruction video/DVD included in the "Brake Align(R)" kit or TSB 01-05-23-001B. 2. Align the V-notch of the selected Brake Align(R) correction plate to the marked wheel stud ("high spot") or between the two points marked (if the "high spot" is between two wheel studs). Important IF Brake Align(R) Correction Plates are not available for the vehicle being serviced, refer to SI Document - Brake Rotor Assembled Lateral Runout Correction for correcting LRO. Important Per Brake Align(R) manufacturer, NEVER attempt to stack two or more Correction Plates together on one hub. NEVER attempt to reuse a previously installed Correction Plate. 3. Reinstall the rotor using the same method and precautions as the first time - found in Step 8. Make sure to index the rotor correctly to the marks made in step 10, otherwise LRO will be comprised. Hubbed / Captured / Trapped Rotor 1. Measure the rotor thickness. 2. Refinish or replace the rotor (see Service Information for further details). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 9498 13. Use a Dial Indicator to measure the rotor to verify the LRO is within specification. 14. If using, BENCH LATHE - DO NOT remove conical washers and lug nuts at this time. ON-CAR LATHE - You must remove adapter and install conical washers and lug nuts to retain rotor position. Important For Hubless rotor design, while removing the adapter, you must hold the rotor tight to the hub and install the top conical washer and lug nut first to ensure no debris falls between the surface while removing the adapter. Then, install the remaining conical washers and lug nuts. Otherwise, LRO will be comprised. 15. Perform Steps 1 through 7 on the opposite side of the vehicle (steps 1-12, if performing LRO). 16. Reinstall the rotors on both sides of the vehicle and perform the following steps: 1. Reinstall the calipers and pads. 2. Pump the brakes to pressurize the calipers. 3. Remove the lug nuts/conical washers. 4. Install and properly torque the wheels. Important It is critical to follow the star pattern wheel torque procedure and use the proper tools (torque stick or torque wrench) as referenced in SI. 17. Road test the vehicle to verify the repairs. Brake Lathe Calibration Procedure BRAKE LATHE CALIBRATION PROCEDURE Calibration of the brake lathe should be performed and recorded monthly or whenever post-service brake rotor LRO measurements are consistently reading above specification. BENCH-TYPE LATHE Use the following procedure to calibrate a Bench-type brake lathe: 1. After refinishing a rotor, loosen the arbor nut and while holding the inside bell clamp to keep it from rotating, rotate the rotor 180 degrees. 2. Retighten the arbor nut and set the dial indicator on the rotor using the same instructions as checking the run out on the vehicle. 3. Rotate the arbor and read the runout. 4. Divide the reading by two and this will give you the amount of runout the lathe is cutting into the rotor. Important If there is any runout, you will need to machine the inside bell clamp in place on the lathe (this procedure is for a Bench type lathe ONLY, DO NOT machine inside the bell clamp on an On-Car type lathe). Machining the Inside Bell Clamp (Bench Type Lathe Only) Any nicks or burrs on the shoulder of the arbor must be removed. An 80-grit stone can be used to accomplish this. Spray WD-40(R) on the shoulder and with the lathe running, hold the stone flat against the shoulder surface using slight pressure. When the burrs are gone, clean the surface. Burrs must also be removed from the hub of the inside bell clamp. This can be accomplished with the stone and WD-40(R). Keep the stone flat on the hub while removing the burrs. After removing the burrs, clean the hub. Place the bell clamp on the arbor of the lathe and use the small radius adapters first and then spacers to allow you to tighten the arbor nut to secure the bell clamp to the lathe. Position the tool bit in the left hand of the rotor truer so you can machine the face of the bell clamp. Machine the face of the bell clamp taking just enough off of it to cut the full face of the clamp the full 360 degrees. Before you loosen the arbor nut, match mark the hub of the bell clamp to the arbor and line up these marks before machining a rotor. A magic marker can be used to make the match marks. Machine a rotor and recheck the calibration. Repeat this procedure on all Inside Bell Clamps used. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 9499 Important If runout is still present, contact the brake lathe supplier. ON-CAR TYPE LATHE Use the following procedure to calibrate an On-Car brake lathe: 1. Connect the lathe to a vehicle using the appropriate adapter. 2. Attach a vise-grip dial indicator to a fixed point in the wheel well and bring the dial indicator to a flat surface on the cutting head. 3. Turn on the lathe and press the "start" button so the lathe begins to compensate. 4. Once compensation is complete, note the runout as measured by the dial indicator. Measured runout at this point is overstated given that it is outside the rotor diameter. 5. If runout is in excess of 0.1016 mm (0.004 in) (0.050 mm (0.002 in) as measured within the rotor diameter), calibration must be tightened. Follow manufacturer's instructions for tightening the calibration of the lathe. This information is found in the manual supplied with the lathe. Important If the machine is taking a long time to compensate during normal use, prior to checking the lathe calibration, it is recommended that the machine be disconnected from the adapter and the adapter (still connected to the vehicle) is rotated 180 degrees and the machine reattached. This will accomplish two things: - It will re-verify the machine is properly attached to the adapter. - It will change the location of the runout (phase) relative to the machine and thus possibly allow for quick compensation as a result of the position change. The following information has been added as a reference to ensure your Pro-Cut PFM lathe provides a consistent smooth surface finish over long term usage. Cutting Tips / Depth of Cut / Tip Life The cutting tips must be right side up. Reference marks always face up. The cutting tips may not have chips or dings in the surface of the points. Cuts of 0.1016-0.381 mm (0.004-0.015 in) will provide the best surface finish and the optimal tip life. When cleaning or rotating the cutting bits, make sure that the seat area for the tip on the tool is free and clear of debris. Cutting Head On each brake job, the technician must center the cutting head for that particular vehicle using one of the mounting bolt holes on the slide plate. Once the head is centered, it is vital that the technician use one hand to push the head firmly and squarely back into the dovetail on the slide plate while using the other hand to tighten the Allen-Hex bolt that secures the head. Failure to do this could result in chatter occurring during the cut. Tool Holder Plate (Cutting Head) The tool holder plate is the plate that the cutting arms are attached to. It can bend or break if a technician accidently runs the cutting arms into the hub of the rotor while the rotor is turning. (Cuts of more than 0.508 mm (0.020 in) can also bend this plate). Once bent, the lathe will most likely not cut properly until the tool holder plate is replaced. In order to verify the condition of the tool holder plate on a machine that will not cut right, remove the mounting bolt and remove the cutting head from the slide plate. With the cutting head titled at an angle, lay the long edge of the tool holder plate down on the flat part of the slide plate. If any gap can be seen between the edge and the slide plate, the tool holder plate is bent and the source of vibration. Also check to ensure that the cutting arms are lying flat on the upper side of the tool holder plate. If the mounting arm post is bent, it will show itself by having the back of the cutting arm lifting off the surface of the tool holder. Gib Adjustment / Loose Gib As wear occurs between the slide plate and the box it rides on, you must take up the slack. You do this by way of a moveable wedge, which we call the gib. Your lathe manual details adjustment process, which you should perform when required after monthly checks or whenever surface finish is inconsistent. Brake Pulsation BRAKE PULSATION Brake pulsation is caused by brake rotor thickness variation. Brake rotor thickness variation causes the piston in the brake caliper, when applied, to "pump" in and out of the caliper housing. The "pumping" effect is transmitted hydraulically to the brake pedal. Brake pulsation concerns may result from two basic conditions: Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 9500 1. Thickness Variation Pulsation is Caused by Lateral Run Out (LRO). LRO on a brake corner assembly is virtually undetectable unless measured (with a dial indicator after the brake service) and will not be detected as brake pulsation during an after brake service test drive. If the brake corner is assembled with excessive LRO (greater than 0.050 mm (0.002 in), thickness variation will develop on the brake rotor over time and miles. Excessive LRO will cause the brake pads to wear the brake rotors unevenly, which causes rotor thickness variation. Pulsation that is the result of excessive Lateral Run Out usually develops in 4,800-16,000 km (3,000-10,000 mi). The more excessive the LRO, the faster the pulsation will develop. LRO can also be induced when uneven torque is applied to wheel nuts (lug nuts). Improper wheel tightening after tire rotation, spare tire usage, brake inspection, etc. can be the cause of brake pulsation. Again, it usually takes 4,800-16,000 km (3,000-10,000 mi) AFTER the service event for the condition to develop. The customer does not usually make the connection between the service event and the awareness of the pulsation. The proper usage of torque wrenches and/or torque sticks (torque limiting sockets) will greatly reduce or eliminate the pulsation conditions after wheel service events. The improper use of impact wrenches on wheel nuts greatly increases the likelihood of pulsation after wheel service. The following are examples of pulsation conditions and reimbursement recommendations: - If the customer noticed the condition between 4,800-16,000 km (3,000-10,000 mi) and it gradually got worse, normally the repair would be covered. The customer may tolerate the condition until it becomes very apparent. - If a GM dealer performed a prior brake service, consider paying for the repair and then strongly reinforce proper brake lathe maintenance. - If the customer had the brake service done outside of a GM dealership, normally GM would not offer any assistance. - If a customer indicated they had wheel service, ask who performed the service. Then; - If a GM dealer performed the service, consider paying for the repair and then strongly reinforce the use of torque sticks at the dealer. Two common size torque sticks cover 90% of all GM products. Each technician needs to use torque sticks properly every time the wheel nuts are tightened. - If the customer had the wheel service done outside of a GM dealership, normally GM would not offer any assistance. 2. Thickness Variation Pulsation Caused by Brake Rotor Corrosion - Rotor corrosion is another form of thickness variation, which can cause a pulsation concern and can be addressed as follows: - Cosmetic Corrosion: In most instances rotor corrosion is cosmetic and refinishing the rotor is unnecessary. - Corrosion - Pulsation Caused by Thickness Variation (Lot Rot / Low Miles - 0-321 km (0-200 mi): At times more extensive corrosion can cause pulsation due to thickness variation. This usually happens when the vehicle is parked for long periods of time in humid type conditions and the braking surface area under the pads corrodes at a different rate compared to the rest of the braking surface area. Cleaning up of braking surfaces (burnishing) can be accomplished by 10 - 15 moderate stops from 56- 64 km/h (35 - 40 mph) with cooling time between stops. If multiple moderate braking stops do not correct this condition, follow the "Brake Rotor Clean-Up Procedure" below. - Corrosion - Pulsation Caused by Thickness Variation (without rotor flaking / higher mileage 3,200-8,000 km (2,000-5,000 mi): In some cases, more extensive corrosion that is not cleaned up by the brake pad over time and miles can cause the same type of pulsation complaint due to thickness variation. In these cases, the rotor surface is usually darker instead of shiny and a brake pad foot print can be seen against the darker surface. This darker surface is usually due to build-up, on the rotor material surface, caused by a combination of corrosion, pad material and heat. To correct this condition, follow the "Brake Rotor Clean-up Procedure" below. - Corrosion - Pulsation Caused by Thickness Variation (with rotor flaking / higher mileage - 8,000 + km (5,000 + miles) : At times, more extensive corrosion over time and miles can cause pulsation due to thickness variation (flaking). This flaking is usually a build up, mostly on the rotor material surface, caused by a combination of corrosion, pad material and heat. When rotor measurements are taken, the low areas are usually close to the original rotor thickness (new rotor) measurement and the high areas usually measure more than the original rotor thickness (new rotor) measurement (depending on mileage and normal wear). To correct this condition, follow the "Brake Rotor Clean-up Procedure" described below. Important In some flaking instances, cleaning-up this type of corrosion may require more rotor material to be removed then desired. Customer consideration should be taken in these situations and handled on a case by case basis, depending on the amount/percentage of rotor life remaining and the vehicle's warranty time and miles. Brake Rotor Clean-Up Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 9501 BRAKE ROTOR CLEAN-UP PROCEDURE Clean-up the rotors on an approved, well-maintained brake lathe to guarantee smooth, flat and parallel surfaces. Check for clean and true lathe adapters and make sure the arbor shoulder is clean and free of debris or burrs. For more information see the "Brake Lathe Calibration Procedure" section in this bulletin. 1. On the outboard area of the rotor, position the cutting tools one eighth of an inch into the brake pad area of the rotor. Feed the cutting tools into the rotor until they cut the rotor to new metal, a full 360 degrees. Zero each dial and back off a full turn. 2. Move the cutting bits to the middle of the rotor and do the same procedure. If zero is passed during the process, reset zero. Back off a full turn. 3. Position the cutting bits one eighth of an inch inside the inboard (closest to the hub) edge of the brake pad contact area. Do the same procedure. If zero is passed during the process, reset zero. 4. Back off a full turn and position the cutting bits all the way inboard in preparation to refinish the full rotor surface. Advance both tool cutters to the zero setting plus just enough to clean up the entire rotor surface. 5. After completing the refinish, sand both sides of the rotor for approximately one minute per side using a sanding block and 130-150 grit sandpaper to obtain a non-directional finish. Important Only remove the necessary amount of material from each side of the rotor and note that equal amounts of material do not have to be removed from both sides on any brake system using a floating caliper. Important In many of these instances, such a minimal amount of material is removed from the rotor that customer satisfaction is not a concern for future brake services. This procedure is intended to "Clean-up" the rotor surface and should be conveyed to the customer as such - not as "cut", "refinish" or "machine", which tends to be terms understood as a substantial reduction of rotor material/life. If the brake lathe equipment being used is not capable of removing minor amounts of material while holding tolerances, further lathe maintenance, repair, updates or equipment replacement may be necessary. Brake Noise BRAKE NOISE Some brake noise is normal and differences in loading, type of driving, or driving style can make a difference in brake wear on the same make and model. Depending on weather conditions, driving patterns and the local environment, brake noise may become more or less apparent. Verify all metal-to-metal contact areas between pads, pad guides, caliper and knuckles are clean and lubricated with a thin layer of high temperature silicone grease. Brake noise is caused by a "slip-stick" vibration of brake components. While intermittent brake noise may be normal, performing 3 to 4 aggressive stops may temporarily reduce or eliminate most brake squeal. If the noise persists and is consistently occurring, a brake dampening compound may be applied to the back of each pad. This allows parts to slide freely and not vibrate when moving relative to each other. Use Silicone Brake Lubricant, ACDelco P/N 88862181 (Canadian P/N 88862496) or equivalent. The following noises are characteristics of all braking systems and are unavoidable. They may not indicate improper operation of the brake system. Squeak/Squeal Noise: - Occurs with front semi-metallic brake pads at medium speeds when light to medium pressure is applied to the brake pedal. - Occasionally a noise may occur on rear brakes during the first few stops or with cold brakes and/or high humidity. Grinding Noise: - Common to rear brakes and some front disc brakes during initial stops after the vehicle has been parked overnight. - Caused by corrosion on the metal surfaces during vehicle non-use. Usually disappears after a few stops. Groan Noise: A groan type noise may be heard when stopping quickly or moving forward slowly from a complete stop. This is normal. On vehicles equipped with ABS, a groan or moan type noise during hard braking applications or loose gravel, wet or icy road conditions is a normal function of the ABS activation. Key Points - Frequently Asked Questions KEY POINTS - FREQUENTLY ASKED QUESTIONS - Q: How do on-car lathes react to Axle Float? Does the play affect the machining of the rotor, either surface finish or LRO? Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 9502 A: Because the Pro-Cut on-car lathe adjusts in a live mode while spinning the hub/rotor, the dynamics of a floating axle are effectively eliminated. Once the lathe is compensated, there is no difference in the cutting/surface finish and LRO are just the same as with a non-floating axle. - Q: Which lathe is essential for performing brake work, the bench or on-car? A: Dealers must have a well maintained bench lathe and well maintained on-car lathe. These lathes need to be calibrated on a monthly basis. BOTH lathes are essential to providing quality brake service. - Q: What is the expected tip life for an on-car lathe? A: The geometry and composition of the Pro-Cut tips are designed for "single pass" cutting. When using the Pro-Cut the cutting depth should be set to take all material needed to get below rust grooves, eliminate all run-out and resurface the entire disc in a single pass. Cuts of 0.1016-0.381 mm (0.004-0.015 in) will provide the best surface finish and the optimal tip life. No "skim cut" or "finish cut" is needed. Failure to follow this procedure will shorten tip life. The Pro-cut tips will last between 7-12 cuts per corner. With three usable corners, a pair of tips is good for at least 21 cuts. - Q: Why does GM recommend the use of single pass (referred to as "positive rake") bench and on-car brake lathes? A: GM Service and GM Brake Engineering have performed competitive evaluations on a significant number of bench and on-car brake lathes. These tests measured critical performance characteristics such as flatness, surface finish and the ability of the lathe to repeat accuracy over many uses. In each test, single pass lathe designs out performed the competitors. Single pass brake lathes are more productive requiring less time to perform the same procedure. - Q: Is it okay to leave the caliper/pads installed while cutting rotors using an on-car lathe? A: On-car lathes should never be used with the pads and calipers installed on the vehicle. The debris from cutting the rotors can contaminate the brake pads/calipers which can lead to other brake concerns and comebacks. - Q: What information needs to be documented on the Repair Order? A: Any claim that is submitted using the labor operations in this bulletin, must have the Original Rotor Thickness and Refinish Rotor Thickness (if refinished) documented on the repair order. For more information, refer to the "Repair Order Required Documentation" section of this bulletin. All Warranty Repair Orders paid by GM, are subject to review for compliance and may be debited where the repair does not comply with this procedure. Brake Warranty BRAKE WARRANTY Brake Rotors: - Brake rotor warranty is covered under the terms of the GM New Vehicle Limited Warranty. Reference the vehicle's warranty guide for verification. - Rotors should not be refinished or replaced during normal/routine pad replacement. - Rotors should not be refinished or replaced and is ineffective in correcting brake squeal type noises and/or premature lining wear out. - Rotors should not be refinished or replaced for cosmetic corrosion. Clean up of braking surfaces can be accomplished by 10-15 moderate stops from 56-64 km/h (35-40 mph) with cooling time between stops. - Rotors should not be refinished or replaced for rotor discoloration/hard spots. - Rotors should be refinished NOT replaced for Customer Pulsation concerns. This condition is a result of rotor thickness variation, usually caused by LRO (wear induced over time and miles) or corrosion (Lot Rot). - When rotor refinishing, only remove the necessary amount of material from each side of the rotor and note that equal amounts of material do not have to be removed from both sides on any brake system using a floating caliper. - Rotors should be refinished for severe scoring - depth in excess of 1.5 mm (0.060 in). Important If the scoring depth is more than 1.5 mm (0.060 in) after the rotor is refinished, it should be replaced. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 9503 - It is not necessary to replace rotors in pairs. Rotors may be replaced individually. However, caution should be exercised, as a variance in surface finish may cause a brake pull condition. - New rotors should not be refinished before installation. Original equipment rotor surfaces are ground to ensure smooth finish and parallelism between mounting and friction surfaces. If a new rotor has more than 0.050 mm (0.002 in) Lateral Run Out (LRO) when properly mounted on the hub, correct it using one of the following methods: 1. For hubless rotor designs, use the correction plate procedure found in the "GM Brake Service Procedure for Hubless Rotors" outlined in this bulletin. 2. For hubbed/trapped/captured rotor designs, refinish the rotor using an On-Car lathe and the procedure outlined in this bulletin. - Never reuse rotors that measure under the Minimum Thickness specification. In this instance, the rotor should be replaced. Important If the Minimum Thickness specification is not visible on the rotor, reference Service Information (SI) for the specific vehicle application. DO NOT use any other manufacturers rotor specifications. Brake Pads: Important When determining the warranty coverage (as an example) - if all four front or four rear brake pads are excessively worn evenly, that would NOT be covered under warranty since this type of wear is most likely due to driving habits or trailering. However, if the brake pads are excessively worn un-evenly, side-to-side or same side/inner-to-outer pads, then consideration should be given to cover this under warranty since this type of wear is most likely due to poor operation of other braking components. - Consideration should be given for covering brake pads up to 39,000 km (24,000 mi) (excluding owner abuse, excessive trailering, or the situations that would not be considered normal use). - Installation of new rotors does not require pad replacement. Do not replace pads unless their condition requires it - excessively worn, damage or contaminated. Brake Wear: Several factors impact brake lining wear and should be taken into account when reviewing related issues: - heavy loads / high temperatures / towing / mountainous driving / city driving / aggressive driving / driver braking characteristics (left foot or two feet) The following are conditions that may extend brake lining wear: - light loads / highway driving / conservative driving / level terrain Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Page 9504 Brake Rotor/Disc: Specifications Front Brakes JD9, JF3, JF7 Rotor Discard Thickness*........................................................................ ....................................................................................................28.0 mm (1.10 in) Rotor Minimum Allowable Thickness After Refinish..................................................................................................................................28.0 mm (1.10 in) Rotor Thickness (new)........................................................................................................... ....................................................................30.0 mm (1.181 in) Rotor Maximum Allowable Assembled Lateral Runout.............................................................................................................................0.05 mm (0.002 in) Rotor Maximum Allowable Scoring...................................................................................... .....................................................................1.50 mm (0.059 in) Rotor Maximum Allowable Thickness Variation.....................................................................................................................................0.025 mm (0.001 in) Front Brakes JH6, JH7 Rotor Discard Thickness*........................................................ ................................................................................................................36.50 mm (1.437 in) Rotor Minimum Allowable Thickness After Refinish................................................................................................................................37.0 mm (1.457 in) Rotor Thickness (new)......................................................................................................... ......................................................................38.0 mm (1.496 in) Rotor Maximum Allowable Assembled Lateral Runout.............................................................................................................................0.13 mm (0.005 in) Rotor Maximum Allowable Scoring...................................................................................... .....................................................................1.50 mm (0.059 in) Rotor Maximum Allowable Thickness Variation.....................................................................................................................................0.025 mm (0.001 in) Rear Brakes JD9 Rotor Discard Thickness*................................................................. .........................................................................................................18.0 mm (0.709 in) Rotor Minimum Allowable Thickness After Refinish..............................................................................................................................18.5 mm (0.7282 in) Rotor Thickness (new)....................................................................................................... ........................................................................20.0 mm (0.787 in) Rotor Maximum Allowable Assembled Lateral Runout.............................................................................................................................0.05 mm (0.002 in) Rotor Maximum Allowable Scoring...................................................................................... .....................................................................1.50 mm (0.059 in) Rotor Maximum Allowable Thickness Variation...................................................................................................................................0.009 mm (0.0004 in) Rear Brakes JH6 Rotor Discard Thickness*............................................................... ...........................................................................................................27.5 mm (1.083 in) Rotor Minimum Allowable Thickness After Refinish................................................................................................................................28.0 mm (1.102 in) Rotor Thickness (new)......................................................................................................... ......................................................................30.0 mm (1.181 in) Rotor Maximum Allowable Assembled Lateral Runout.............................................................................................................................0.13 mm (0.005 in) Rotor Maximum Allowable Scoring...................................................................................... .....................................................................1.50 mm (0.059 in) Rotor Maximum Allowable Thickness Variation.....................................................................................................................................0.025 mm (0.001 in) Rear Brakes JH7 Rotor Discard Thickness*................................................................. .........................................................................................................28.5 mm (1.122 in) Rotor Minimum Allowable Thickness After Refinish................................................................................................................................29.0 mm (1.142 in) Rotor Thickness (new)......................................................................................................... ......................................................................30.0 mm (1.181 in) Rotor Maximum Allowable Assembled Lateral Runout.............................................................................................................................0.13 mm (0.005 in) Rotor Maximum Allowable Scoring...................................................................................... .....................................................................1.50 mm (0.059 in) Rotor Maximum Allowable Thickness Variation.....................................................................................................................................0.025 mm (0.001 in) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Testing and Inspection > Brake Pad and Rotor Burnishing Brake Rotor/Disc: Testing and Inspection Brake Pad and Rotor Burnishing Brake Pad and Rotor Burnishing Warning Road test a vehicle under safe conditions and while obeying all traffic laws. Do not attempt any maneuvers that could jeopardize vehicle control. Failure to adhere to these precautions could lead to serious personal injury and vehicle damage. Burnishing the brake pads and brake rotors is necessary in order to ensure that the braking surfaces are properly prepared after service has been performed on the disc brake system. This procedure should be performed whenever the disc brake rotors have been refinished or replaced, and/or whenever the disc brake pads have been replaced. 1. Select a smooth road with little or no traffic. 2. Accelerate the vehicle to 48 km/h (30 mph). Note: Use care to avoid overheating the brakes while performing this step. 3. Using moderate to firm pressure, apply the brakes to bring the vehicle to a stop. Do not allow the brakes to lock. 4. Repeat steps 2 and 3 until approximately 20 stops have been completed. Allow sufficient cooling periods between stops in order to properly burnish the brake pads and rotors. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Testing and Inspection > Brake Pad and Rotor Burnishing > Page 9507 Brake Rotor/Disc: Testing and Inspection Brake Rotor Assembled Lateral Runout Correction Brake Rotor Assembled Lateral Runout Correction Note: * Brake rotor thickness variation MUST be checked BEFORE checking for assembled lateral runout (LRO). Thickness variation exceeding the maximum acceptable level can cause brake pulsation. Refer to Brake Rotor Thickness Variation Measurement (See: Brake Rotor Thickness Variation Measurement). * Brake rotor assembled lateral runout (LRO) exceeding the maximum allowable specification can cause thickness variation to develop in the brake rotor over time, usually between 4,800-11,300 km (3,000-7,000 mi). Refer to Brake Rotor Assembled Lateral Runout Measurement (See: Brake Rotor Assembled Lateral Runout Measurement). Review the following acceptable methods for bringing the brake rotor assembled LRO to within specifications. Determine which method to use for the specific vehicle being repaired. * The indexing method of correcting assembled LRO is most effective when the LRO specification is only exceeded by a relatively small amount: 0.025-0.127 mm (0.001-0.005 in). Indexing is used to achieve the best possible match of high spots to low spots between related components. Refer to Brake Rotor Assembled Lateral Runout Correction - Indexing (See: Brake Rotor Assembled Lateral Runout Correction - Indexing). * The on-vehicle brake lathe method is used to bring the LRO to within specifications through compensating for LRO while refinishing the brake rotor. Refer to Brake Rotor Assembled Lateral Runout Correction - On Vehicle Lathe (See: Brake Rotor Assembled Lateral Runout Correction On Vehicle Lathe). If the assembled LRO cannot be corrected using these methods, then other components must be suspected as causing and/or contributing to the LRO concern. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Testing and Inspection > Brake Pad and Rotor Burnishing > Page 9508 Brake Rotor/Disc: Testing and Inspection Brake Rotor Assembled Lateral Runout Correction Indexing Brake Rotor Assembled Lateral Runout Correction - Indexing Special Tools * CH-39544-KIT - Complete Torque Socket Set - 10 PCS , or equivalent * CH-45101-100 - Conical Brake Rotor Washers For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). Note: * Brake rotor thickness variation MUST be checked BEFORE checking for assembled lateral runout (LRO). Thickness variation exceeding the maximum acceptable level can cause brake pulsation. Refer to Brake Rotor Thickness Variation Measurement (See: Brake Rotor Thickness Variation Measurement). * Brake rotor assembled LRO exceeding the maximum allowable specification can cause thickness variation to develop in the brake rotor over time, usually between 4,800-11, 300 km (3,000-7,000 mi). Refer to Brake Rotor Assembled Lateral Runout Measurement (See: Brake Rotor Assembled Lateral Runout Measurement). 1. Remove the CH-45101-100 - Conical Brake Rotor Washers and the lug nuts that were installed during the assembled LRO measurement procedure. 2. Inspect the mating surface of the hub/axle flange and the brake rotor to ensure that there are no foreign particles or debris remaining. 3. Index the brake rotor in a different orientation to the hub/axle flange. 4. Hold the rotor firmly in place against the hub/axle flange and install one of the CH-45101-100 - Conical Brake Rotor Washers (1) and one lug nut (2) onto the upper-most wheel stud. 5. Continue to hold the rotor secure and tighten the lug nut firmly by hand. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Testing and Inspection > Brake Pad and Rotor Burnishing > Page 9509 6. Install the remaining CH-45101-100 - Conical Brake Rotor Washers and lug nuts onto the wheel studs and tighten the nuts firmly by hand in a star-pattern. 7. Using the CH-39544-KIT - Complete Torque Socket Set - 10 PCS , or equivalent, tighten the lug nuts in a star-pattern to specification, in order to properly secure the rotor. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 8. Measure the assembled LRO of the brake rotor. Refer to Brake Rotor Assembled Lateral Runout Measurement (See: Brake Rotor Assembled Lateral Runout Measurement). 9. Compare the amount of change between this measurement and the original measurement. 10. If this measurement is within specifications, proceed to step 14. 11. If this measurement still exceeds specifications, repeat steps 1-9 until the best assembled LRO measurement is obtained. 12. Matchmark the final location of the rotor to the wheel studs if the orientation is different than it was originally. 13. If the brake rotor assembled LRO measurement still exceeds the maximum allowable specification, refer to Brake Rotor Assembled Lateral Runout Correction (See: Brake Rotor Assembled Lateral Runout Correction). 14. If the brake rotor assembled LRO is within specification, install the brake caliper and depress the brake pedal several times to secure the rotor in place before removing the CH-45101-100 - Conical Brake Rotor Washers and the lug nuts. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Testing and Inspection > Brake Pad and Rotor Burnishing > Page 9510 Brake Rotor/Disc: Testing and Inspection Brake Rotor Assembled Lateral Runout Correction - On Vehicle Lathe Brake Rotor Assembled Lateral Runout Correction - On Vehicle Lathe Special Tools CH-45101-100 - Conical Brake Rotor Washers For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). Note: * Brake rotor thickness variation MUST be checked BEFORE checking for assembled lateral runout (LRO). Thickness variation exceeding the maximum acceptable level can cause brake pulsation. Refer to Brake Rotor Thickness Variation Measurement (See: Brake Rotor Thickness Variation Measurement). * Brake rotor assembled LRO exceeding the maximum allowable specification can cause thickness variation to develop in the brake rotor over time, usually between 4 800-11 300 km (3,000-7,000 mi). Refer to Brake Rotor Assembled Lateral Runout Measurement (See: Brake Rotor Assembled Lateral Runout Measurement). 1. Ensure that the caliper and caliper bracket that are already being supported, are clear from contacting any rotating components, such as the brake rotor. 2. Remove the CH-45101-100 - Conical Brake Rotor Washers and the lug nuts that were installed during the assembled LRO measurement procedure and/or the indexing correction procedure. 3. Inspect the mounting surface of the hub/axle flange and the brake rotor to ensure that there are no foreign particles or debris remaining. 4. Set up the lathe, following the manufacturer's instructions. 5. Refinish the brake rotor, following the brake lathe manufacturer's instructions. 6. After each successive cut, inspect the brake rotor thickness. Refer to Brake Rotor Thickness Measurement (See: Brake Rotor Thickness Measurement). 7. If at any time the brake rotor exceeds the minimum allowable thickness after refinish specification, the brake rotor must be replaced. After replacing the rotor, proceed to step 10. 8. After refinishing the brake rotor, use the following procedure in order to obtain the desired non-directional finish: 1. Follow the brake lathe manufacturer's recommended speed setting for applying a non-directional finish. 2. Using moderate pressure, apply the non-directional finish: * If the lathe is equipped with a non-directional finishing tool, apply the finish with 120-grit aluminum oxide sandpaper. * If the lathe is not equipped with a non-directional finishing tool, apply the finish with a sanding block and 150-grit aluminum oxide sandpaper. 3. After applying a non-directional finish, clean each friction surface of the brake rotor with denatured alcohol, or an equivalent approved brake cleaner. 9. Remove the lathe from the vehicle. 10. Measure the assembled LRO of the brake rotor. Refer to Brake Rotor Assembled Lateral Runout Measurement (See: Brake Rotor Assembled Lateral Runout Measurement). 11. If the brake rotor assembled LRO measurement still exceeds the maximum allowable specification, refer to Brake Rotor Assembled Lateral Runout Correction (See: Brake Rotor Assembled Lateral Runout Correction). 12. If the brake rotor assembled LRO is within specification, install the brake caliper and depress the brake pedal several times to secure the rotor in place before removing the CH-45101-100 - Conical Brake Rotor Washers and the lug nuts. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Testing and Inspection > Brake Pad and Rotor Burnishing > Page 9511 Brake Rotor/Disc: Testing and Inspection Brake Pad and Rotor Burnishing Brake Pad and Rotor Burnishing Warning Road test a vehicle under safe conditions and while obeying all traffic laws. Do not attempt any maneuvers that could jeopardize vehicle control. Failure to adhere to these precautions could lead to serious personal injury and vehicle damage. Burnishing the brake pads and brake rotors is necessary in order to ensure that the braking surfaces are properly prepared after service has been performed on the disc brake system. This procedure should be performed whenever the disc brake rotors have been refinished or replaced, and/or whenever the disc brake pads have been replaced. 1. Select a smooth road with little or no traffic. 2. Accelerate the vehicle to 48 km/h (30 mph). Note: Use care to avoid overheating the brakes while performing this step. 3. Using moderate to firm pressure, apply the brakes to bring the vehicle to a stop. Do not allow the brakes to lock. 4. Repeat steps 2 and 3 until approximately 20 stops have been completed. Allow sufficient cooling periods between stops in order to properly burnish the brake pads and rotors. Brake Rotor Assembled Lateral Runout Correction Brake Rotor Assembled Lateral Runout Correction Note: * Brake rotor thickness variation MUST be checked BEFORE checking for assembled lateral runout (LRO). Thickness variation exceeding the maximum acceptable level can cause brake pulsation. Refer to Brake Rotor Thickness Variation Measurement (See: Brake Rotor Thickness Variation Measurement). * Brake rotor assembled lateral runout (LRO) exceeding the maximum allowable specification can cause thickness variation to develop in the brake rotor over time, usually between 4,800-11,300 km (3,000-7,000 mi). Refer to Brake Rotor Assembled Lateral Runout Measurement (See: Brake Rotor Assembled Lateral Runout Measurement). Review the following acceptable methods for bringing the brake rotor assembled LRO to within specifications. Determine which method to use for the specific vehicle being repaired. * The indexing method of correcting assembled LRO is most effective when the LRO specification is only exceeded by a relatively small amount: 0.025-0.127 mm (0.001-0.005 in). Indexing is used to achieve the best possible match of high spots to low spots between related components. Refer to Brake Rotor Assembled Lateral Runout Correction - Indexing (See: Brake Rotor Assembled Lateral Runout Correction - Indexing). * The on-vehicle brake lathe method is used to bring the LRO to within specifications through compensating for LRO while refinishing the brake rotor. Refer to Brake Rotor Assembled Lateral Runout Correction - On Vehicle Lathe (See: Brake Rotor Assembled Lateral Runout Correction On Vehicle Lathe). If the assembled LRO cannot be corrected using these methods, then other components must be suspected as causing and/or contributing to the LRO concern. Brake Rotor Assembled Lateral Runout Correction - Indexing Brake Rotor Assembled Lateral Runout Correction - Indexing Special Tools * CH-39544-KIT - Complete Torque Socket Set - 10 PCS , or equivalent * CH-45101-100 - Conical Brake Rotor Washers For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Testing and Inspection > Brake Pad and Rotor Burnishing > Page 9512 Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). Note: * Brake rotor thickness variation MUST be checked BEFORE checking for assembled lateral runout (LRO). Thickness variation exceeding the maximum acceptable level can cause brake pulsation. Refer to Brake Rotor Thickness Variation Measurement (See: Brake Rotor Thickness Variation Measurement). * Brake rotor assembled LRO exceeding the maximum allowable specification can cause thickness variation to develop in the brake rotor over time, usually between 4,800-11, 300 km (3,000-7,000 mi). Refer to Brake Rotor Assembled Lateral Runout Measurement (See: Brake Rotor Assembled Lateral Runout Measurement). 1. Remove the CH-45101-100 - Conical Brake Rotor Washers and the lug nuts that were installed during the assembled LRO measurement procedure. 2. Inspect the mating surface of the hub/axle flange and the brake rotor to ensure that there are no foreign particles or debris remaining. 3. Index the brake rotor in a different orientation to the hub/axle flange. 4. Hold the rotor firmly in place against the hub/axle flange and install one of the CH-45101-100 - Conical Brake Rotor Washers (1) and one lug nut (2) onto the upper-most wheel stud. 5. Continue to hold the rotor secure and tighten the lug nut firmly by hand. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Testing and Inspection > Brake Pad and Rotor Burnishing > Page 9513 6. Install the remaining CH-45101-100 - Conical Brake Rotor Washers and lug nuts onto the wheel studs and tighten the nuts firmly by hand in a star-pattern. 7. Using the CH-39544-KIT - Complete Torque Socket Set - 10 PCS , or equivalent, tighten the lug nuts in a star-pattern to specification, in order to properly secure the rotor. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 8. Measure the assembled LRO of the brake rotor. Refer to Brake Rotor Assembled Lateral Runout Measurement (See: Brake Rotor Assembled Lateral Runout Measurement). 9. Compare the amount of change between this measurement and the original measurement. 10. If this measurement is within specifications, proceed to step 14. 11. If this measurement still exceeds specifications, repeat steps 1-9 until the best assembled LRO measurement is obtained. 12. Matchmark the final location of the rotor to the wheel studs if the orientation is different than it was originally. 13. If the brake rotor assembled LRO measurement still exceeds the maximum allowable specification, refer to Brake Rotor Assembled Lateral Runout Correction (See: Brake Rotor Assembled Lateral Runout Correction). 14. If the brake rotor assembled LRO is within specification, install the brake caliper and depress the brake pedal several times to secure the rotor in place before removing the CH-45101-100 - Conical Brake Rotor Washers and the lug nuts. Brake Rotor Assembled Lateral Runout Correction - On Vehicle Lathe Brake Rotor Assembled Lateral Runout Correction - On Vehicle Lathe Special Tools CH-45101-100 - Conical Brake Rotor Washers For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). Note: * Brake rotor thickness variation MUST be checked BEFORE checking for assembled lateral runout (LRO). Thickness variation exceeding the maximum acceptable level can cause brake pulsation. Refer to Brake Rotor Thickness Variation Measurement (See: Brake Rotor Thickness Variation Measurement). * Brake rotor assembled LRO exceeding the maximum allowable specification can cause thickness variation to develop in the brake rotor over time, usually between 4 800-11 300 km (3,000-7,000 mi). Refer to Brake Rotor Assembled Lateral Runout Measurement (See: Brake Rotor Assembled Lateral Runout Measurement). 1. Ensure that the caliper and caliper bracket that are already being supported, are clear from contacting any rotating components, such as the brake rotor. 2. Remove the CH-45101-100 - Conical Brake Rotor Washers and the lug nuts that were installed during the assembled LRO measurement procedure and/or the indexing correction procedure. 3. Inspect the mounting surface of the hub/axle flange and the brake rotor to ensure that there are no foreign particles or debris remaining. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Testing and Inspection > Brake Pad and Rotor Burnishing > Page 9514 4. Set up the lathe, following the manufacturer's instructions. 5. Refinish the brake rotor, following the brake lathe manufacturer's instructions. 6. After each successive cut, inspect the brake rotor thickness. Refer to Brake Rotor Thickness Measurement (See: Brake Rotor Thickness Measurement). 7. If at any time the brake rotor exceeds the minimum allowable thickness after refinish specification, the brake rotor must be replaced. After replacing the rotor, proceed to step 10. 8. After refinishing the brake rotor, use the following procedure in order to obtain the desired non-directional finish: 1. Follow the brake lathe manufacturer's recommended speed setting for applying a non-directional finish. 2. Using moderate pressure, apply the non-directional finish: * If the lathe is equipped with a non-directional finishing tool, apply the finish with 120-grit aluminum oxide sandpaper. * If the lathe is not equipped with a non-directional finishing tool, apply the finish with a sanding block and 150-grit aluminum oxide sandpaper. 3. After applying a non-directional finish, clean each friction surface of the brake rotor with denatured alcohol, or an equivalent approved brake cleaner. 9. Remove the lathe from the vehicle. 10. Measure the assembled LRO of the brake rotor. Refer to Brake Rotor Assembled Lateral Runout Measurement (See: Brake Rotor Assembled Lateral Runout Measurement). 11. If the brake rotor assembled LRO measurement still exceeds the maximum allowable specification, refer to Brake Rotor Assembled Lateral Runout Correction (See: Brake Rotor Assembled Lateral Runout Correction). 12. If the brake rotor assembled LRO is within specification, install the brake caliper and depress the brake pedal several times to secure the rotor in place before removing the CH-45101-100 - Conical Brake Rotor Washers and the lug nuts. Brake Rotor Assembled Lateral Runout Measurement Brake Rotor Assembled Lateral Runout Measurement Special Tools * J-39544-KIT - Torque-Limiting Socket Set , or equivalent * J-41013 - Rotor Resurfacing Kit * J-42450-A - Wheel Hub Resurfacing Kit * J-45101 - Hub and Wheel Runout Gauge * J-45101-100 - Conical Brake Rotor Washers Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). Note: * Brake rotor assembled lateral runout (LRO) exceeding the maximum allowable specification can cause thickness variation to develop in the brake rotor over time, usually between 4,800-11,300 km (3,000-7,000 mi). * Brake rotor thickness variation MUST be checked BEFORE checking for assembled lateral runout (LRO). Thickness variation exceeding the maximum acceptable level can cause brake pulsation. Refer to Brake Rotor Thickness Variation Measurement (See: Brake Rotor Thickness Variation Measurement). 1. Matchmark the position of the brake rotor to the wheel studs if this has not been done already. Note: Whenever the brake rotor has been separated from the hub/axle flange, any rust or contaminants should be cleaned from the hub/axle flange and the brake rotor mating surfaces. Failure to do this may result in excessive assembled lateral runout (LRO) of the brake rotor, which could lead to brake pulsation. 2. Inspect the mating surface of the hub/axle flange and the brake rotor to ensure that there are no foreign particles, corrosion, rust, or debris remaining. If the wheel hub/axle flange and/or if the brake rotor mating surfaces exhibit these conditions, perform the following steps: 1. Remove the brake rotor from the vehicle. Refer to Front Brake Rotor Replacement (JD9, JF3, JF7, JG4) (See: Service and Repair/Front Brake Rotor Replacement (JD9, JF3, JF7, JG4))Front Brake Rotor Replacement (JH6, JH7) (See: Service and Repair/Front Brake Rotor Replacement (JH6, JH7)) and/or Rear Brake Rotor Replacement (JD9) (See: Service and Repair/Rear Brake Rotor Replacement (JD9))Rear Brake Rotor Replacement (JH6) (See: Service and Repair/Rear Brake Rotor Replacement (JH6))Rear Brake Rotor Replacement (JH7) (See: Service and Repair/Rear Brake Rotor Replacement (JH7)). 2. Using the J-42450-A - Wheel Hub Resurfacing Kit , thoroughly clean any rust or corrosion from the mating surface of the hub/axle flange. 3. Using the J-41013 - Rotor Resurfacing Kit , thoroughly clean any rust or corrosion from the mating surface of the brake rotor. 4. Clean the friction surfaces of the brake rotor with denatured alcohol, or an equivalent approved brake cleaner. 3. Install the rotor to the hub/axle flange using the matchmark made prior to removal. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Testing and Inspection > Brake Pad and Rotor Burnishing > Page 9515 4. Hold the rotor firmly in place against the hub/axle flange and install one of the J-45101-100 Conical Brake Rotor Washers (1), and one lug nut (2) onto the upper-most wheel stud. 5. Continue to hold the rotor secure and tighten the lug nut firmly by hand. 6. Install the remaining J-45101-100 - Conical Brake Rotor Washers and lug nuts onto the wheel studs and tighten the nuts firmly by hand in a star-pattern. 7. Using the J-39544-KIT - Torque-Limiting Socket Set , or equivalent, tighten the lug nuts in a star-pattern to specification, in order to properly secure the rotor. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 8. If the brake rotor has been REFINISHED or REPLACED with a new rotor, proceed to step 14. 9. If the brake rotor meets the following criteria, proceed to step 10. * The rotor is within specifications and is being REUSED * The rotor has NOT been refinished * The rotor does NOT exhibit thickness variation exceeding the maximum allowable level Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Testing and Inspection > Brake Pad and Rotor Burnishing > Page 9516 10. Mount a dial indicator, J-45101 - Hub and Wheel Runout Gauge , or equivalent, to the steering knuckle and position the indicator button so it contacts the brake rotor friction surface at a 90 degree angle, approximately 13 mm (0.5 in) from the outer edge of the rotor. 11. Measure and record the assembled LRO of the brake rotor. 1. Rotate the rotor until the lowest reading is displayed on the indicator dial, then set the dial to zero. 2. Rotate the rotor until the highest reading is displayed on the dial. 3. Mark the location of the high spot relative to the nearest wheel stud, or studs. 4. Measure and record the amount of LRO. 12. Compare the brake rotor assembled LRO to the following specifications: Brake rotor maximum allowable assembled lateral runout: 0.05 mm (0.002 in) Brake rotor maximum allowable assembled lateral runout: 0.05 mm (0.002 in) Brake rotor maximum allowable assembled lateral runout: 0.05 mm (0.002 in) 13. If the brake rotor assembled LRO is within specifications, proceed to step 18. If the brake rotor assembled LRO exceeds the specification, refinish the rotor to ensure true parallelism, refer to Brake Rotor Refinishing (See: Brake Rotor Refinishing). After refinishing the rotor, proceed to step 14. 14. Mount a dial indicator, J-45101 - Hub and Wheel Runout Gauge , or equivalent, to the steering knuckle and position the indicator button so it contacts the brake rotor friction surface at a 90 degree angle, approximately 13 mm (0.5 in) from the outer edge of the rotor. 15. Measure and record the assembled LRO of the brake rotor. 1. Rotate the rotor until the lowest reading is displayed on the indicator dial, then set the dial to zero. 2. Rotate the rotor until the highest reading is displayed on the dial. 3. Mark the location of the high spot relative to the nearest wheel stud, or studs. 4. Measure and record the amount of LRO. 16. Compare the brake rotor assembled LRO to the following specification: Brake rotor maximum allowable assembled lateral runout: 0.05 mm (0.002 in) Brake rotor maximum allowable assembled lateral runout: 0.13 mm (0.005 in) 17. If the brake rotor assembled LRO measurement exceeds the specification, bring the LRO to within specifications. Refer to Brake Rotor Assembled Lateral Runout Correction (See: Brake Rotor Assembled Lateral Runout Correction). 18. If the brake rotor assembled LRO measurement is within specification, install the brake caliper and depress the brake pedal several times to secure the rotor in place before removing the J-45101-100 - Conical Brake Rotor Washers and the lug nuts. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Testing and Inspection > Brake Pad and Rotor Burnishing > Page 9517 Brake Rotor Refinishing Brake Rotor Refinishing Special Tools * CH-41013 - Rotor Resurfacing Kit * CH-42450-A - Wheel Hub Resurfacing Kit For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). Note: * The disc brake rotors do not require refinishing as part of routine brake system service. New disc brake rotors do not require refinishing. Do not refinish disc brake rotors in an attempt to correct the following conditions: - Brake system noise - squeal, growl, groan - Uneven and/or premature disc brake pad wear - Superficial or cosmetic corrosion/rust of the disc brake rotor friction surface - Scoring of the disc brake rotor friction surface less than the maximum allowable specification * Before refinishing a brake rotor, the rotor MUST first be checked for adequate thickness to allow the rotor to be refinished and remain above the minimum allowable thickness after refinish specification. Refer to Brake Rotor Thickness Measurement (See: Brake Rotor Thickness Measurement). Disc brake rotors should only be refinished if they have adequate thickness to be refinished and if one or more of the following conditions exist: - Thickness variation in excess of the maximum allowable specification - Excessive corrosion/rust and/or pitting - Cracks and/or heat spots - Excessive blueing discoloration - Scoring of the disc brake rotor surface in excess of the maximum allowable specification * Disc brake rotors may need to be refinished as part of the process for correcting brake rotor assembled lateral runout (LRO) that exceeds the maximum allowable specification. Note: If the vehicle is equipped with cross-drilled rotors, use a lathe with positive rake tooling. This setup requires less cutting pressure, which will result in less vibration, and a better surface finish. Also, use a vibration dampener when cutting. Otherwise, refinish according to the following instructions. Note: Whenever the brake rotor has been separated from the hub/axle flange, clean any rust or contaminants from the hub/axle flange and the brake rotor mating surfaces. Failure to do this may result in increased assembled lateral runout (LRO) of the brake rotor, which could lead to brake pulsation. 1. Using the CH-42450-A - Wheel Hub Resurfacing Kit , thoroughly clean any rust or corrosion from the mating surface of the hub/axle flange. 2. Using the CH-41013 - Rotor Resurfacing Kit , thoroughly clean any rust or corrosion from the mating surface and mounting surface of the brake rotor. 3. Inspect the mating surfaces of the hub/axle flange and the rotor to ensure that there are no foreign particles or debris remaining. 4. Mount the brake rotor to the brake lathe according to the lathe manufacturer's instructions, ensuring that all mounting attachments and adapters are clean and free of debris. 5. Ensure that any vibration dampening attachments are securely in place. 6. With the brake lathe running, slowly bring in the cutting tools until they just contact the brake rotor friction surfaces. 7. Observe the witness mark on the brake rotor. If the witness mark extends approximately three-quarters or more of the way around the brake rotor friction surface on each side, the brake rotor is properly mounted to the lathe. 8. If the witness mark does not extend three-quarters or more of the way around the brake rotor, re-mount the rotor to the lathe. 9. Following the brake lathe manufacturer's instructions, refinish the brake rotor. 10. After each successive cut, inspect the brake rotor thickness. Refer to Brake Rotor Thickness Measurement (See: Brake Rotor Thickness Measurement). 11. If at any time the brake rotor exceeds the minimum allowable thickness after refinish specification, the brake rotor must be replaced. 12. After refinishing the brake rotor, use the following procedure in order to obtain the desired non-directional finish: 1. Follow the brake lathe manufacturer's recommended speed setting for applying a non-directional finish. 2. Using moderate pressure, apply the non-directional finish: * If the lathe is equipped with a non-directional finishing tool, apply the finish with 120-grit aluminum oxide sandpaper. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Testing and Inspection > Brake Pad and Rotor Burnishing > Page 9518 * If the lathe is not equipped with a non-directional finishing tool, apply the finish with a sanding block and 150-grit aluminum oxide sandpaper. 3. After applying a non-directional finish, clean each friction surface of the brake rotor with denatured alcohol, or an equivalent approved brake cleaner and wipe each friction surface using a clean shop towel to remove metal particles remaining from machining. Repeat the cleaning process if necessary to remove all metal particles. 13. Remove the brake rotor from the brake lathe. 14. Measure the assembled LRO of the brake rotor to ensure optimum performance of the disc brakes. Refer to Brake Rotor Assembled Lateral Runout Measurement (See: Brake Rotor Assembled Lateral Runout Measurement). 15. If the brake rotor assembled LRO measurement exceeds the specification, bring the LRO to within specifications. Refer to Brake Rotor Assembled Lateral Runout Correction (See: Brake Rotor Assembled Lateral Runout Correction). Brake Rotor Surface and Wear Inspection Brake Rotor Surface and Wear Inspection Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). 1. If the inboard friction surface of the brake rotor is not accessible, reposition and support the caliper with the brake pads. Refer to Front Disc Brake Pads Replacement (JD9, JF3, JF7, JG4) (See: Brake Pad/Service and Repair/Removal and Replacement/Front Disc Brake Pads Replacement (JD9, JF3, JF7, JG4))Front Disc Brake Pads Replacement (JH6, JH7) (See: Brake Pad/Service and Repair/Removal and Replacement/Front Disc Brake Pads Replacement (JH6, JH7)) and/or Rear Disc Brake Pads Replacement (JD9) (See: Brake Pad/Service and Repair/Removal and Replacement/Rear Disc Brake Pads Replacement (JD9))Rear Disc Brake Pads Replacement (JH6, JH7) (See: Brake Pad/Service and Repair/Removal and Replacement/Rear Disc Brake Pads Replacement (JH6, JH7)). 2. Clean the friction surfaces of the brake rotor with denatured alcohol, or an equivalent approved brake cleaner. 3. Inspect the friction surfaces of the brake rotor for the following Braking Surface Conditions: * Heavy rust and/or pitting Light surface rust can be removed with an abrasive disc. Heavy surface rust and/or pitting must be removed by refinishing the rotor. * Cracks and/or heat spots * Excessive blueing discoloration 4. If the friction surfaces of the brake rotor exhibit one or more of the Braking Surface Conditions, the rotor requires refinishing or replacement. 5. Using a micrometer calibrated in thousandths-of-a-millimeter, or ten-thousandths-of-an-inch, measure and record the scoring depth of any grooves present on the rotor friction surfaces. 6. Compare the groove scoring depth recorded to the following specification: Brake rotor maximum allowable scoring: 1.50 mm (0.059 in) 7. If the brake rotor scoring depth exceeds the specification, or if an excessive amount of scoring is present, the rotor requires refinishing or replacement. Brake Rotor Thickness Measurement Brake Rotor Thickness Measurement Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning) 1. If the inboard friction surface of the brake rotor is not accessible, reposition and support the caliper with the brake pads. Refer to Front Disc Brake Pads Replacement (JD9, JF3, JF7, JG4) (See: Brake Pad/Service and Repair/Removal and Replacement/Front Disc Brake Pads Replacement (JD9, JF3, JF7, JG4))Front Disc Brake Pads Replacement (JH6, JH7) (See: Brake Pad/Service and Repair/Removal and Replacement/Front Disc Brake Pads Replacement (JH6, JH7)) and/or Rear Disc Brake Pads Replacement (JD9) (See: Brake Pad/Service and Repair/Removal and Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Testing and Inspection > Brake Pad and Rotor Burnishing > Page 9519 Replacement/Rear Disc Brake Pads Replacement (JD9))Rear Disc Brake Pads Replacement (JH6, JH7) (See: Brake Pad/Service and Repair/Removal and Replacement/Rear Disc Brake Pads Replacement (JH6, JH7)). 2. Clean the friction surfaces of the brake rotor with denatured alcohol, or an equivalent approved brake cleaner. 3. Using a micrometer calibrated in thousandths-of-a-millimeter, or ten-thousandths-of-an-inch, measure and record the thickness of the brake rotor at four or more points, evenly spaced around the rotor. Ensure that the measurements are only taken within the friction surfaces and that the micrometer is positioned the same distance from the outer edge of the rotor, about 13 mm (1/2 in) for each measurement. 4. Compare the lowest thickness measurement recorded to the following specifications: - Brake rotor minimum allowable thickness after refinishing 37.0 mm (1.457 in) - Brake rotor discard thickness 36.50 mm (1.437 in) - Brake rotor minimum allowable thickness after refinishing 28.0 mm (1.10 in) - Brake rotor discard thickness 28.0 mm (1.10 in) - Brake rotor minimum allowable thickness after refinishing 18.5 mm (0.728 in) - Brake rotor discard thickness 18.0 mm (0.709 in) - Brake rotor minimum allowable thickness after refinishing 28.0 mm (1.102 in) - Brake rotor discard thickness 27.50 mm (1.083 in) - Brake rotor minimum allowable thickness after refinishing 29.0 mm (1.142 in) - Brake rotor discard thickness 28.50 mm (1.122 in) 5. If the lowest thickness measurement of the brake rotor is above the minimum allowable thickness after refinishing specification, the rotor may be able to be refinished, depending upon surface and wear conditions which may be present. 6. If the lowest thickness measurement of the brake rotor is at or below the minimum allowable thickness after refinishing specification, the rotor may not be refinished. 7. If the lowest thickness measurement of the brake rotor is at or below the discard thickness specification, the rotor requires replacement. Brake Rotor Thickness Variation Measurement Brake Rotor Thickness Variation Measurement Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). Note: Any disc brake rotor that exhibits thickness variation exceeding the maximum acceptable level must be refinished or replaced. Thickness variation exceeding the maximum acceptable level can cause brake pulsation. 1. If the inboard friction surface of the brake rotor is not accessible, reposition and support the caliper with the brake pads. Refer to Front Disc Brake Pads Replacement (JD9, JF3, JF7, JG4) (See: Brake Pad/Service and Repair/Removal and Replacement/Front Disc Brake Pads Replacement (JD9, JF3, JF7, JG4))Front Disc Brake Pads Replacement (JH6, JH7) (See: Brake Pad/Service and Repair/Removal and Replacement/Front Disc Brake Pads Replacement (JH6, JH7)) and/or Rear Disc Brake Pads Replacement (JD9) (See: Brake Pad/Service and Repair/Removal and Replacement/Rear Disc Brake Pads Replacement (JD9))Rear Disc Brake Pads Replacement (JH6, JH7) (See: Brake Pad/Service and Repair/Removal and Replacement/Rear Disc Brake Pads Replacement (JH6, JH7)). 2. Clean the friction surfaces of the brake rotor with denatured alcohol, or an equivalent approved brake cleaner. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Testing and Inspection > Brake Pad and Rotor Burnishing > Page 9520 3. Using a micrometer calibrated in thousandths-of-a-millimeter, or ten-thousandths-of-an-inch, measure and record the thickness of the brake rotor at four or more points, evenly spaced around the rotor. Ensure that the measurements are only taken within the friction surfaces and that the micrometer is positioned the same distance from the outer edge of the rotor, about 13 mm (1/2 in), for each measurement. 4. Calculate the difference between the highest and lowest thickness measurement recorded to obtain the amount of thickness variation. 5. Compare the thickness variation measurement to the following specifications: Brake rotor maximum allowable thickness variation: 0.025 mm (0.001 in) Brake rotor maximum allowable thickness variation: 0.018 mm (0.0007 in) Brake rotor maximum allowable thickness variation: 0.018 mm (0.0007 in) Note: Whenever a brake rotor is refinished or replaced, the assembled lateral runout (LRO) of the rotor must be measured to ensure optimum performance of the disc brakes. 6. If the brake rotor thickness variation measurement exceeds the specification, the rotor requires refinishing or replacement. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Front Brake Rotor Replacement (JD9, JF3, JF7, JG4) Brake Rotor/Disc: Service and Repair Front Brake Rotor Replacement (JD9, JF3, JF7, JG4) Front Brake Rotor Replacement (JD9, JF3, JF7, JG4) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Front Brake Rotor Replacement (JD9, JF3, JF7, JG4) > Page 9523 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Front Brake Rotor Replacement (JD9, JF3, JF7, JG4) > Page 9524 Brake Rotor/Disc: Service and Repair Front Brake Rotor Replacement (JH6, JH7) Front Brake Rotor Replacement (JH6, JH7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Front Brake Rotor Replacement (JD9, JF3, JF7, JG4) > Page 9525 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Front Brake Rotor Replacement (JD9, JF3, JF7, JG4) > Page 9526 Brake Rotor/Disc: Service and Repair Rear Brake Rotor Replacement (JD9) Rear Brake Rotor Replacement (JD9) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Front Brake Rotor Replacement (JD9, JF3, JF7, JG4) > Page 9527 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Front Brake Rotor Replacement (JD9, JF3, JF7, JG4) > Page 9528 Brake Rotor/Disc: Service and Repair Rear Brake Rotor Replacement (JH6) Rear Brake Rotor Replacement (JH6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Front Brake Rotor Replacement (JD9, JF3, JF7, JG4) > Page 9529 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Front Brake Rotor Replacement (JD9, JF3, JF7, JG4) > Page 9530 Brake Rotor/Disc: Service and Repair Rear Brake Rotor Replacement (JH7) Rear Brake Rotor Replacement (JH7) Removal Procedure Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). 1. Release the park brake. 2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 3. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair ). 4. Remove the hub and rotor assembly. Refer to Rear Axle Hub, Bearing, Cup, and/or Seal Replacement (See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Bearing/Service and Repair/Rear Axle Hub, Bearing, Cup, and/or Seal Replacement). 5. Mark the relationship of the hub to the rotor. 6. Place the hub and rotor assembly on a hydraulic press. 7. Press the wheel studs out of the hub and rotor assembly. 8. Separate the hub from the rotor. Installation Procedure 1. Align the hub and the rotor. 2. Install each of the new wheel studs into the hub and rotor assembly by performing the following: 1. Install the stud. 2. Install 4 washers to the stud. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Front Brake Rotor Replacement (JD9, JF3, JF7, JG4) > Page 9531 3. Install a lug nut to the stud with the flat side of the nut toward the washers. 4. Tighten the lug nut to draw the stud into the hub and rotor assembly. 5. Inspect the hub and rotor assembly to ensure the stud is seated completely. 6. Remove the lug nut and the washers. 3. Install the hub and rotor assembly to the vehicle. Refer to Rear Axle Hub, Bearing, Cup, and/or Seal Replacement (See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Bearing/Service and Repair/Rear Axle Hub, Bearing, Cup, and/or Seal Replacement). 4. With the engine OFF, gradually apply the brake pedal to 2/3 of its travel distance. 5. Slowly release the brake pedal. 6. Wait 15 seconds, then repeat steps 4-5 until a firm brake pedal is obtained. This will properly seat the brake caliper pistons and brake pads. 7. Fill the master cylinder reservoir, if necessary. Refer to Master Cylinder Reservoir Filling (Non-Hybrid) (See: Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Reservoir Filling)Master Cylinder Reservoir Filling (Two-mode Hybrid) (See: Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Reservoir Filling). 8. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 9. If the brake rotor was refinished or replaced, burnish the brake pads and rotors. Refer to Brake Pad and Rotor Burnishing (See: Brake Pad/Service and Repair/Procedures). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Service and Repair Backing Plate: Service and Repair Rear Brake Backing Plate Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Specifications Brake Drum: Specifications Brake drum maximum allowable scoring .................................................................................................................................................... 1.5 mm (0.06 in) Maximum allowable radial runout ......................................................................................................................................................... 0.06 mm (0.0024 in) Maximum allowable diameter ............................................................................................................................................................. 296.5 mm (11.673 in) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Testing and Inspection > Brake Drum Diameter Measurement Brake Drum: Testing and Inspection Brake Drum Diameter Measurement Brake Drum Diameter Measurement 1. Clean the brake shoe lining contact surface of the brake drum with denatured alcohol or an equivalent brake cleaner. 2. Using a brake drum micrometer calibrated in thousands of an inch, measure and record the largest diameter of the brake drum at 4 or more points, equally spaced around the drum. Ensure that the measurements are only taken within the brake shoe lining contact area and that the micrometer is positioned the same distance from the outside edge of the drum for each measurement. 3. The maximum allowable diameter : Maximum allowable measurement 296.5 mm (11.673 in) 4. If the largest diameter measurement of the brake drum is less than the maximum allowable diameter, the drum may be able to be resurfaced, depending upon surface and wear conditions which may be present. 5. If the largest diameter measurement of the brake drum is equal to or greater than the maximum allowable measurement, the drum requires replacement. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Testing and Inspection > Brake Drum Diameter Measurement > Page 9541 Brake Drum: Testing and Inspection Brake Drum Surface and Wear Inspection Brake Drum Surface and Wear Inspection Special Tools J 8001 Dial Indicator Set, or equivalent Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). 1. With the brake drum removed, clean the braking (friction) surface of the brake drum with denatured alcohol or an equivalent approved brake cleaner. 2. Inspect the braking surface of the brake drum for the following braking surface conditions: * Heavy rust and/or pitting-Light surface rust can be removed with an abrasive disc. Heavy surface rust and/or pitting must be removed by refinishing the drum. * Cracks and/or heat spots * Excessive blueing discoloration * Missing balance weights 3. If the braking surface of the brake drum exhibits 1 or more of the braking surface conditions, the drum requires refinishing or replacement. 4. Using a brake drum micrometer calibrated in thousands of an inch, measure and record any grooves present on the drum braking surface. Ensure that the measurements are only taken within the brake shoe lining contact area. 5. Compare the groove, scoring, depth recorded to the following specification: Brake drum maximum allowable scoring 1.5 mm (0.06 in). 6. If the brake drum scoring depth exceeds the specification, or if an excessive amount of scoring is present, the drum requires refinishing or replacement. 7. Mount the brake drum on a brake lathe. 8. Mount a dial indicator, J 8001 or equivalent, and position the indicator button so it contacts the braking surface of the brake drum at a 90 degree angle, approximately 19 mm (0.75 in) from the drum's outer edge. 9. Measure and record the radial runout of the brake drum. 1. Rotate the drum until the lowest reading is displayed on the indicator dial, then zero the dial. 2. Rotate the drum until the highest reading is displayed on the dial. 10. Compare the radial runout of the brake drum to the following specification: Brake drum maximum allowable radial runout 0.06 mm (0.0024 in). 11. If the brake drum radial runout exceeds the specification, the drum requires refinishing or replacement. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Service and Repair > Procedures Brake Drum: Procedures Brake Drum Refinishing Special Tools * J 41013 Rotor/Drum Flange Resurfacing Kit * J 42450-A Hub Cleaning Kit Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). 1. The brake drums do not require refinishing as part of routine brake system service. Do not refinish brake drums in an attempt to correct the following conditions: * Brake system noise (squeal, growl, groan) * Uneven and/or premature brake lining wear * Superficial or cosmetic corrosion/rust of the brake drum surface * Scoring of the brake drum surface (less than the maximum allowable specification) 2. Brake drums should only be refinished if the following conditions exist: * Excessive corrosion/rust and/or pitting * Cracks and/or heat spots * Excessive blueing discoloration * Scoring of the brake drum surface (in excess of the maximum allowable specification) * Radial runout in excess of the maximum allowable specification 3. Inspect each of the brake drums and determine if the brake drums can be refinished and remain within the maximum allowable diameter after refinish specification: 1. With the tire and wheel assemblies removed, measure the diameter of each of the brake drums. Refer to Brake Drum Diameter Measurement ( See: Testing and Inspection/Brake Drum Diameter Measurement). 2. Inspect each of the brake drums for excessive surface wear and/or radial runout. Refer to Brake Drum Surface and Wear Inspection (See: Testing and Inspection/Brake Drum Surface and Wear Inspection). 4. If the brake drums can be refinished, proceed with the rotor refinishing procedure. 5. If necessary, use the J 41013 in order to thoroughly clean any corrosion/rust from the brake drum flange. 6. Mount the brake drum to the brake lathe according to the lathe manufacturer's instructions. 7. Ensure that any vibration dampening attachments are securely in place. 8. With the brake lathe running, slowly bring in the cutting tool until it just contacts the brake drum friction surface. 9. Observe the witness mark on the brake drum. If the witness mark extends approximately three-quarters or more of the way around the brake drum surface, the brake drum is properly mounted to the lathe. 10. If the witness mark does not extend three-quarters or more of the way around the brake drum, re-mount the brake drum to the lathe. 11. Following the brake lathe manufacturer's instructions, refinish the brake drum. 12. After each successive cut, inspect the brake drum diameter. Refer to Brake Drum Diameter Measurement (See: Testing and Inspection/Brake Drum Diameter Measurement). 13. If at any time the brake drum exceeds the maximum allowable diameter after refinish specification, the brake drum must be replaced. 14. After refinishing the brake drum, use the following procedure in order to obtain the desired non-directional finish: 1. Follow the brake lathe manufacturer's recommended speed setting for applying a non-directional finish 2. Using moderate pressure, apply the non-directional finish: * If the lathe is equipped with a non-directional finishing tool, apply the finish with 120 grit aluminum oxide sandpaper. * If the lathe is not equipped with a non-directional finishing tool, apply the finish with a sanding block and 150 grit aluminum oxide sandpaper. 3. After applying a non-directional finish, clean the friction surface of the brake drum with denatured alcohol or an equivalent brake cleaner and wipe the friction surface using a clean shop towel to remove metal particles remaining from machining. Repeat the cleaning process if necessary to remove all metal particles. 15. Remove the brake drum from the brake lathe. Note: Failure to clean the corrosion from the wheel bearing flange may result in increased lateral runout of the brake drum and brake system pulsation. 16. If necessary, use the J 42450-A in order to thoroughly clean any corrosion from the wheel bearing flange. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Service and Repair > Procedures > Page 9544 Brake Drum: Removal and Replacement Brake Drum Replacement Special Tools J-42450-A - Wheel Hub Resurfacing Kit Removal Procedure Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair ). 3. Remove and discard the brake drum retainers (1), if equipped. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Service and Repair > Procedures > Page 9545 4. Remove the brake drum (1). 5. If the brake shoes prevent the brake drum from being removed, retract the brake shoe adjuster. Refer to Drum Brake Adjustment (See: Adjustments). Installation Procedure 1. Using the J-42450-A - Wheel Hub Resurfacing Kit , remove any corrosion from the rear axle flange contact surface. 2. Install the brake drum (1). 3. Adjust the drum brakes. Refer to Drum Brake Adjustment (See: Adjustments). 4. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications Brake Shoe: Specifications Replace the shoe and lining assemblies when the thickness of any lining is worn within 0.72 mm (0.030 in) of the shoe. Replace riveted shoe and lining assemblies when the lining is worn to within 0.76 mm (0.030 in) of any rivet head. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications > Page 9549 Brake Shoe: Testing and Inspection Brake Shoe Inspection Inspect the linings every 9 650 km (6,000 mi) and any time the wheels are removed (tire rotation, etc.). Inspect the lining for wear by removing the plug and using the inspection hole. Replace the shoe and lining assemblies when the thickness of any lining is worn within 0.72 mm (0.030 in) of the shoe. Replace riveted shoe and lining assemblies when the lining is worn to within 0.76 mm (0.030 in) of any rivet head. Always replace shoe and lining assemblies as a complete axle set. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications > Page 9550 Brake Shoe: Service and Repair Brake Shoe Replacement Removal Procedure Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). 1. Remove the brake drum. Refer to Brake Drum Replacement (See: Brake Drum/Service and Repair/Removal and Replacement). 2. Remove the brake shoe adjuster actuator lever spring (1). 3. Remove the adjuster actuator lever (1). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications > Page 9551 4. Spread the brake shoes apart slightly and remove the brake shoe adjuster (1). 5. Inspect and replace any missing, worn, or damaged drum brake adjuster hardware. Refer to Drum Brake Adjusting Hardware Inspection (See: Testing and Inspection/Drum Brake Adjusting Hardware Inspection). 6. Remove the brake shoe hold down springs and cups (1). Compress the spring and rotate the assembly 1/4 turn to remove from the hold down pins. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications > Page 9552 7. Remove the lower brake shoe spring (1). 8. Rotate the primary brake shoe (1) outward, disengage the return spring from the brake shoe web and remove the primary brake shoe. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications > Page 9553 9. Remove the brake shoe return spring. 10. Compress the park brake cable spring, disengage the park brake cable fitting end from the park brake lever and remove the secondary brake shoe (1). 11. Clean the backing plate and apply high temperature brake lubricant to the brake shoe contact surfaces of the rear brake backing plate. 12. Inspect and replace any missing, worn, or damaged drum brake hardware. Refer to Drum Brake Hardware Inspection (See: Testing and Inspection/Drum Brake Hardware Inspection). Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications > Page 9554 1. Compress the park brake cable spring and insert the park brake cable fitting end to the park brake on the secondary brake shoe (1). Position the secondary brake shoe to the rear brake backing plate. 2. Install the brake shoe return spring. Insert the hook end of the return spring to the brake shoe from behind the web. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications > Page 9555 3. Install the primary brake (1) shoe return spring and position the primary brake shoe to the rear brake backing plate. Insert the hook end of the return spring to the brake shoe web from the outer face. 4. Install the lower brake shoe spring (1). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications > Page 9556 5. Install the brake shoe hold down springs and cups (1). Compress the spring and rotate the assembly 1/4 turn to install to the hold down pins. 6. Disassemble, clean and lubricate the threads of the brake shoe adjuster with high temperature brake lubricant. 7. Assemble the brake shoe adjuster. 8. Spread the brake shoes apart slightly and install the brake shoe adjuster (1). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications > Page 9557 9. Install the adjuster actuator lever (1) to the pivot pin on the primary brake shoe. 10. Install the brake shoe adjuster actuator lever spring (1). 11. Install the brake drum. Refer to Brake Drum Replacement (See: Brake Drum/Service and Repair/Removal and Replacement). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair Wheel Cylinder: Service and Repair Rear Brake Cylinder Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Antilock Brake Automated Bleed Procedure Brake Bleeding: Service and Repair Antilock Brake Automated Bleed Procedure Less Than 3900 KG (8600 Lb) GVW Antilock Brake System Automated Bleed Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings). Note: The base hydraulic brake system must be bled before performing this automated bleeding procedure. If you have not yet performed the base hydraulic brake system bleeding procedure, refer to Hydraulic Brake System Bleeding (Manual) (See: )Hydraulic Brake System Bleeding (Pressure) ( See: )Hydraulic Brake System Bleeding (Two-mode Hybrid) (See: ) before proceeding. 1. Install a scan tool to the vehicle. 2. Start the engine and allow the engine to idle. 3. Using the scan tool, begin the automated bleed procedure. 4. Follow the instructions on the scan tool to complete the automated bleed procedure. Apply the brake pedal when instructed by the scan tool. 5. Turn the ignition OFF. 6. Remove the scan tool from the vehicle. 7. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 8. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) (See: )Hydraulic Brake System Bleeding (Pressure) ( See: )Hydraulic Brake System Bleeding (Two-mode Hybrid) (See: ). 9. With the ignition OFF, apply the brakes 3-5 times, or until the brake pedal becomes firm, in order to deplete the brake booster power reserve. 10. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 11. If the brake pedal feels spongy, repeat the automated bleeding procedure. If the brake pedal still feels spongy after repeating the automated bleeding procedure inspect the brake system for external leaks. Refer to Brake System External Leak Inspection (See: Testing and Inspection/Component Tests and General Diagnostics/Brake System External Leak Inspection). 12. Turn the ignition key ON, with the engine OFF; check to see if the brake system warning lamp remains illuminated. 13. If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. Refer to Symptoms - Hydraulic Brakes (See: Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Hydraulic Brakes). 14. Drive the vehicle to exceed 13 km/h (8 mph) to allow ABS initialization to occur. Observe brake pedal feel. 15. If the brake pedal feels spongy, repeat the automated bleeding procedure until a firm brake pedal is obtained. Greater Than/Equal to 3900 KG (8600 Lb) GVW Antilock Brake System Automated Bleed Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings). Note: * Before performing the ABS Automated Bleed Procedure, first perform a manual or pressure bleed of the base hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) (See: )Hydraulic Brake System Bleeding (Pressure) (See: )Hydraulic Brake System Bleeding (Two-mode Hybrid) (See: ). * The automated bleed procedure must be performed when a new brake pressure modulator valve (BPMV) is installed, because the secondary circuits of the new BPMV are not prefilled with brake fluid. * The automated bleed procedure is recommended when one of the following conditions exist: * Base brake system bleeding does not achieve the desired pedal height or feel * Extreme loss of brake fluid has occurred * Air ingestion is suspected in the secondary circuits of the brake modulator assembly The ABS Automated Bleed Procedure uses a scan tool to cycle the system solenoid valves and run the pump in order to purge any air from the secondary circuits. These circuits are normally closed off, and are only opened during system initialization at vehicle start up and during ABS operation. The automated bleed procedure opens these secondary circuits and allows any air trapped in these circuits to flow out away from the brake modulator assembly, which is then forced out at the brake corners by the pressure bleeder. Automated Bleed Procedure Caution: The Auto Bleed Procedure may be terminated at any time during the process by pressing the EXIT button. No further Scan Tool prompts pertaining to the Auto Bleed procedure will be given. After exiting the bleed procedure, relieve bleed pressure and disconnect bleed equipment per manufacturers instructions. Failure to properly relieve pressure may result in spilled brake fluid causing damage to components and Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Antilock Brake Automated Bleed Procedure > Page 9566 painted surfaces. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 3. Inspect the brake system for leaks and visual damage. Refer to Symptoms - Hydraulic Brakes (See: Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Hydraulic Brakes). Repair or replace components as needed. 4. Lower the vehicle. 5. Prepare the brake bleeding equipment and the vehicle for a pressure bleed of the base hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) (See: )Hydraulic Brake System Bleeding (Pressure) (See: )Hydraulic Brake System Bleeding (Two-mode Hybrid) (See: ). 6. Inspect the battery state of charge. Refer to Battery Inspection/Test (See: Starting and Charging/Testing and Inspection/Component Tests and General Diagnostics). 7. Install a scan tool. 8. Turn the ignition ON, with the engine OFF. 9. With the scan tool, perform the following steps: 1. Select Diagnostics 2. Select the appropriate vehicle information 3. Select Chassis 4. Select Electronic Brake Control Module (EBCM) 5. Select Special Functions 6. Select Automated Bleed 10. With an assistant ready, raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). Note: * Apply the brake pedal when instructed, using moderate effort. * Ensure the pedal remains applied until instructed to release by the scan tool. * Do not exceed the time period allowed by the scan tool for having the bleeder valves open. * The bleed sequence for each corner is as follows: - Left front - Right front - Right rear - Left rear 11. Perform the automated bleed procedure as instructed by the scan tool. 12. If the automated bleed procedure is aborted, a malfunction exists. If a DTC is detected, refer to Diagnostic Trouble Code (DTC) List - Vehicle ( See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle) to diagnose the DTC. 13. After completion of the automated bleed procedure, press and hold the brake pedal to inspect for pedal firmness. 14. If the brake pedal feels spongy, repeat the bleed procedure completely. 15. Remove the scan tool. 16. Install the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair ). 17. Lower the vehicle. 18. Adjust the brake fluid level. Refer to Master Cylinder Reservoir Filling (Non-Hybrid) (See: Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Reservoir Filling)Master Cylinder Reservoir Filling (Two-mode Hybrid) (See: Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Reservoir Filling). 19. Road test the vehicle while confirming the brake pedal remains high and firm. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Antilock Brake Automated Bleed Procedure > Page 9567 Brake Bleeding: Service and Repair Hydraulic Brake Bleeding (Manual) Hydraulic Brake System Bleeding (Manual) Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings). 1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort increases significantly, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add GM approved brake fluid from a clean, sealed brake fluid container. Refer to Fluid and Lubricant Recommendations (USA and Canada) (See: Maintenance). If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. 2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 4. Reconnect the brake pipe to the master cylinder port and tighten securely. 5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the master cylinder. 9. With the front brake pipe installed securely to the master cylinder, after all air has been purged from the front port of the master cylinder, loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8. 10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 4. Fill the brake master cylinder reservoir with GM approved brake fluid from a clean, sealed brake fluid container. Refer to Master Cylinder Reservoir Filling (Non-Hybrid) (See: Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Reservoir Filling )Master Cylinder Reservoir Filling (Two-mode Hybrid) (See: Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Reservoir Filling). Ensure that the brake master cylinder reservoir remains at least half-full during this bleeding procedure. Add fluid as needed to maintain the proper level. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 6. Install a transparent hose over the end of the bleeder valve. 7. Submerge the open end of the transparent hose into a transparent container partially filled with GM approved brake fluid from a clean, sealed brake fluid container. Refer to Fluid and Lubricant Recommendations (USA and Canada) (See: Maintenance). 8. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 9. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. 10. Tighten the bleeder valve, then have the assistant slowly release the brake pedal. 11. Wait 15 seconds, then repeat steps 8-10 until all air is purged from the same wheel hydraulic circuit. 12. With the right rear wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the right rear hydraulic circuit install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 13. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 14. With the left rear wheel hydraulic circuit bleeder valve tightened securely, after all air purged from the left rear hydraulic circuit, install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve. 15. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 16. With the right front wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the right front hydraulic circuit, install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 17. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 18. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. 19. Fill the brake master cylinder reservoir to the maximum-fill level with GM approved brake fluid from a clean, sealed brake fluid container. Refer to Master Cylinder Reservoir Filling (Non-Hybrid) (See: Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Reservoir Filling)Master Cylinder Reservoir Filling (Two-mode Hybrid) (See: Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Reservoir Filling). 20. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 21. If the brake pedal feels spongy, repeat the bleeding procedure again. If the brake pedal still feels spongy after repeating the bleeding procedure, perform the following steps: 1. Inspect the brake system for external leaks. Refer to Brake System External Leak Inspection (See: Testing and Inspection/Component Tests and General Diagnostics/Brake System External Leak Inspection). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Antilock Brake Automated Bleed Procedure > Page 9568 2. Pressure bleed the hydraulic brake system in order to purge any air that may still be trapped in the system. 22. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. Note: If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. 23. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic Brakes (See: Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Hydraulic Brakes). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Antilock Brake Automated Bleed Procedure > Page 9569 Brake Bleeding: Service and Repair Hydraulic Brake Bleeding (Pressure) Hydraulic Brake System Bleeding (Pressure) Special Tools * J-29532 - Diaphragm Pressure Bleeder, or equivalent * J-35589-A - Brake Pressure Bleeder Adapter Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings). Caution: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort increases significantly, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. 2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 4. Reconnect the brake pipe to the master cylinder port and tighten securely. 5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the master cylinder. 9. With the front brake pipe installed securely to the master cylinder, after all air has been purged from the front port of the master cylinder, loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8. 10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 4. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Install the J-35589-A - Brake Pressure Bleeder Adapter to the brake master cylinder reservoir. 6. Check the brake fluid level in the J-29532 - Diaphragm Pressure Bleeder, or equivalent. Add Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container as necessary to bring the level to approximately the half-full point. 7. Connect the J-29532 - Diaphragm Pressure Bleeder, or equivalent , to the J-35589-A - Brake Pressure Bleeder Adapter. 8. Charge the J-29532 - Diaphragm Pressure Bleeder, or equivalent , air tank to 175-205 kPa (25-30 psi). 9. Open the J-29532 - Diaphragm Pressure Bleeder, or equivalent , fluid tank valve to allow pressurized brake fluid to enter the brake system. 10. Wait approximately 30 seconds, then inspect the entire hydraulic brake system in order to ensure that there are no existing external brake fluid leaks. Any brake fluid leaks identified require repair prior to completing this procedure. 11. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 12. Install a transparent hose over the end of the bleeder valve. 13. Submerge the open end of the transparent hose into a transparent container partially filled with Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 14. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. Allow fluid to flow until air bubbles stop flowing from the bleeder, then tighten the bleeder valve. 15. With the right rear wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the right rear hydraulic circuit, install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 16. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 17. With the left rear wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the left rear hydraulic circuit, install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve. 18. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 19. With the right front wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the right front hydraulic circuit, Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Antilock Brake Automated Bleed Procedure > Page 9570 install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 20. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 21. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. 22. Close the J-29532 - Diaphragm Pressure Bleeder, or equivalent , fluid tank valve, then disconnect the J-29532 - Diaphragm Pressure Bleeder, or equivalent , from the J-35589-A - Brake Pressure Bleeder Adapter. 23. Remove the J-35589-A - Brake Pressure Bleeder Adapter from the brake master cylinder reservoir. 24. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 25. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 26. If the brake pedal feels spongy perform the following steps: 1. Inspect the brake system for external leaks. Refer to Brake System External Leak Inspection (See: Testing and Inspection/Component Tests and General Diagnostics/Brake System External Leak Inspection). 2. Using a scan tool, perform the antilock brake system automated bleeding procedure to remove any air that may have been trapped in the brake pressure modulator valve (BPMV). Refer to the following procedures, as appropriate: * Antilock Brake System Automated Bleed (See: )for Two-mode Hybrid vehicles * Antilock Brake System Automated Bleed (See: )for non-hybrid vehicles less than 3900 kg (8600 lb) GVW * Antilock Brake System Automated Bleed (See: )for non-hybrid vehicles greater than/equal to 3900 kg (8600 lb) GVW 27. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. Note: If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. 28. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic Brakes (See: Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Hydraulic Brakes). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Antilock Brake Automated Bleed Procedure > Page 9571 Brake Bleeding: Service and Repair Hydraulic Brake Flushing Hydraulic Brake System Flushing Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings). Caution: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Inspect the brake fluid for the following conditions, indicating brake fluid contamination: * Fluid separation, indicating two types of fluid are present; a substance other than the recommended brake fluid has been introduced into the brake hydraulic system - Swirled appearance - oil-based substance - Layered appearance - silicone-based substance * Fluid discoloration, indicating the presence of moisture or particles that have been introduced into the brake hydraulic system - Cloudy appearance - moisture - Dark appearance/suspended particles in fluid - dirt, rust, corrosion, brake dust 2. Inspect the master cylinder reservoir cap diaphragm and the reservoir-to-master cylinder grommets for swelling, indicating brake fluid contamination. 3. If the brake fluid WAS contaminated with an oil-based or a silicone-based substance, indicated by fluid separation and/or a swollen master cylinder reservoir cap diaphragm and/or swollen reservoir-to-master cylinder grommets, perform the following: 1. Remove ALL of the following components listed from the vehicle. Each component contains internal rubber seals/linings which have been contaminated by the contaminated brake fluid in the brake hydraulic system. Refer to the procedures indicated: * Master Cylinder Replacement (Vacuum Assist) (See: Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Replacement)Master Cylinder Replacement (Two-Mode Hybrid) (See: Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Replacement)Master Cylinder Replacement (Hydraulic Assist) (See: Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Replacement) * Front Brake Hose Replacement (JH6, JH7) (See: Brake Hose/Line/Service and Repair/Front Brake Hose Replacement (JH6, JH7))Front Brake Hose Replacement (JD9, JF3, JF7, JG4) (See: Brake Hose/Line/Service and Repair/Front Brake Hose Replacement (JD9, JF3, JF7, JG4)) * Rear Brake Hose Replacement (To Axle - JF3 without JL4, JF7, JG4) (See: Brake Hose/Line/Service and Repair/Rear Brake Hose Replacement (To Axle - JF3 without JL4, JF7, JG4))Rear Brake Hose Replacement (To Axle - JD9, JF3 with JL4) (See: Brake Hose/Line/Service and Repair/Rear Brake Hose Replacement (To Axle - JD9, JF3 with JL4))Rear Brake Hose Replacement (Frame to Axle - JH6, JH7) (See: Brake Hose/Line/Service and Repair/Rear Brake Hose Replacement (Frame to Axle - JH6, JH7))Rear Brake Hose Replacement (To Caliper - JD9) (See: Brake Hose/Line/Service and Repair/Rear Brake Hose Replacement (To Caliper - JD9))Rear Brake Hose Replacement (Caliper - JH6, JH7) (See: Brake Hose/Line/Service and Repair/Rear Brake Hose Replacement (Caliper - JH6, JH7)) * Front Brake Caliper Replacement (JD9, JF3, JF7, JG4) (See: Brake Caliper/Service and Repair/Removal and Replacement/Front Brake Caliper Replacement (JD9, JF3, JF7, JG4))Front Brake Caliper Replacement (JH6, JH7) (See: Brake Caliper/Service and Repair/Removal and Replacement/Front Brake Caliper Replacement (JH6, JH7)) * Rear Brake Caliper Replacement (JD9) (See: Brake Caliper/Service and Repair/Removal and Replacement/Rear Brake Caliper Replacement (JD9))Rear Brake Caliper Replacement (JH6, JH7) (See: Brake Caliper/Service and Repair/Removal and Replacement/Rear Brake Caliper Replacement (JH6, JH7)) * Brake Pressure Modulator Valve Replacement (See: Hydraulic Control Assembly - Antilock Brakes/Service and Repair) * Brake Pressure Modulator Valve Replacement (See: Hydraulic Control Assembly - Antilock Brakes/Service and Repair/Non-Hybrid Less than 3900 kg (8600 lb) GVW) * Brake Pressure Modulator Valve Replacement (See: Hydraulic Control Assembly - Antilock Brakes/Service and Repair/Non-Hybrid Greater than/Equal to 3900 kg (8600 lb) GVW) 2. Clean out all the hydraulic brake pipes using denatured alcohol, or equivalent. 3. Dry the brake pipes using non-lubricated, filtered air. 4. Repair or replace ALL of the following components listed and install them to the vehicle. Each component contains internal rubber seals/linings which have been contaminated by the contaminated brake fluid in the brake hydraulic system. Refer to the procedures indicated: Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Antilock Brake Automated Bleed Procedure > Page 9572 * Master Cylinder Replacement (Vacuum Assist) (See: Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Replacement)Master Cylinder Replacement (Two-Mode Hybrid) (See: Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Replacement)Master Cylinder Replacement (Hydraulic Assist) (See: Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Replacement) ; also perform the following: Clean the brake master cylinder reservoir using denatured alcohol, or equivalent, then dry the reservoir using non-lubricated, filtered air. Inspect the reservoir for cracks and/or damage and replace if necessary. Refer to Master Cylinder Reservoir Replacement (Vacuum Assist) (See: Brake Fluid Reservoir/Service and Repair/Master Cylinder Reservoir Replacement (Vacuum Assist))Master Cylinder Reservoir Replacement (Hydraulic Assist) (See: Brake Fluid Reservoir/Service and Repair/Master Cylinder Reservoir Replacement (Hydraulic Assist))Master Cylinder Reservoir Replacement (Two-mode Hybrid) (). Replace the brake master cylinder reservoir cap diaphragm. * Front Brake Hose Replacement (JH6, JH7) (See: Brake Hose/Line/Service and Repair/Front Brake Hose Replacement (JH6, JH7))Front Brake Hose Replacement (JD9, JF3, JF7, JG4) (See: Brake Hose/Line/Service and Repair/Front Brake Hose Replacement (JD9, JF3, JF7, JG4)) * Rear Brake Hose Replacement (To Axle - JF3 without JL4, JF7, JG4) (See: Brake Hose/Line/Service and Repair/Rear Brake Hose Replacement (To Axle - JF3 without JL4, JF7, JG4))Rear Brake Hose Replacement (To Axle - JD9, JF3 with JL4) (See: Brake Hose/Line/Service and Repair/Rear Brake Hose Replacement (To Axle - JD9, JF3 with JL4))Rear Brake Hose Replacement (Frame to Axle - JH6, JH7) (See: Brake Hose/Line/Service and Repair/Rear Brake Hose Replacement (Frame to Axle - JH6, JH7))Rear Brake Hose Replacement (To Caliper - JD9) (See: Brake Hose/Line/Service and Repair/Rear Brake Hose Replacement (To Caliper - JD9))Rear Brake Hose Replacement (Caliper - JH6, JH7) (See: Brake Hose/Line/Service and Repair/Rear Brake Hose Replacement (Caliper - JH6, JH7)) * Front Brake Caliper Overhaul (JH6, JH7) (See: Brake Caliper/Service and Repair/Overhaul/Front Brake Caliper Overhaul (JH6, JH7)) or Front Brake Caliper Replacement (JD9, JF3, JF7, JG4) (See: Brake Caliper/Service and Repair/Removal and Replacement/Front Brake Caliper Replacement (JD9, JF3, JF7, JG4))Front Brake Caliper Replacement (JH6, JH7) (See: Brake Caliper/Service and Repair/Removal and Replacement/Front Brake Caliper Replacement (JH6, JH7)) * Rear Brake Caliper Overhaul (JH6, JH7) (See: Brake Caliper/Service and Repair/Overhaul/Rear Brake Caliper Overhaul (JH6, JH7)) or Rear Brake Caliper Replacement (JD9) (See: Brake Caliper/Service and Repair/Removal and Replacement/Rear Brake Caliper Replacement (JD9))Rear Brake Caliper Replacement (JH6, JH7) (See: Brake Caliper/Service and Repair/Removal and Replacement/Rear Brake Caliper Replacement (JH6, JH7)) * Brake Pressure Modulator Valve Replacement (See: Hydraulic Control Assembly - Antilock Brakes/Service and Repair) * Brake Pressure Modulator Valve Replacement (See: Hydraulic Control Assembly - Antilock Brakes/Service and Repair/Non-Hybrid Less than 3900 kg (8600 lb) GVW) * Brake Pressure Modulator Valve Replacement (See: Hydraulic Control Assembly - Antilock Brakes/Service and Repair/Non-Hybrid Greater than/Equal to 3900 kg (8600 lb) GVW) 4. If the brake fluid was NOT contaminated with an oil-based or a silicone-based substance, but WAS contaminated with water or dirt, rust, corrosion, and/or brake dust, replace the brake master cylinder reservoir cap diaphragm. The diaphragm may have allowed the moisture or particles to enter the hydraulic system. 5. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11(R), GM P/N 12377967 (Canada P/N 992667) or equivalent, DOT-3 brake fluid from a clean, sealed brake fluid container. 6. Pressure bleed the hydraulic brake system. Begin the procedure with the pressure bleeder reservoir filled to the maximum-fill level with the correct brake fluid as indicated. Refer to Hydraulic Brake System Bleeding (Manual) (See: )Hydraulic Brake System Bleeding (Pressure) (See: )Hydraulic Brake System Bleeding (Two-mode Hybrid) (See: ). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Testing and Inspection Brake Caliper: Testing and Inspection Brake Caliper Inspection Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). 1. Inspect the brake caliper housing (1) for cracks, excess wear, and/or damage. If any of these conditions are present, the brake caliper requires replacement. 2. Inspect the caliper piston dust boot seal (2) for cracks, tears, cuts, deterioration and/or improper seating in the caliper body. If any of these conditions are present, the brake caliper requires overhaul or replacement. 3. Inspect for brake fluid leakage around the caliper piston dust boot seal (2) and on the disc brake pads. If there is any evidence of brake fluid leakage, the brake caliper requires overhaul or replacement. 4. Inspect for smooth and complete travel of the caliper pistons into the caliper bores: The movement of the caliper pistons into the caliper bores should be smooth and even. If the caliper piston is frozen or difficult to bottom, the caliper requires overhaul or replacement. * For single piston caliper applications, insert a discarded inner brake pad (2) or block of wood in front of the piston. Using a large C-clamp (1) installed over the body of the caliper (3) and against the brake pad or block of wood, slowly bottom the piston in the bore. * For dual piston caliper applications, insert a discarded inner brake pad (2) or block of wood in front of the pistons. Using 2 large C-clamps (1) installed over the body of the caliper (3) and against the brake pad or block of wood, slowly bottom the pistons evenly into the bores. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement Brake Caliper: Removal and Replacement Front Brake Caliper Replacement (JD9, JF3, JF7, JG4) Front Brake Caliper Replacement (JD9, JF3, JF7, JG4) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 9578 Front Brake Caliper Replacement (JH6, JH7) Front Brake Caliper Replacement (JH6, JH7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 9579 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 9580 Rear Brake Caliper Replacement (JD9) Rear Brake Caliper Replacement (JD9) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 9581 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 9582 Rear Brake Caliper Replacement (JH6, JH7) Rear Brake Caliper Replacement (JH6, JH7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 9583 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 9584 Front Brake Caliper Hardware Replacement (JD9, JF3, JF7, JG4) Front Brake Caliper Hardware Replacement (JD9, JF3, JF7, JG4) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 9585 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 9586 Front Brake Caliper Hardware Replacement (JH6, JH7) Front Brake Caliper Hardware Replacement (JH6, JH7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 9587 Rear Brake Caliper Hardware Replacement (JD9) Rear Brake Caliper Hardware Replacement (JD9) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 9588 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 9589 Rear Brake Caliper Hardware Replacement (JH6, JH7) Rear Brake Caliper Hardware Replacement (JH6, JH7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 9590 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 9591 Front Brake Caliper Bracket Replacement (JD9, JF3, JF7, JG4) Front Brake Caliper Bracket Replacement (JD9, JF3, JF7, JG4) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 9592 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 9593 Front Brake Caliper Bracket Replacement (JH6, JH7) Front Brake Caliper Bracket Replacement (JH6, JH7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 9594 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 9595 Rear Brake Caliper Bracket Replacement (JD9) Rear Brake Caliper Bracket Replacement (JD9) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 9596 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 9597 Rear Brake Caliper Bracket Replacement (JH6, JH7) Rear Brake Caliper Bracket Replacement (JH6, JH7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 9598 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 9599 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 9600 Brake Caliper: Overhaul Front Brake Caliper Overhaul (JH6, JH7) Front Brake Caliper Overhaul (JH6, JH7) Disassembly Procedure Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). 1. Remove the brake caliper. Refer to Front Brake Caliper Replacement (JD9, JF3, JF7, JG4) (See: Removal and Replacement/Front Brake Caliper Replacement (JD9, JF3, JF7, JG4))Front Brake Caliper Replacement (JH6, JH7) (See: Removal and Replacement/Front Brake Caliper Replacement (JH6, JH7)). 2. Drain all the brake fluid from the caliper. Note: The brake calipers use phenolic pistons that have stainless steel caps which contact the brake pads. Use compressed air to remove the piston from the brake caliper. 3. Secure the brake caliper in a suitable holding device. 4. Insert a piece of wood in the brake caliper between the pistons and the outer bridge. 5. Cover the brake caliper with a shop towel. 6. Apply filtered, non-lubricated compressed air into the brake hose inlet fitting port of the brake caliper. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 9601 7. If one of the pistons fails to be removed from the brake caliper, perform the following steps. 1. Reposition the piston that has been removed back into the brake caliper. 2. Using a small block of wood and a C-clamp, slowly tighten the C-clamp until the piston is half way into the brake caliper. It does not have to be fully seated. 3. Position a second block of wood in front of the piston that remains in the brake caliper. 4. Cover the brake caliper with a shop towel. 5. Apply filtered, non-lubricated compressed air into the brake hose inlet fitting port of the brake caliper. 8. Remove the pistons (3) from the caliper bores. 9. Remove the boots (4) from the caliper bores. Do not scratch the caliper bores. 10. Remove the piston seals (2) from the caliper bores. Do not use a metal tool. 11. Remove the bleeder valve cap (5). 12. Remove the bleeder valve (6) from the caliper housing (1). 13. Clean the bleeder valve, the caliper bores, the caliper passages and the pistons with denatured alcohol. Dry the parts and blow out the brake fluid passages using filtered, non-lubricated compressed air. 14. Replace the pistons or the caliper if any of the following conditions exist: Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 9602 * Scoring in the caliper bores * Corrosion in the caliper bores * Pitting in the caliper bores * Damage to the pistons (phenolic) 15. Clean the brake caliper assembly with denatured alcohol. 16. Dry with filtered , non-lubricated compressed air. Assembly Procedure Note: When applying the clean brake fluid to the piston bores, piston seals and pistons, only apply the brake fluid to one bore at a time. This is done to ensure that the brake caliper, seals and pistons DO NOT become contaminated with dirt or other foreign material. 1. Apply a small amount of clean DOT-3 brake fluid to the piston, piston seal, and piston bore. 2. Install the square-cut piston seal in the brake caliper bore groove. 3. Ensure that the square-cut piston seal is not twisted. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 9603 4. Install the boot over the end of the piston so that the fold will face toward the brake caliper housing piston bore opening. Note: Position the piston in the bore so that it is straight and level. 5. Position the piston to the brake caliper bore and seat the boot into the brake caliper bore groove. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 9604 6. Position a piece of wood across the piston to be installed. 7. Applying equal pressure by hand while pushing down, install the piston in the bore. 8. Remove the piece of wood. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 9. Install the bleeder valve in the brake caliper housing. Tighten the bleeder valve to 12 Nm (106 lb in). 10. Install the bleeder valve cap. 11. Install the brake caliper. Refer to Front Brake Caliper Replacement (JD9, JF3, JF7, JG4) (See: Removal and Replacement/Front Brake Caliper Replacement (JD9, JF3, JF7, JG4))Front Brake Caliper Replacement (JH6, JH7) (See: Removal and Replacement/Front Brake Caliper Replacement (JH6, JH7)). Rear Brake Caliper Overhaul (JH6, JH7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 9605 Rear Brake Caliper Overhaul (JH6, JH7) Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Disassembly Procedure 1. Remove the brake caliper. Refer to Rear Brake Caliper Replacement (JD9) (See: Removal and Replacement/Rear Brake Caliper Replacement (JD9))Rear Brake Caliper Replacement (JH6, JH7) (See: Removal and Replacement/Rear Brake Caliper Replacement (JH6, JH7)). 2. Drain all the brake fluid from the caliper. Note: The brake calipers use phenolic pistons with stainless steel caps which contact the brake pads. Use compressed air to remove the piston from the brake caliper. 3. Secure the brake caliper in a suitable holding device. 4. Insert a piece of wood in the brake caliper between the pistons and the outer bridge. 5. Cover the brake caliper with a shop towel. 6. Apply filtered, non-lubricated compressed air into the brake hose inlet fitting port of the brake caliper. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 9606 7. If one of the pistons fails to be removed from the brake caliper, perform the following steps. 1. Reposition the piston that has been removed back into the brake caliper. 2. Using a small block of wood and a C-clamp, slowly tighten the C-clamp until the piston is half way into the brake caliper. It does not have to be fully seated. 3. Position a second block of wood in front of the piston that remains in the brake caliper. 4. Cover the brake caliper with a shop towel. 5. Apply filtered, non-lubricated compressed air into the brake hose inlet fitting port of the brake caliper. 8. Remove the pistons (3) from the caliper bores. 9. Remove the boots (4) from the caliper bores. Do not scratch the caliper bores. 10. Remove the piston seals (2) from the caliper bores. Do not use a metal tool. 11. Remove the bleeder valve cap (5). 12. Remove the bleeder valve (6) from the caliper housing (1). 13. Clean the bleeder valve, the caliper bores, the caliper passages and the pistons with denatured alcohol. Dry the parts and blow out the brake fluid passages using filtered, non-lubricated compressed air. 14. Replace the pistons or the caliper if any of the following conditions exist: Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 9607 * Scoring in the caliper bores * Corrosion in the caliper bores * Pitting in the caliper bores * Damage to the pistons (phenolic) 15. Clean the brake caliper assembly with denatured alcohol. 16. Dry with filtered , non-lubricated compressed air. Assembly Procedure Note: When applying the clean brake fluid to the piston bores, piston seals and pistons, only apply the brake fluid to one bore at a time. This is done to ensure the brake caliper, seals and pistons DO NOT become contaminated with dirt or other foreign material. 1. Apply a small amount of clean DOT-3 brake fluid to the piston, piston seal, and piston bore. 2. Install the square-cut piston seal in the brake caliper bore groove. 3. Ensure the square-cut piston seal is not twisted. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 9608 4. Install the boot over the end of the piston so the fold will face toward the brake caliper housing piston bore opening. Note: Position the piston in the bore so that it is straight and level. 5. Position the piston to the brake caliper bore and seat the boot into the brake caliper bore groove. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Replacement > Page 9609 6. Position a piece of wood across the piston to be installed. 7. Applying equal pressure by hand while pushing down, install the piston in the bore. 8. Remove the piece of wood. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 9. Install the bleeder valve in the brake caliper housing. Tighten the bleeder valve to 12 Nm (106 lb in). 10. Install the bleeder valve cap. 11. Install the brake caliper. Refer to Rear Brake Caliper Replacement (JD9) (See: Removal and Replacement/Rear Brake Caliper Replacement (JD9))Rear Brake Caliper Replacement (JH6, JH7) (See: Removal and Replacement/Rear Brake Caliper Replacement (JH6, JH7)). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications Brake Fluid: Specifications Hydraulic Brake System: DOT 3 Hydraulic Brake Fluid (GM Part No. U.S. 12377967, in Canada 89021320). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Diagrams Brake Fluid Level Sensor/Switch: Diagrams Component Connector End Views Brake Fluid Level Switch Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Diagrams > Page 9616 Brake Fluid Level Sensor/Switch: Service and Repair Brake Fluid Level Indicator Switch Replacement (Non-Hybrid) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Pressure Sensor/Switch > Component Information > Diagrams Brake Fluid Pressure Sensor/Switch: Diagrams Component Connector End Views Brake Master Cylinder Pressure Sensor (JL1) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Pressure Sensor/Switch > Component Information > Diagrams > Page 9620 Brake Fluid Pressure Sensor/Switch: Service and Repair Brake Master Cylinder Pressure Sensor Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Reservoir > Component Information > Service and Repair > Master Cylinder Reservoir Replacement (Vacuum Assist) Brake Fluid Reservoir: Service and Repair Master Cylinder Reservoir Replacement (Vacuum Assist) Master Cylinder Reservoir Replacement (Vacuum Assist) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Reservoir > Component Information > Service and Repair > Master Cylinder Reservoir Replacement (Vacuum Assist) > Page 9625 Brake Fluid Reservoir: Service and Repair Master Cylinder Reservoir Replacement (Hydraulic Assist) Master Cylinder Reservoir Replacement (Hydraulic Assist) Removal Procedure Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings). 1. Using a suitable tool, remove the brake fluid from the brake master cylinder reservoir. 2. Discard the brake fluid into an approved container. 3. Disconnect the brake fluid level indicator switch electrical connector. 4. Remove the master cylinder reservoir bolts (1). 5. Carefully lift the master cylinder reservoir (1) straight upward and remove the reservoir from the master cylinder. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Reservoir > Component Information > Service and Repair > Master Cylinder Reservoir Replacement (Vacuum Assist) > Page 9626 6. Remove the master cylinder reservoir seals (1). Installation Procedure 1. Lubricate the master cylinder reservoir seals (1) and the outer surface area of the reservoir-to-housing barrels with GM approved brake fluid from a clean, sealed brake fluid container. 2. If reinstalling the master cylinder reservoir, clean the reservoir with denatured alcohol, or equivalent and allow to dry. 3. Install the master cylinder reservoir seals to the master cylinder. Ensure the master cylinder reservoir seals are fully seated in the master cylinder body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Reservoir > Component Information > Service and Repair > Master Cylinder Reservoir Replacement (Vacuum Assist) > Page 9627 4. Lubricate the master cylinder reservoir-to-master cylinder barrels with GM approved brake fluid from a clean, sealed brake fluid container. 5. Carefully press the master cylinder reservoir (1) straight downward and install the reservoir to the master cylinder. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 6. Install the master cylinder reservoir bolts (1) and tighten to 8 Nm (71 lb in). 7. Connect the brake fluid level indicator switch electrical connector. 8. Fill the master cylinder reservoir. Refer to Master Cylinder Reservoir Filling (Non-Hybrid) (See: Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Reservoir Filling)Master Cylinder Reservoir Filling (Two-mode Hybrid) (See: Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Reservoir Filling). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement Brake Hose/Line: Service and Repair Brake Pipe Replacement Brake Pipe Replacement Special Tools J 45405 Pipe Flaring Tool Kit Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Warning Always use double walled steel brake pipe when replacing brake pipes. The use of any other pipe is not recommended and may cause brake system failure. Carefully route and retain replacement brake pipes. Always use the correct fasteners and the original location for replacement brake pipes. Failure to properly route and retain brake pipes may cause damage to the brake pipes and cause brake system failure. Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings). Note: When servicing the brake pipes, note the following: * If sectioning the brake pipe, use replacement pipe of the same type and outside diameter. * Use fittings of the appropriate size and type. * Only create flares of the same type or design as originally equipped on the vehicle. 1. Inspect the area of brake pipe to be repaired or replaced. 2. Release the brake pipe to be replaced from the retainers, as required. 3. Select an appropriate location to section the brake pipe, if necessary. * Allow adequate clearance in order to maneuver the J 45405 . * Avoid sectioning the brake pipe at bends or mounting points. 4. Using a string or wire, measure the length of the pipe to be replaced including all pipe bends. 5. Add to the measurement taken the appropriate additional length required for each flare to be created. * 6.35 mm (0.250 in) for 4.76 mm (3/16 in) diameter pipe * 9.50 mm (0.374 in) for 6.35 mm (1/4 in) diameter pipe * 12.67 mm (0.499 in) for 7.94 mm (5/16 in) diameter pipe Note: Ensure that the brake pipe end to be flared is cut at a square, 90 degree angle to the pipe length. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 9632 6. Using the pipe cutter included in the J 45405 , carefully cut the brake pipe squarely to the measured length. 7. Remove the sectioned brake pipe from the vehicle. 8. Select the appropriate size of brake pipe and tube nuts, as necessary. The brake pipe outside diameter determines brake pipe size. 9. Strip the nylon coating from the brake pipe end to be flared, if necessary. * Select the appropriate blade on the coating stripping tool included in the J 45405 , by unthreading the blade block from the stripping tool and installing the block with the desired blade facing the tool rollers. - 6.35 mm (0.250 in) blade for 4.76 mm (3/16 in) diameter pipe - 9.50 mm (0.374 in) blade for 6.35 mm (1/4 in) and 7.94 mm (5/16 in) diameter pipe * Insert the brake pipe end to be flared into the stripping tool to the depth of the ledge on the tool rollers. * While holding the brake pipe firmly against the stripping tool roller ledges, rotate the thumbwheel of the tool until the blade contacts the brake pipe coated surface. Note: Do not gouge the metal surface of the brake pipe. * Rotate the stripping tool in a clockwise direction, ensuring that the brake pipe end remains against the tool roller ledges. * After each successive revolution of the stripping tool, carefully rotate the thumbwheel of the tool clockwise, in order to continue stripping the coating from the brake pipe until the metal pipe surface is exposed. * Loosen the thumbwheel of the tool and remove the brake pipe. Note: Ensure that all loose remnants of the nylon coating have been removed from the brake pipe. * Inspect the stripped end of the brake pipe to ensure that the proper amount of coating has been removed. - 6.35 mm (0.250 in) for 4.76 mm (3/16 in) diameter pipe - 9.50 mm (0.374 in) for 6.35 mm (1/4 in) and 7.94 mm (5/16 in) diameter pipe Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 9633 10. Chamfer the inside and outside diameter of the pipe with the de-burring tool included in the J 45405 . 11. Install the tube nuts on the brake pipe, noting their orientation. 12. Clean the brake pipe and the J 45405 of lubricant, contaminants, and debris. 13. Loosen the die clamping screw of the J 45405 . 14. Select the corresponding die set and install the die halves into the die cage with the full, flat face of one die facing the clamping screw, and the counterbores of both dies facing the forming ram. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 9634 15. Place the flat face of an unused die (1) against the die halves in the clamping cage and hold firmly against the counterbored face of the dies. 16. Insert the prepared end of the pipe to be flared through the back of the dies until the pipe is seated against the flat surface of the unused die (1). 17. Remove the unused die (1). 18. Ensure that the rear of both dies are seated firmly against the enclosed end of the die cage. 19. Firmly hand tighten the clamping screw (2) against the dies. 20. Select the appropriate forming mandrel and place into the forming ram. 21. Rotate the hydraulic fluid control valve clockwise to the closed position. 22. Rotate the body of the J 45405 until it bottoms against the die cage. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 9635 23. While guiding the forming mandrel into the exposed end of pipe to be flared, operate the lever of the J 45405 until the forming mandrel bottoms against the clamping dies. 24. Rotate the hydraulic fluid control valve counterclockwise to the open position to allow the hydraulic forming ram to retract. 25. Insert the finishing cone into the forming ram. 26. Rotate the hydraulic fluid control valve clockwise to the closed position. 27. Rotate the body of the J 45405 until it bottoms against the die cage. 28. While guiding the finishing cone into the exposed end of pipe to be flared, operate the lever of the J 45405 until the finishing cone bottoms against the dies. 29. Rotate the hydraulic fluid control valve counterclockwise to the open position to allow the hydraulic forming ram to retract. 30. Loosen the die clamping screw and remove the dies and pipe. 31. If necessary, lightly tap the dies until the die halves separate. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 9636 32. Inspect the brake pipe flare for correct shape and diameter (a). * 6.74-7.10 mm (0.265-0.279 in) flare diameter for 4.76 mm (3/16 in) diameter pipe * 8.57-9.27 mm (0.344-0.358 in) flare diameter for 6.35 mm (1/4 in) diameter pipe * 10.42-10.79 mm (0.410-0.425 in) flare diameter for 7.94 mm (5/16 in) diameter pipe 33. If necessary, using the removed section of brake pipe as a template, shape the new pipe with a suitable brake pipe bending tool. Note: When installing the pipe, maintain a clearance of 19 mm (3/4 in) from all moving or vibrating components. 34. Install the pipe to the vehicle with the appropriate brake pipe unions, as required. 35. If previously released, secure the brake pipe to the retainers. 36. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) (See: Brake Bleeding/Service and Repair)Hydraulic Brake System Bleeding (Pressure) (See: Brake Bleeding/Service and Repair)Hydraulic Brake System Bleeding (Two-mode Hybrid) (See: Brake Bleeding/Service and Repair). 37. With the aid of an assistant, inspect the brake pipe flares for leaks by starting the engine and applying the brakes. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 9637 Brake Hose/Line: Service and Repair Front Brake Hose Replacement (JH6, JH7) Front Brake Hose Replacement (JH6, JH7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 9638 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 9639 Brake Hose/Line: Service and Repair Front Brake Hose Replacement (JD9, JF3, JF7, JG4) Front Brake Hose Replacement (JD9, JF3, JF7, JG4) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 9640 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 9641 Brake Hose/Line: Service and Repair Rear Brake Hose Replacement (To Axle - JF3 without JL4, JF7, JG4) Rear Brake Hose Replacement (To Axle - JF3 without JL4, JF7, JG4) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 9642 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 9643 Brake Hose/Line: Service and Repair Brake Pipe Replacement Brake Pipe Replacement Special Tools J 45405 Pipe Flaring Tool Kit Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Warning Always use double walled steel brake pipe when replacing brake pipes. The use of any other pipe is not recommended and may cause brake system failure. Carefully route and retain replacement brake pipes. Always use the correct fasteners and the original location for replacement brake pipes. Failure to properly route and retain brake pipes may cause damage to the brake pipes and cause brake system failure. Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings). Note: When servicing the brake pipes, note the following: * If sectioning the brake pipe, use replacement pipe of the same type and outside diameter. * Use fittings of the appropriate size and type. * Only create flares of the same type or design as originally equipped on the vehicle. 1. Inspect the area of brake pipe to be repaired or replaced. 2. Release the brake pipe to be replaced from the retainers, as required. 3. Select an appropriate location to section the brake pipe, if necessary. * Allow adequate clearance in order to maneuver the J 45405 . * Avoid sectioning the brake pipe at bends or mounting points. 4. Using a string or wire, measure the length of the pipe to be replaced including all pipe bends. 5. Add to the measurement taken the appropriate additional length required for each flare to be created. * 6.35 mm (0.250 in) for 4.76 mm (3/16 in) diameter pipe * 9.50 mm (0.374 in) for 6.35 mm (1/4 in) diameter pipe * 12.67 mm (0.499 in) for 7.94 mm (5/16 in) diameter pipe Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 9644 Note: Ensure that the brake pipe end to be flared is cut at a square, 90 degree angle to the pipe length. 6. Using the pipe cutter included in the J 45405 , carefully cut the brake pipe squarely to the measured length. 7. Remove the sectioned brake pipe from the vehicle. 8. Select the appropriate size of brake pipe and tube nuts, as necessary. The brake pipe outside diameter determines brake pipe size. 9. Strip the nylon coating from the brake pipe end to be flared, if necessary. * Select the appropriate blade on the coating stripping tool included in the J 45405 , by unthreading the blade block from the stripping tool and installing the block with the desired blade facing the tool rollers. - 6.35 mm (0.250 in) blade for 4.76 mm (3/16 in) diameter pipe - 9.50 mm (0.374 in) blade for 6.35 mm (1/4 in) and 7.94 mm (5/16 in) diameter pipe * Insert the brake pipe end to be flared into the stripping tool to the depth of the ledge on the tool rollers. * While holding the brake pipe firmly against the stripping tool roller ledges, rotate the thumbwheel of the tool until the blade contacts the brake pipe coated surface. Note: Do not gouge the metal surface of the brake pipe. * Rotate the stripping tool in a clockwise direction, ensuring that the brake pipe end remains against the tool roller ledges. * After each successive revolution of the stripping tool, carefully rotate the thumbwheel of the tool clockwise, in order to continue stripping the coating from the brake pipe until the metal pipe surface is exposed. * Loosen the thumbwheel of the tool and remove the brake pipe. Note: Ensure that all loose remnants of the nylon coating have been removed from the brake pipe. * Inspect the stripped end of the brake pipe to ensure that the proper amount of coating has been removed. - 6.35 mm (0.250 in) for 4.76 mm (3/16 in) diameter pipe - 9.50 mm (0.374 in) for 6.35 mm (1/4 in) and 7.94 mm (5/16 in) diameter pipe Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 9645 10. Chamfer the inside and outside diameter of the pipe with the de-burring tool included in the J 45405 . 11. Install the tube nuts on the brake pipe, noting their orientation. 12. Clean the brake pipe and the J 45405 of lubricant, contaminants, and debris. 13. Loosen the die clamping screw of the J 45405 . 14. Select the corresponding die set and install the die halves into the die cage with the full, flat face of one die facing the clamping screw, and the counterbores of both dies facing the forming ram. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 9646 15. Place the flat face of an unused die (1) against the die halves in the clamping cage and hold firmly against the counterbored face of the dies. 16. Insert the prepared end of the pipe to be flared through the back of the dies until the pipe is seated against the flat surface of the unused die (1). 17. Remove the unused die (1). 18. Ensure that the rear of both dies are seated firmly against the enclosed end of the die cage. 19. Firmly hand tighten the clamping screw (2) against the dies. 20. Select the appropriate forming mandrel and place into the forming ram. 21. Rotate the hydraulic fluid control valve clockwise to the closed position. 22. Rotate the body of the J 45405 until it bottoms against the die cage. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 9647 23. While guiding the forming mandrel into the exposed end of pipe to be flared, operate the lever of the J 45405 until the forming mandrel bottoms against the clamping dies. 24. Rotate the hydraulic fluid control valve counterclockwise to the open position to allow the hydraulic forming ram to retract. 25. Insert the finishing cone into the forming ram. 26. Rotate the hydraulic fluid control valve clockwise to the closed position. 27. Rotate the body of the J 45405 until it bottoms against the die cage. 28. While guiding the finishing cone into the exposed end of pipe to be flared, operate the lever of the J 45405 until the finishing cone bottoms against the dies. 29. Rotate the hydraulic fluid control valve counterclockwise to the open position to allow the hydraulic forming ram to retract. 30. Loosen the die clamping screw and remove the dies and pipe. 31. If necessary, lightly tap the dies until the die halves separate. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 9648 32. Inspect the brake pipe flare for correct shape and diameter (a). * 6.74-7.10 mm (0.265-0.279 in) flare diameter for 4.76 mm (3/16 in) diameter pipe * 8.57-9.27 mm (0.344-0.358 in) flare diameter for 6.35 mm (1/4 in) diameter pipe * 10.42-10.79 mm (0.410-0.425 in) flare diameter for 7.94 mm (5/16 in) diameter pipe 33. If necessary, using the removed section of brake pipe as a template, shape the new pipe with a suitable brake pipe bending tool. Note: When installing the pipe, maintain a clearance of 19 mm (3/4 in) from all moving or vibrating components. 34. Install the pipe to the vehicle with the appropriate brake pipe unions, as required. 35. If previously released, secure the brake pipe to the retainers. 36. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) (See: Brake Bleeding/Service and Repair)Hydraulic Brake System Bleeding (Pressure) (See: Brake Bleeding/Service and Repair)Hydraulic Brake System Bleeding (Two-mode Hybrid) (See: Brake Bleeding/Service and Repair). 37. With the aid of an assistant, inspect the brake pipe flares for leaks by starting the engine and applying the brakes. Front Brake Hose Replacement (JH6, JH7) Front Brake Hose Replacement (JH6, JH7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 9649 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 9650 Front Brake Hose Replacement (JD9, JF3, JF7, JG4) Front Brake Hose Replacement (JD9, JF3, JF7, JG4) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 9651 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 9652 Rear Brake Hose Replacement (To Axle - JF3 without JL4, JF7, JG4) Rear Brake Hose Replacement (To Axle - JF3 without JL4, JF7, JG4) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 9653 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 9654 Rear Brake Hose Replacement (To Axle - JD9, JF3 with JL4) Rear Brake Hose Replacement (To Axle - JD9, JF3 with JL4) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 9655 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 9656 Rear Brake Hose Replacement (To Caliper - JD9) Rear Brake Hose Replacement (To Caliper - JD9) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 9657 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 9658 Rear Brake Hose Replacement (Caliper - JH6, JH7) Rear Brake Hose Replacement (Caliper - JH6, JH7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 9659 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 9660 Rear Brake Hose Replacement (Frame to Axle - JH6, JH7) Rear Brake Hose Replacement (Frame to Axle - JH6, JH7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 9661 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 9662 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Non-Hybrid Less than 3900 kg (8600 lb) GVW Hydraulic Control Assembly - Antilock Brakes: Service and Repair Non-Hybrid Less than 3900 kg (8600 lb) GVW Brake Pressure Modulator Valve Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Non-Hybrid Less than 3900 kg (8600 lb) GVW > Page 9667 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Non-Hybrid Less than 3900 kg (8600 lb) GVW > Page 9668 Hydraulic Control Assembly - Antilock Brakes: Service and Repair Non-Hybrid Greater than/Equal to 3900 kg (8600 lb) GVW Brake Pressure Modulator Valve Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Non-Hybrid Less than 3900 kg (8600 lb) GVW > Page 9669 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures Brake Master Cylinder: Procedures Master Cylinder Bench Bleeding (Non-Hybrid) Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings). 1. Secure the mounting flange of the brake master cylinder in a bench vise so that the rear of the primary piston is accessible. 2. Remove the master cylinder reservoir cap and diaphragm. 3. Install suitable fittings to the master cylinder ports that match the type of flare seat required and also provide for hose attachment. 4. Install transparent hoses to the fittings installed to the master cylinder ports, then route the hoses into the master cylinder reservoir. 5. Fill the master cylinder reservoir to at least the half-way point with GM approved brake fluid from a clean, sealed brake fluid container. Refer to Master Cylinder Reservoir Filling (Non-Hybrid) (See: Removal and Replacement/Master Cylinder Reservoir Filling)Master Cylinder Reservoir Filling (Two-mode Hybrid) (See: Removal and Replacement/Master Cylinder Reservoir Filling). 6. Ensure that the ends of the transparent hoses running into the master cylinder reservoir are fully submerged in the brake fluid. 7. Using a smooth, round-ended tool, depress and release the primary piston as far as it will travel, a depth of about 25 mm (1 in), several times. Observe the flow of fluid coming from the ports. As air is bled from the primary and secondary pistons, the effort required to depress the primary piston will increase and the amount of travel will decrease. 8. Continue to depress and release the primary piston until fluid flows freely from the ports with no evidence of air bubbles. 9. Remove the transparent hoses from the master cylinder reservoir. 10. Install the master cylinder reservoir cap and diaphragm. 11. Remove the fittings with the transparent hoses from the master cylinder ports. Wrap the master cylinder with a clean shop cloth to prevent brake fluid spills. 12. Remove the master cylinder from the vise. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 9674 Brake Master Cylinder: Removal and Replacement Brake Master Cylinder Reservoir Hose Replacement Brake Master Cylinder Reservoir Hose Replacement Removal Procedure Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings). Note: The ignition must be in the OFF position, without pausing at ACCESSORY, and without applying the brake pedal to ensure the brake modulator and high pressure accumulator (HPA) pressure relief occurs. This process will take approximately 1 to 3 minutes. 1. Turn the ignition to OFF, without pausing at ACCESSORY, and remove the ignition key. Note: During the pressure relief process, the fluid level in the master cylinder reservoir will rise. Do not remove the master cylinder reservoir cap during the pressure relief process. 2. Wait approximately 1 to 3 minutes until the brake modulator and HPA pressure relief is complete. 3. Remove the brake fluid from the brake master cylinder reservoir until the level is below the reservoir supply hose fitting and discard into an approved container. 4. Disconnect the brake fluid level sensor electrical connector. 5. Disconnect the brake master cylinder reservoir return hose quick connect (1). 6. Disconnect the brake master cylinder reservoir supply hose quick connect (2). 7. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 8. Remove the left front wheelhouse liner. Refer to Front Wheelhouse Liner Replacement - Left Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Left Side)Front Wheelhouse Liner Replacement - Left Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Left Side). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 9675 9. Remove the antilock brake system (ABS) module splash shield retainer (1). 10. Remove the ABS module splash shield bolts (1). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 9676 11. Remove the ABS module splash shield (1). 12. Clean all dirt and debris from the brake pressure modulator valve (BPMV) assembly and the brake hose fittings. 13. Disconnect the BPMV supply hose quick connect (1). Cap the BPMV inlet port and plug the supply hose to prevent brake fluid loss and contamination. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 9677 14. Disconnect the BPMV return hose quick connect (1). Cap the BPMV outlet port and plug the return hose to prevent brake fluid loss and contamination. 15. Release the supply and return hoses from the retainers and remove the hoses from the vehicle. Installation Procedure 1. Install the supply and return hoses to the vehicle and the retainers. 2. Connect the BPMV return hose quick connect (1). Ensure the return hose quick connect is fully engaged by attempting to pull the return hose from the outlet fitting. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 9678 3. Connect the BPMV supply hose quick connect (1). Ensure the supply hose quick connect is fully engaged by attempting to pull the supply hose from the inlet fitting. 4. Install the ABS module splash shield (1). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 9679 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Install the ABS module splash shield bolts (1) and tighten to 20 Nm (15 lb ft). 6. Install the ABS module splash shield retainer (1). 7. Install the left front wheelhouse liner. Refer to Front Wheelhouse Liner Replacement - Left Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Left Side)Front Wheelhouse Liner Replacement - Left Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Left Side). 8. Lower the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 9680 9. Connect the brake master cylinder reservoir return hose quick connect (1). 10. Connect the brake master cylinder reservoir supply hose quick connect (2). 11. Fill the brake master cylinder reservoir. Refer to Master Cylinder Reservoir Filling (Non-Hybrid) (See: Master Cylinder Reservoir Filling)Master Cylinder Reservoir Filling (Two-mode Hybrid) (See: Master Cylinder Reservoir Filling). Master Cylinder Replacement (Vacuum Assist) Master Cylinder Replacement (Vacuum Assist) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 9681 Master Cylinder Replacement (Hydraulic Assist) Master Cylinder Replacement (Hydraulic Assist) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 9682 Brake Master Cylinder Adapter Replacement Brake Master Cylinder Adapter Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 9683 Removal Procedure 1. Place the transmission in the PARK or NEUTRAL position. 2. Apply the park brake. Note: The ignition must be in the OFF position, without pausing at ACCESSORY, and without applying the brake pedal to ensure the brake modulator and high pressure accumulator (HPA) pressure relief occurs. This process will take approximately 1 to 3 minutes. 3. Turn the ignition to OFF, without pausing at ACCESSORY, and without applying the brake pedal. Remove the ignition key. 4. Wait approximately 1 to 3 minutes until the brake modulator and HPA pressure relief is complete. 5. Remove the master cylinder nuts (1). Discard the master cylinder nuts. 6. Without disconnecting the brake pipes, release and carefully position aside the master cylinder (1). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 9684 Support the master cylinder with heavy mechanics wire or equivalent. 7. Inspect the master cylinder seal (1) for damage and replace, if necessary. 8. Disconnect the brake master cylinder (BMC) primary piston position sensor electrical connector. 9. Remove the brake pushrod retainer bolt (1), if equipped. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 9685 10. Remove the brake pushrod retainer (1). 11. Slide the stoplamp switch (1) off of the brake pedal pushrod pin while simultaneously disconnecting the brake pushrod. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 9686 12. Remove the 4 brake pedal bracket nuts (1). 13. Remove the brake master cylinder adapter (1). 14. Inspect the master cylinder adapter gasket for damage and replace, if necessary. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 9687 1. Install the master cylinder adapter gasket, if removed. 2. Install the brake master cylinder adapter (1). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the 4 brake pedal bracket nuts (1) and tighten to 25 Nm (18 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 9688 4. Connect the brake pedal pushrod while simultaneously installing the stoplamp switch (1). 5. Install the brake pushrod retainer (1). Rotate the brake pushrod retainer 360 degrees to ensure the retainer is fully engaged in the brake pedal pushrod pivot pin groove. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 9689 6. Install the brake pushrod retainer bolt (1), if equipped and tighten to 10 Nm (89 lb in). 7. Connect the BMC primary piston position sensor electrical connector. 8. Install the master cylinder seal (1), if removed. Ensure the brake master cylinder seal is fully seated in the groove on the master cylinder housing. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 9690 9. Position the master cylinder (1) to the master cylinder adapter. 10. Install 2 new master cylinder nuts (1) and tighten to 33 Nm (24 lb ft). 11. Inspect the battery state of charge. Refer to Battery Inspection/Test (See: Starting and Charging/Testing and Inspection/Component Tests and General Diagnostics). 12. If necessary, connect a battery charger to the 12V battery. Refer to Battery Charging (See: Starting and Charging/Battery/Service and Repair/Procedures). 13. Install a scan tool to the vehicle. Note: The ignition switch must remain in the ON position with the engine OFF during this procedure. 14. Turn the ignition ON with the engine OFF. 15. Using the scan tool, perform the following steps: 1. Select Diagnostics 2. Select the appropriate vehicle information 3. Select Chassis Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 9691 4. Select Electronic Brake Control Module (EBCM) 5. Select Module Setup 6. Select BMC Primary Piston Position Relearn and follow the instructions on the scan tool Master Cylinder Reservoir Filling Master Cylinder Reservoir Filling (Non-Hybrid) Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings). 1. Visually inspect the brake fluid level through the brake master cylinder reservoir. 2. If the brake fluid level is at or below the half-full point during routine fluid checks, the brake system should be inspected for wear and possible brake fluid leaks. 3. If the brake fluid level is at or below the half-full point during routine fluid checks, and an inspection of the brake system did not reveal wear or brake fluid leaks, the brake fluid may be topped-off up to the maximum-fill level. 4. If brake system service was just completed, the brake fluid may be topped-off up to the maximum-fill level. 5. If the brake fluid level is above the half-full point, adding brake fluid is not recommended under normal conditions. 6. If brake fluid is to be added to the master cylinder reservoir, clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. Use only Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair Wheel Cylinder: Service and Repair Rear Brake Cylinder Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Actuator > Component Information > Service and Repair Parking Brake Actuator: Service and Repair Parking Brake Actuator Replacement (JD9) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures Parking Brake Cable: Procedures Parking Brake Cable Adjuster Disabling Parking Brake Cable Adjuster Disabling Before any components of the parking brake system are serviced, the following procedure must be followed. Two technicians are required to perform this procedure, one inside the vehicle and one outside the vehicle. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Hold the pedal in the FULL upward position. 3. Pull rearward on the front park brake cable until the pedal drum (2) reaches its full reset position. 4. Insert a thin tool (1) on an upward angle through the hole in the front of the pedal assembly, past the retracted pedal drum, and into the hole in the back of the pedal assembly (3). 5. Slowly release the cable. 6. Remove the component that requires service. Parking Brake Cable Adjuster Enabling Parking Brake Cable Adjuster Enabling 1. Hold the park brake pedal in the FULL upward position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 9703 2. Pull rearward on the front park brake cable until the tension is released from the tool (1) installed in the pedal assembly. 3. Remove the tool (1). 4. Slowly release the park brake cable until it returns to its original position. 5. Release the park brake pedal. 6. Lower the vehicle. 7. Apply and release the park brake pedal 3 times. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 9704 Parking Brake Cable: Removal and Replacement Parking Brake Intermediate Cable Replacement (JD9, JF3, JF7) Parking Brake Intermediate Cable Replacement (JD9, JF3, JF7) Removal Procedure 1. Release the park brake. 2. Disable the park brake cable automatic adjuster. Refer to Parking Brake Cable Adjuster Disabling (See: Procedures/Parking Brake Cable Adjuster Disabling). 3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 4. Disconnect the front park brake cable (2) from the intermediate cable connector by drilling a 3 mm (1/8 in) hole through the dimple in the front to intermediate park brake cable connector (1). 5. Disconnect the left park brake cable (1) and the right park brake cable (2) from the equalizer bar (3) on the intermediate park brake cable. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 9705 6. Remove the intermediate park brake cable. Installation Procedure 1. Connect the left park brake cable (1) and the right park brake cable (2) to the equalizer bar (3) on the intermediate park brake cable. 2. Connect the front park brake cable (2) to the intermediate cable connector. 3. Enable the park brake cable automatic adjuster. Refer to Parking Brake Cable Adjuster Enabling (See: Procedures/Parking Brake Cable Adjuster Enabling). 4. Adjust the park brake. Refer to Parking Brake Adjustment (1500 Drum Brake) ()Parking Brake Adjustment (1500 Disc Brake) ()Parking Brake Adjustment (2500/3500 SRW) (See: Adjustments/Parking Brake Adjustment (SRW))Parking Brake Adjustment (3500 DRW) (See: Adjustments/Parking Brake Adjustment (DRW)). Parking Brake Intermediate Cable Replacement (JH6, JH7) Parking Brake Intermediate Cable Replacement (JH6, JH7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 9706 Removal Procedure 1. Release the park brake. 2. Disable the park brake cable automatic adjuster. Refer to Parking Brake Cable Adjuster Disabling (See: Procedures/Parking Brake Cable Adjuster Disabling). 3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 4. Disconnect the front park brake cable (2) from the intermediate cable connector (1) by drilling a 3 mm (1/8 in) hole through the dimple in the front to intermediate park brake cable connector. 5. Disconnect the left park brake cable (2) from the intermediate cable connector (1) by drilling a 3 mm (1/8 in) hole through the dimple in the front to intermediate park brake cable connector. 6. Remove the intermediate park brake cable. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 9707 1. Connect the left park brake cable (2) to the intermediate park brake cable connector (1). 2. Connect the front park brake cable (2) to the intermediate park brake cable connector (1). 3. Enable the park brake cable automatic adjuster. Refer to Parking Brake Cable Adjuster Enabling (See: Procedures/Parking Brake Cable Adjuster Enabling). 4. Adjust the park brake. Refer to Parking Brake Adjustment (1500 Drum Brake) ()Parking Brake Adjustment (1500 Disc Brake) ()Parking Brake Adjustment (2500/3500 SRW) (See: Adjustments/Parking Brake Adjustment (SRW))Parking Brake Adjustment (3500 DRW) (See: Adjustments/Parking Brake Adjustment (DRW)). Parking Brake Rear Cable Replacement - Left Side (JD9) Parking Brake Rear Cable Replacement - Left Side (JD9) Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 9708 1. Release the park brake. 2. Disable the park brake cable automatic adjuster. Refer to Parking Brake Cable Adjuster Disabling (See: Procedures/Parking Brake Cable Adjuster Disabling). 3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 4. Disconnect the left park brake cable (1) from the intermediate cable equalizer bar (2). 5. Release the left park brake cable from the frame bracket by compressing the locking tabs and pulling the cable conduit (3) rearward. 6. Remove the park brake cable clip bolt. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 9709 7. Release the park brake cable from the rear axle bracket by compressing the locking tabs and pulling the park brake cable conduit (1) rearward. 8. Disconnect the park brake cable eye (2) from the park brake actuator lever. 9. Remove the park brake cable assembly from the vehicle. Installation Procedure 1. Connect the left park brake cable eye (2) to the park brake actuator lever. 2. Install the park brake cable to the rear axle bracket by pulling the cable conduit (1) rearward and inserting the cable conduit into the rear axle bracket. Ensure the locking tabs on the cable conduit are fully engaged into the rear axle bracket. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 9710 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the park brake cable clip bolt. Tighten the bolt to 22 Nm (16 lb ft). 4. Connect the left rear park brake cable (1) to the intermediate cable equalizer bar (2). 5. Insert the park brake cable conduit (3) into the frame bracket. Ensure the locking tabs on the cable conduit are fully engaged into the frame bracket. 6. Enable the park brake cable automatic adjuster. Refer to Parking Brake Cable Adjuster Enabling (See: Procedures/Parking Brake Cable Adjuster Enabling). 7. Adjust the park brake. Refer to Parking Brake Adjustment (1500 Drum Brake) ()Parking Brake Adjustment (1500 Disc Brake) ()Parking Brake Adjustment (2500/3500 SRW) (See: Adjustments/Parking Brake Adjustment (SRW))Parking Brake Adjustment (3500 DRW) (See: Adjustments/Parking Brake Adjustment (DRW)). Parking Brake Rear Cable Replacement - Left Side (JF3, JF7, JG4) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 9711 Parking Brake Rear Cable Replacement - Left Side (JF3, JF7, JG4) Tools Required J 37043 Park Brake Cable Release Tool Removal Procedure 1. Release the park brake. 2. Disable the park brake cable automatic adjuster. Refer to Parking Brake Cable Adjuster Disabling (See: Procedures/Parking Brake Cable Adjuster Disabling). 3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 4. Disconnect the left park brake cable (1) from the intermediate cable equalizer bar (2). 5. Release the left park brake cable from the frame bracket by compressing the locking tabs and pulling the cable conduit (3) rearward. 6. Remove the park brake cable from the cable guides. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 9712 7. Remove the brake shoes. Refer to Brake Shoe Replacement (See: Drum Brake System/Brake Shoe/Service and Repair). 8. Using the J 37043 (1), remove the park brake cable from the backing plate. 9. Remove the park brake cable assembly from the vehicle. Installation Procedure 1. Install the park brake cable assembly into the backing plate. 2. Install the brake shoes. Refer to Brake Shoe Replacement (See: Drum Brake System/Brake Shoe/Service and Repair). 3. Install the park brake cable to the cable guides. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 9713 4. Connect the left rear park brake cable (1) to the intermediate cable equalizer bar (2). 5. Insert the park brake cable conduit (3) into the frame bracket. Ensure the locking tabs on the cable conduit are fully engaged into the frame bracket. 6. Enable the park brake cable automatic adjuster. Refer to Parking Brake Cable Adjuster Enabling (See: Procedures/Parking Brake Cable Adjuster Enabling). 7. Adjust the park brake. Refer to Parking Brake Adjustment (1500 Drum Brake) ()Parking Brake Adjustment (1500 Disc Brake) ()Parking Brake Adjustment (2500/3500 SRW) (See: Adjustments/Parking Brake Adjustment (SRW))Parking Brake Adjustment (3500 DRW) (See: Adjustments/Parking Brake Adjustment (DRW)). Parking Brake Rear Cable Replacement - Left Side (JH6, JH7) Parking Brake Rear Cable Replacement - Left Side (JH6, JH7) Removal Procedure 1. Release the park brake. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 9714 2. Disable the park brake cable automatic adjuster. Refer to Parking Brake Cable Adjuster Disabling (See: Procedures/Parking Brake Cable Adjuster Disabling). 3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 4. Disconnect the left park brake cable from the intermediate cable connector (1) by drilling a 3 mm (1/8 in) hole through the dimple in the intermediate park brake cable connector. 5. Release the left park brake cable from the equalizer (3) by compressing the locking tabs on the cable conduit (2) and pulling the cable rearward. 6. Remove the park brake cable clip bolt. 7. Disconnect the park brake cable eye (1) from the park brake actuator lever (2). 8. Remove the park brake cable (3) from the bracket by pulling the cable conduit rearward to compress the spring and sliding the cable conduit out of the bracket. 9. Remove the park brake cable assembly from the vehicle. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 9715 1. Connect the left park brake cable eye (1) to the park brake actuator lever (2). 2. Install the park brake cable to the rear axle bracket by pulling the cable conduit (3) rearward to compress the spring and inserting the cable conduit into the rear axle bracket. Ensure the locking tabs on the cable conduit are fully engaged into the rear axle bracket. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the park brake cable clip bolt and tighten to 22 Nm (16 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 9716 4. Insert the park brake cable conduit (2) into the equalizer (3). Ensure the locking tabs on the cable conduit are fully engaged into the equalizer. 5. Connect the left rear park brake cable to the intermediate cable connector (1). 6. Enable the park brake cable automatic adjuster. Refer to Parking Brake Cable Adjuster Enabling (See: Procedures/Parking Brake Cable Adjuster Enabling). 7. Adjust the park brake. Refer to Parking Brake Adjustment (1500 Drum Brake) ()Parking Brake Adjustment (1500 Disc Brake) ()Parking Brake Adjustment (2500/3500 SRW) (See: Adjustments/Parking Brake Adjustment (SRW))Parking Brake Adjustment (3500 DRW) (See: Adjustments/Parking Brake Adjustment (DRW)). Parking Brake Rear Cable Replacement - Right Side (JD9) Parking Brake Rear Cable Replacement - Right Side (JD9) Removal Procedure 1. Release the park brake. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 9717 2. Disable the park brake cable automatic adjuster. Refer to Parking Brake Cable Adjuster Disabling (See: Procedures/Parking Brake Cable Adjuster Disabling). 3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 4. Disconnect the right park brake cable (1) from the intermediate cable equalizer bar (2). 5. Release the right park brake cable from the frame bracket by compressing the locking tabs and pulling the cable conduit (3) rearward. 6. Release the park brake cable (1) from the rear axle housing cover clip. 7. Remove the park brake cable clip bolt (2). 8. Release the park brake cable from the rear axle bracket by compressing the locking tabs and pulling the park brake cable conduit (1) rearward. 9. Disconnect the park brake cable eye (2) from the park brake actuator lever. 10. Remove the park brake cable assembly from the vehicle. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 9718 1. Connect the right park brake cable eye (2) to the park brake actuator lever. 2. Install the park brake cable to the rear axle bracket by pulling the cable conduit (1) rearward and inserting the cable conduit into the rear axle bracket. Ensure the locking tabs on the cable conduit are fully engaged into the rear axle bracket. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the park brake cable clip bolt (2). Tighten the bolt to 22 Nm (16 lb ft). 4. Connect the park brake cable (1) to the rear axle housing cover clip. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 9719 5. Connect the right rear park brake cable (1) to the intermediate cable equalizer bar (2). 6. Insert the park brake cable conduit (3) into the frame bracket. Ensure the locking tabs on the cable conduit are fully engaged into the frame bracket. 7. Enable the park brake cable automatic adjuster. Refer to Parking Brake Cable Adjuster Enabling (See: Procedures/Parking Brake Cable Adjuster Enabling). 8. Adjust the park brake. Refer to Parking Brake Adjustment (1500 Drum Brake) ()Parking Brake Adjustment (1500 Disc Brake) ()Parking Brake Adjustment (2500/3500 SRW) (See: Adjustments/Parking Brake Adjustment (SRW))Parking Brake Adjustment (3500 DRW) (See: Adjustments/Parking Brake Adjustment (DRW)). Parking Brake Rear Cable Replacement - Right Side (JF3, JF7, JG4) Parking Brake Rear Cable Replacement - Right Side (JF3, JF7, JG4) Special Tools J 37043 Park Brake Cable Release Tool Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 9720 1. Release the park brake. 2. Disable the park brake cable automatic adjuster. Refer to Parking Brake Cable Adjuster Disabling (See: Procedures/Parking Brake Cable Adjuster Disabling). 3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 4. Disconnect the right park brake cable (1) from the intermediate cable equalizer bar (2). 5. Release the right park brake cable from the frame bracket by compressing the locking tabs and pulling the cable conduit (3) rearward. 6. Release the park brake cable (1) from the rear axle housing cover clip. 7. Remove the park brake cable clip bolt (2). 8. Remove the park brake cable from the cable guides. 9. Remove the brake shoes. Refer to Brake Shoe Replacement (See: Drum Brake System/Brake Shoe/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 9721 10. Using the J 37043 (1), remove the park brake cable from the backing plate. 11. Remove the park brake cable from the vehicle. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 9722 1. Install the park brake cable to the vehicle. 2. Install the brake shoes. Refer to Brake Shoe Replacement (See: Drum Brake System/Brake Shoe/Service and Repair). Ensure the locking tabs on the cable conduit are fully engaged into the rear axle bracket. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the park brake cable clip bolt (2). Tighten the bolt to 22 Nm (16 lb ft). 4. Connect the park brake cable (1) to the rear axle housing cover clip. 5. Install the park brake cable to the cable guides. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 9723 6. Connect the right rear park brake cable (1) to the intermediate cable equalizer bar (2). 7. Insert the park brake cable conduit (3) into the frame bracket. Ensure the locking tabs on the cable conduit are fully engaged into the frame bracket. 8. Enable the park brake cable automatic adjuster. Refer to Parking Brake Cable Adjuster Enabling (See: Procedures/Parking Brake Cable Adjuster Enabling). 9. Adjust the park brake. Refer to Parking Brake Adjustment (1500 Drum Brake) ()Parking Brake Adjustment (1500 Disc Brake) ()Parking Brake Adjustment (2500/3500 SRW) (See: Adjustments/Parking Brake Adjustment (SRW))Parking Brake Adjustment (3500 DRW) (See: Adjustments/Parking Brake Adjustment (DRW)). Parking Brake Rear Cable Replacement - Right Side (JH6, JH7) Parking Brake Rear Cable Replacement - Right Side (JH6, JH7) Removal Procedure 1. Release the park brake. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 9724 2. Disable the park brake cable automatic adjuster. Refer to Parking Brake Cable Adjuster Disabling (See: Procedures/Parking Brake Cable Adjuster Disabling). 3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 4. Disconnect the right park brake cable from the equalizer (1). 5. Release the right park brake cable from the frame bracket by compressing the locking tabs on the cable conduit (2) and pulling the cable rearward. 6. Release the park brake cable (1) from the rear axle housing cover clip. 7. Remove the park brake cable clip bolt (2). 8. Disconnect the park brake cable eye (3) from the park brake actuator lever (2). 9. Remove the park brake cable from the bracket by pulling the cable conduit (1) rearward to compress the spring and sliding the cable conduit out of the bracket. 10. Remove the park brake cable assembly from the vehicle. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 9725 1. Connect the right park brake cable eye (3) to the park brake actuator lever (2). 2. Install the park brake cable to the rear axle bracket by pulling the cable conduit (1) rearward to compress the spring and inserting the cable conduit into the rear axle bracket. 3. Connect the park brake cable (1) to the rear axle housing cover clip. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the park brake cable clip bolt (2) and tighten to 22 Nm (16 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 9726 5. Insert the park brake cable conduit (2) into the frame bracket. Ensure the locking tabs on the cable conduit are fully engaged into the frame bracket. 6. Connect the right rear park brake cable to the equalizer (1). 7. Enable the park brake cable automatic adjuster. Refer to Parking Brake Cable Adjuster Enabling (See: Procedures/Parking Brake Cable Adjuster Enabling). 8. Adjust the park brake. Refer to Parking Brake Adjustment (1500 Drum Brake) ()Parking Brake Adjustment (1500 Disc Brake) ()Parking Brake Adjustment (2500/3500 SRW) (See: Adjustments/Parking Brake Adjustment (SRW))Parking Brake Adjustment (3500 DRW) (See: Adjustments/Parking Brake Adjustment (DRW)). Parking Brake Cable Guide Replacement Parking Brake Cable Guide Replacement Removal Procedure 1. Release the park brake. 2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Procedures > Page 9727 3. Remove the park brake cable guide bolt from the frame. 4. Remove the park brake cable guide. 5. Remove the park brake cable guide from the park brake cable. Installation Procedure 1. Install the park brake cable guide to the park brake cable. 2. Install the park brake cable guide. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the park brake cable guide bolt to the frame and tighten to 12 Nm (106 lb in). 4. Lower the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Service and Repair Parking Brake Lever: Service and Repair Parking Brake Lever Pedal Assembly Replacement Removal Procedure Note: The following service procedure includes the removal of the front park brake cable. The front park brake cable is NOT serviced separately, but serviced with the park brake pedal assembly. 1. Remove the left side hinge pillar trim panel. Refer to Body Hinge Pillar Trim Panel Replacement (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Body Hinge Pillar Trim Panel Replacement). 2. Disconnect the park brake warning lamp electrical connector. 3. Disable the park brake cable automatic adjuster. Refer to Parking Brake Cable Adjuster Disabling (See: Parking Brake Cable/Service and Repair/Procedures/Parking Brake Cable Adjuster Disabling). 4. Remove the bolt and disconnect the park brake pedal release handle from the instrument panel. 5. Without disconnecting the electrical connectors, remove the left side instrument panel electrical center/junction block and position aside. Refer to Instrument Panel Electrical Center or Junction Block Replacement - Left Side (See: Maintenance/Fuses and Circuit Breakers/Fuse Block/Service and Repair/Removal and Replacement/Instrument Panel Electrical Center or Junction Block Replacement - Left Side). 6. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 7. Disconnect the front park brake cable from the intermediate cable connector by drilling a 3 mm (1/8 in) hole through the dimple in the front to intermediate park brake cable connector. 8. Release the front park brake cable from the frame by depressing the locking tabs. 9. Lower the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Service and Repair > Page 9731 10. Remove the park brake lever mounting nuts. 11. Position the floor carpet to expose the park brake cable pass-through grommet. 12. Release the park brake cable pass-through grommet from the vehicle floor. 13. Remove the park brake lever and front cable from the vehicle. Installation Procedure Note: Ensure the grommet for the front park brake cable is properly seated in the front floor panel. 1. Insert the front brake cable through the hole in the front floor panel and seat the pass-through grommet. 2. Position the floor carpet to the floor pan. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Service and Repair > Page 9732 3. Position the park brake pedal assembly on the side panel. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install and finger tighten the mounting nuts. Tighten the nuts to 25 Nm (18 lb ft). 5. Connect the park brake warning lamp connection. 6. Install the park brake release handle to the instrument panel. 7. Install the park brake release handle bolt and tighten to 9 Nm (80 lb in). 8. Install the hinge pillar trim panel. Refer to Body Hinge Pillar Trim Panel Replacement (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Body Hinge Pillar Trim Panel Replacement). 9. Install the left side instrument panel electrical center/junction block. Refer to Instrument Panel Electrical Center or Junction Block Replacement Left Side (See: Maintenance/Fuses and Circuit Breakers/Fuse Block/Service and Repair/Removal and Replacement/Instrument Panel Electrical Center or Junction Block Replacement - Left Side). 10. Raise the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Service and Repair > Page 9733 11. Install the front park brake cable to the frame and press the retainer into place. 12. Connect the front park brake cable to the front to intermediate park brake cable connector. 13. Lower the vehicle. 14. Enable the park brake cable automatic adjuster. Refer to Parking Brake Cable Adjuster Enabling (See: Parking Brake Cable/Service and Repair/Procedures/Parking Brake Cable Adjuster Enabling). 15. Adjust the park brake. Refer to Parking Brake Adjustment (1500 Drum Brake) ()Parking Brake Adjustment (1500 Disc Brake) ()Parking Brake Adjustment (2500/3500 SRW) (See: Adjustments/Parking Brake Adjustment (SRW))Parking Brake Adjustment (3500 DRW) (See: Adjustments/Parking Brake Adjustment (DRW)). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Parking Brake Shoe Replacement (JD9) Parking Brake Shoe: Service and Repair Parking Brake Shoe Replacement (JD9) Parking Brake Shoe Replacement (JD9) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Parking Brake Shoe Replacement (JD9) > Page 9738 Parking Brake Shoe: Service and Repair Parking Brake Shoe Replacement (JH6, JH7) Parking Brake Shoe Replacement (JH6, JH7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Parking Brake Shoe Replacement (JD9) > Page 9739 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Diagrams Parking Brake Warning Switch: Diagrams Component Connector End Views Park Brake Switch Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Diagrams > Page 9743 Parking Brake Warning Switch: Service and Repair Parking Brake Indicator Switch Replacement Removal Procedure Warning: Refer to Battery Disconnect Warning (See: Starting and Charging/Battery/Service Precautions). 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 2. Without disconnecting the electrical connectors, remove the left side instrument panel electrical center/junction block and position aside. Refer to Instrument Panel Electrical Center or Junction Block Replacement - Left Side (See: Maintenance/Fuses and Circuit Breakers/Fuse Block/Service and Repair/Removal and Replacement/Instrument Panel Electrical Center or Junction Block Replacement - Left Side). 3. Disconnect the park brake warning lamp switch electrical connector. 4. Remove the park brake warning lamp switch bolt. 5. Remove the park brake warning lamp switch. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Diagrams > Page 9744 1. Install the park brake warning lamp switch. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the park brake warning lamp switch bolt and tighten to 3 Nm (27 lb in). 3. Connect the park brake warning lamp switch electrical connector. 4. Install the left side instrument panel electrical center/junction block. Refer to Instrument Panel Electrical Center or Junction Block Replacement Left Side (See: Maintenance/Fuses and Circuit Breakers/Fuse Block/Service and Repair/Removal and Replacement/Instrument Panel Electrical Center or Junction Block Replacement - Left Side). 5. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Brake Booster Vacuum Sensor > Component Information > Diagrams Brake Booster Vacuum Sensor: Diagrams Component Connector End Views Brake Booster Vacuum Sensor (JL4 with 10 Series) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Brake Booster Vacuum Sensor > Component Information > Diagrams > Page 9749 Brake Booster Vacuum Sensor: Service and Repair Power Brake Booster Vacuum Sensor Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Service and Repair > Power Brake Booster Replacement (Non-Adjustable Pedals) Hydraulic Brake Booster: Service and Repair Power Brake Booster Replacement (Non-Adjustable Pedals) Power Brake Booster Replacement (Non-Adjustable Pedals) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Service and Repair > Power Brake Booster Replacement (Non-Adjustable Pedals) > Page 9754 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Service and Repair > Power Brake Booster Replacement (Non-Adjustable Pedals) > Page 9755 Hydraulic Brake Booster: Service and Repair Power Brake Booster Replacement (Adjustable Pedals) Power Brake Booster Replacement (Adjustable Pedals) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Service and Repair > Power Brake Booster Replacement (Non-Adjustable Pedals) > Page 9756 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster Pump > Component Information > Service and Repair Hydraulic Brake Booster Pump: Service and Repair Power Brake Booster Pump Fluid Accumulator Replacement (Non-Hybrid) Special Tools J-26889 - Accumulator Piston Compressor Removal Procedure Warning The accumulator contains compressed gas. Always use the proper tools and follow the recommended procedures or personal injury may result. Do not apply heat to accumulator. Do not attempt to repair an inoperative accumulator. Always replace an inoperative accumulator with a new one. Dispose of an inoperative accumulator by drilling a 1.5 mm (1/16 in) diameter hole through the end of the accumulator can, opposite the O-ring. Warning Push rod removal is not recommended. Improper staking of the push rod to the Hydroboost reaction piston can result in a loss of brakes. If the rod or seals require service, the entire unit must be replaced. 1. Apply the park brake and block the wheels. 2. Depress brake pedal at least 10 times in order to relieve pressure in the accumulator. 3. Remove the master cylinder from the hydraulic booster. Refer to Master Cylinder Replacement (Vacuum Assist) (See: Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Replacement)Master Cylinder Replacement (Two-Mode Hybrid) (See: Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Replacement)Master Cylinder Replacement (Hydraulic Assist) (See: Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Replacement). 4. Place the J-26889 - Accumulator Piston Compressor over the end of the accumulator. 5. Install the nut on the stud. 6. Depress the accumulator with a C-clamp. If the accumulator does not move with moderate pressure, remove the C-clamp and depress the brake pedal ten times in order to relieve pressure in the accumulator. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster Pump > Component Information > Service and Repair > Page 9760 7. Rotate the retaining ring (2) until either end of the ring is under the access hole (1). 8. Depress and hold the retaining ring (2) with a small tool inserted into the access hole (1). 9. Remove the accumulator retainer ring (1) using a small hook shaped tool. 10. Release the C-clamp. 11. Remove the nut from the stud. 12. Remove the J-26889 Compressor. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster Pump > Component Information > Service and Repair > Page 9761 13. Remove the accumulator (2) and the O-ring seal (3). Installation Procedure 1. Lubricate all of the seals and the metal friction points with power steering fluid. 2. Install the accumulator (2) and the O-ring seal (3). 3. Place the J-26889 - Compressor over the end of the accumulator. 4. Install the nut on the stud. 5. Depress the accumulator with a C-clamp. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster Pump > Component Information > Service and Repair > Page 9762 6. Install the accumulator retainer ring (1). 7. Release the C-clamp. 8. Remove the nut from the stud. 9. Remove the J-26889 - Compressor. 10. Install the master cylinder to the hydraulic booster. Refer to Master Cylinder Replacement (Vacuum Assist) (See: Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Replacement)Master Cylinder Replacement (Two-Mode Hybrid) (See: Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Replacement)Master Cylinder Replacement (Hydraulic Assist) (See: Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement/Master Cylinder Replacement). 11. Release the park brake and unblock the wheels. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Fluid Accumulator > Component Information > Service and Repair Hydraulic Fluid Accumulator: Service and Repair Power Brake Booster Pump Fluid Accumulator Disposal Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Power Vacuum Brake Booster Replacement (Without JF4) Vacuum Brake Booster: Service and Repair Power Vacuum Brake Booster Replacement (Without JF4) Power Vacuum Brake Booster Replacement (Without JF4) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Power Vacuum Brake Booster Replacement (Without JF4) > Page 9770 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Power Vacuum Brake Booster Replacement (Without JF4) > Page 9771 Vacuum Brake Booster: Service and Repair Power Vacuum Brake Booster Replacement (With JF4) Power Vacuum Brake Booster Replacement (With JF4) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Power Vacuum Brake Booster Replacement (Without JF4) > Page 9772 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Pump, Brakes > Component Information > Service and Repair Vacuum Pump: Service and Repair Power Brake Booster Vacuum Check Valve and Hose Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Trailer Brakes > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Accessories - Aftermarket Trailer Brake Controller Trailer Brake Control Module: Technical Service Bulletins Accessories - Aftermarket Trailer Brake Controller INFORMATION Bulletin No.: 07-08-45-001F Date: November 09, 2010 Subject: Procedure for Installation of an Aftermarket Trailer Brake Controller Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2010 HUMMER H2 with Integrated Trailer Brake Controller Supercede: This bulletin is being revised to combine information from bulletins 06-08-45-008D and 07-08-45-001E. Please discard Corporate Bulletin Numbers 07-08-45-001E and 06-08-45-008D (Section 08 - Body and Accessories). Important Installation of an electric brake controller and the wiring connections outlined in this bulletin are the responsibility of the dealership or customer. These repairs should never be charged to warranty. If you have any questions, please consult with your District Service Manager. Some customers may request to have an aftermarket trailer brake controller added to their vehicle, OR in lieu of the factory integrated trailer brake controller (ITBC) (RPO JL1). Installation Instructions Starting with the new 2007 full-size utilities and pickups and 2008 HUMMER H2, there is no longer an electric trailer brake controller pigtail harness. To install an aftermarket trailer brake controller, use the four blunt cut wires located near the data link connector. The following steps should be used to complete the installation. Important Ensure that the ringlets are not interfering with the UBEC cover. 1. Place the terminal on the larger of the two studs at the front of the electrical center and secure with an M8 nut. This is circuit #242 to stud #2, to power the aftermarket trailer brake controller. Important The fuse is already present in the vehicle to power the electrical trailer brake controller system. 2. ONLY For Vehicles Equipped with JL1 - Locate connector X126 or X115 (varies with vehicle build; refer to SI) near the underhood fuse block. Refer to SI Document ID# 1849049 - I/P Harness-Engine Compartment. Circuit 47 from the blunt cut wires near the data link connector will end Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Trailer Brakes > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Accessories - Aftermarket Trailer Brake Controller > Page 9781 at connector X126 terminal "G" or X115 terminal "B5." Obtain enough Dark Blue 12 gauge wire to run from X126/X115 to the 7-way trailer connector at the bumper. On one end of the Dark Blue wire attach terminal part number 15304732, located in Delphi Tray 8 and insert into X126 "G" or terminal part number 15304720 located in Delphi Tray 19 and insert into X115 "B5." Run the Dark Blue wire in its own conduit along the frame to the 7-way trailer connector at the bumper. Remove circuit 47 from the 7-way trailer connector terminal "C" and tape the bare terminal and attach to the harness. Attach terminal part number 12110853, located in Delphi Tray 4, to the other end of the Dark Blue wire and insert it into the 7-way trailer connector terminal "C." 3. ONLY For Vehicles Equipped with JL1 - The Red/Black wire, circuit 242, must be connected to stud #2 of the 30 Amp fuse of the underhood fuse block. This wire is located between the left fender and the underhood fuse block. Important This procedure will not result in any trailer brake related display messages to be set. However, ITBC diagnostics will continue to function. If an ITBC fault is detected, a "Service Trailer Brake System" message will be displayed on the driver information center (DIC) and an appropriate DTC will be stored in the ITBC module. The operator will still be able to adjust gain and access the "Trailer Gain / Output" display page in the DIC. However, the factory installed ITBC system will not sense a trailer connection and will not provide output to the trailer. 4. Locate the trailer brake control circuits that are looped and taped to the main harness under the instrument panel. 5. Pull the trailering wire harness down. 6. Match the vehicle harness label circuit functions to the trailer brake controller jumper harness functions. Important The color or wires to be joined together may not match. - Dark Blue Wire: switched power from controller to trailer brakes - Red with Black Stripe: fused vehicle power to electrical brake controller Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Trailer Brakes > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Accessories - Aftermarket Trailer Brake Controller > Page 9782 - Light Blue with White Stripe: Brake switch input to power electric brake controller - White: ground - Orange: CHMSL (Center High Mounted Stop Lamp) - not required with most systems 7. After completing the under dash connections to the electric brake controller, open the hood and locate the red wire that is taped to the harness between the underhood electrical center and the driver side front fender. 8. Break the tape on the red/black wire and pull it toward the front of vehicle. 9. Remove the lid from the electrical center. Auxiliary Power (Applies to All LD and 2007-2009 HD's Only) Without JL1 Circuit #742 for Auxiliary Power at the 7-way trailer connector is no longer connected by the GM Assembly Plant. If the customer desires auxiliary power at the trailer connector location (i.e. refrigeration, battery charger or interior light in the trailer), complete the following steps to connect circuit #742: 1. Locate the red/black wire, looped and taped to the chassis harness, below the brake master cylinder. 2. Break the tape and route the wire to the front of the underhood electrical center. Important Ensure that the ringlets are not interfering with the UBEC cover. 3. Place the terminal on the smaller of the two studs on the electrical center and secure with an M6 fastener. This is circuit #742 to stud #1 for auxiliary power to the 7-way trailer connector. 4. ONLY for vehicles without RPO TP2 - Auxiliary Battery, install a 40 amp fuse to power the circuit. Important For vehicles equipped with RPO TP2 - Devices powered by this fuse will drain the vehicle battery if left connected with the vehicle not running. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Trailer Brakes > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Accessories - Aftermarket Trailer Brake Controller > Page 9783 Warranty Information This installation procedure is to be performed at the customer's request and at their expense. It is not a warranty repair and a claim should not be submitted for reimbursement. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Trailer Brakes > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Accessories - Aftermarket Trailer Brake Controller > Page 9784 Trailer Brake Control Module: Technical Service Bulletins Brakes - Aftermarket Trailer Brake Controllers INFORMATION Bulletin No.: 06-08-45-008D Date: July 12, 2010 Subject: Information on Auxiliary Power Wire at Trailer and Installation of Aftermarket Trailer Brake Controller - Towing, Tow Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2011 HUMMER H2 Supercede: This bulletin is being revised to add the 2011 model year and information about the orientation of the ringlet. Please discard Corporate Bulletin Number 06-08-45-008C (Section 08 Body and Accessories). Important Installation of an electric brake controller and the wiring connections outlined in this bulletin are the responsibility of the dealership or customer. These repairs should never be charged to warranty. If you have any questions, please consult with your District Service Manager. Some customers may have questions on how to connect an electric trailer brake controller or where the brake controller pigtail harness is located. Starting with the new 2007 full-size utilities and pickups and 2008 HUMMER H2, there is no longer an electric trailer brake controller pigtail harness. An aftermarket brake controller will need to be installed/connected to the blunt wires under the left side of the IP for vehicles built without JL1 - Integrated Brake Controller (full-size utilities and pickups). The following steps should be used to complete the installation. 1. Locate the trailer brake control circuits that are looped and taped to the main harness under the instrument panel. 2. Pull the trailering wire harness down. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Trailer Brakes > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Accessories - Aftermarket Trailer Brake Controller > Page 9785 3. Match the vehicle harness label circuit functions to the trailer brake controller jumper harness functions. Important The color or wires to be joined together may not match. - Dark Blue Wire: switched power from controller to trailer brakes - Red with Black Stripe: fused vehicle power to electrical brake controller - Light Blue with White Stripe: Brake switch input to power electric brake controller - White: ground - Orange: CHMSL (Center High Mounted Stop Lamp) - not required with most systems 4. After completing the under dash connections to the electric brake controller, open the hood and locate the red wire that is taped to the harness between the underhood electrical center and the driver side front fender. 5. Break the tape on the red/black wire and pull it toward the front of vehicle. 6. Remove the lid from the electrical center. Important Ensure that the ringlets are not interfering with the UBEC cover. 7. Place the terminal on the larger of the two studs at the front of the electrical center and secure with an M8 nut. This is circuit #242 to stud #2, to power the aftermarket trailer brake controller. Important The fuse is already present in the vehicle to power the electrical trailer brake controller system. Auxiliary Power (Applies to All LD & 07-09 HD's Only) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Trailer Brakes > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Accessories - Aftermarket Trailer Brake Controller > Page 9786 Circuit #742 for Auxiliary Power at the 7-way trailer connector is no longer connected by the GM Assembly Plant. If the customer desires auxiliary power at the trailer connector location (i.e. refrigeration, battery charger or interior light in the trailer), complete the following steps to connect circuit #742: 1. Locate the red/black wire, looped and taped to the chassis harness, below the brake master cylinder. 2. Break the tape and route the wire to the front of the underhood electrical center. Important Ensure that the ringlets are not interfering with the UBEC cover. 3. Place the terminal on the smaller of the two studs on the electrical center and secure with an M6 fastener. This is circuit #742 to stud #1 for auxiliary power to the 7-way trailer connector. 4. ONLY for vehicles without RPO TP2 - Auxiliary Battery, install a 40 amp fuse to power the circuit. Important For vehicles equipped with RPO TP2 - Devices powered by this fuse will drain the vehicle battery if left connected with the vehicle not running. Warranty Information This installation procedure is to be performed at the customer's request and at their expense. It is not a warranty repair and a claim should not be submitted for reimbursement. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Trailer Brakes > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Page 9787 Trailer Brake Control Module: Diagrams Component Connector End Views Trailer Brake Control Module (JL1 except 31 Series) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Trailer Brakes > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Page 9788 Trailer Brake Control Module (JL1 with 31 Series) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Trailer Brakes > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Page 9789 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Trailer Brakes > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Page 9790 Fuel Pump/Trailer Brake Control Module (Gas with JL1 and except LU3, LY6 or LY6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Trailer Brakes > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Page 9791 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Trailer Brakes > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Page 9792 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Trailer Brakes > Trailer Brake Control Module > Component Information > Service and Repair > Trailer Brake Control Switch Replacement Trailer Brake Control Module: Service and Repair Trailer Brake Control Switch Replacement Trailer Brake Control Switch Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Trailer Brakes > Trailer Brake Control Module > Component Information > Service and Repair > Trailer Brake Control Switch Replacement > Page 9795 Trailer Brake Control Module: Service and Repair Trailer Brake Control Module Replacement Trailer Brake Control Module Replacement (2500, 3500) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams Electronic Brake Control Module: Diagrams Component Connector End Views Electronic Brake Control Module (EBCM) (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Page 9800 Electronic Brake Control Module (EBCM) (JF3 or JF7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Page 9801 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Page 9802 Electronic Brake Control Module (EBCM) (JH6 or JH7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Page 9803 Electronic Brake Control Module (EBCM) (JL4 except 10 Series) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Page 9804 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Page 9805 Electronic Brake Control Module (EBCM) (JL4 with 10 Series) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Page 9806 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Page 9807 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Non-Hybrid Less than 3900 kg (8600 lb) GVW Electronic Brake Control Module: Service and Repair Non-Hybrid Less than 3900 kg (8600 lb) GVW Electronic Brake Control Module Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Non-Hybrid Less than 3900 kg (8600 lb) GVW > Page 9810 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Non-Hybrid Less than 3900 kg (8600 lb) GVW > Page 9811 Electronic Brake Control Module: Service and Repair Non-Hybrid Greater than/Equal to 3900 kg (8600 lb) GVW Electronic Brake Control Module Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Accessories - Aftermarket Trailer Brake Controller Trailer Brake Control Module: Technical Service Bulletins Accessories - Aftermarket Trailer Brake Controller INFORMATION Bulletin No.: 07-08-45-001F Date: November 09, 2010 Subject: Procedure for Installation of an Aftermarket Trailer Brake Controller Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2010 HUMMER H2 with Integrated Trailer Brake Controller Supercede: This bulletin is being revised to combine information from bulletins 06-08-45-008D and 07-08-45-001E. Please discard Corporate Bulletin Numbers 07-08-45-001E and 06-08-45-008D (Section 08 - Body and Accessories). Important Installation of an electric brake controller and the wiring connections outlined in this bulletin are the responsibility of the dealership or customer. These repairs should never be charged to warranty. If you have any questions, please consult with your District Service Manager. Some customers may request to have an aftermarket trailer brake controller added to their vehicle, OR in lieu of the factory integrated trailer brake controller (ITBC) (RPO JL1). Installation Instructions Starting with the new 2007 full-size utilities and pickups and 2008 HUMMER H2, there is no longer an electric trailer brake controller pigtail harness. To install an aftermarket trailer brake controller, use the four blunt cut wires located near the data link connector. The following steps should be used to complete the installation. Important Ensure that the ringlets are not interfering with the UBEC cover. 1. Place the terminal on the larger of the two studs at the front of the electrical center and secure with an M8 nut. This is circuit #242 to stud #2, to power the aftermarket trailer brake controller. Important The fuse is already present in the vehicle to power the electrical trailer brake controller system. 2. ONLY For Vehicles Equipped with JL1 - Locate connector X126 or X115 (varies with vehicle build; refer to SI) near the underhood fuse block. Refer to SI Document ID# 1849049 - I/P Harness-Engine Compartment. Circuit 47 from the blunt cut wires near the data link connector will end Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Accessories - Aftermarket Trailer Brake Controller > Page 9816 at connector X126 terminal "G" or X115 terminal "B5." Obtain enough Dark Blue 12 gauge wire to run from X126/X115 to the 7-way trailer connector at the bumper. On one end of the Dark Blue wire attach terminal part number 15304732, located in Delphi Tray 8 and insert into X126 "G" or terminal part number 15304720 located in Delphi Tray 19 and insert into X115 "B5." Run the Dark Blue wire in its own conduit along the frame to the 7-way trailer connector at the bumper. Remove circuit 47 from the 7-way trailer connector terminal "C" and tape the bare terminal and attach to the harness. Attach terminal part number 12110853, located in Delphi Tray 4, to the other end of the Dark Blue wire and insert it into the 7-way trailer connector terminal "C." 3. ONLY For Vehicles Equipped with JL1 - The Red/Black wire, circuit 242, must be connected to stud #2 of the 30 Amp fuse of the underhood fuse block. This wire is located between the left fender and the underhood fuse block. Important This procedure will not result in any trailer brake related display messages to be set. However, ITBC diagnostics will continue to function. If an ITBC fault is detected, a "Service Trailer Brake System" message will be displayed on the driver information center (DIC) and an appropriate DTC will be stored in the ITBC module. The operator will still be able to adjust gain and access the "Trailer Gain / Output" display page in the DIC. However, the factory installed ITBC system will not sense a trailer connection and will not provide output to the trailer. 4. Locate the trailer brake control circuits that are looped and taped to the main harness under the instrument panel. 5. Pull the trailering wire harness down. 6. Match the vehicle harness label circuit functions to the trailer brake controller jumper harness functions. Important The color or wires to be joined together may not match. - Dark Blue Wire: switched power from controller to trailer brakes - Red with Black Stripe: fused vehicle power to electrical brake controller Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Accessories - Aftermarket Trailer Brake Controller > Page 9817 - Light Blue with White Stripe: Brake switch input to power electric brake controller - White: ground - Orange: CHMSL (Center High Mounted Stop Lamp) - not required with most systems 7. After completing the under dash connections to the electric brake controller, open the hood and locate the red wire that is taped to the harness between the underhood electrical center and the driver side front fender. 8. Break the tape on the red/black wire and pull it toward the front of vehicle. 9. Remove the lid from the electrical center. Auxiliary Power (Applies to All LD and 2007-2009 HD's Only) Without JL1 Circuit #742 for Auxiliary Power at the 7-way trailer connector is no longer connected by the GM Assembly Plant. If the customer desires auxiliary power at the trailer connector location (i.e. refrigeration, battery charger or interior light in the trailer), complete the following steps to connect circuit #742: 1. Locate the red/black wire, looped and taped to the chassis harness, below the brake master cylinder. 2. Break the tape and route the wire to the front of the underhood electrical center. Important Ensure that the ringlets are not interfering with the UBEC cover. 3. Place the terminal on the smaller of the two studs on the electrical center and secure with an M6 fastener. This is circuit #742 to stud #1 for auxiliary power to the 7-way trailer connector. 4. ONLY for vehicles without RPO TP2 - Auxiliary Battery, install a 40 amp fuse to power the circuit. Important For vehicles equipped with RPO TP2 - Devices powered by this fuse will drain the vehicle battery if left connected with the vehicle not running. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Accessories - Aftermarket Trailer Brake Controller > Page 9818 Warranty Information This installation procedure is to be performed at the customer's request and at their expense. It is not a warranty repair and a claim should not be submitted for reimbursement. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Accessories - Aftermarket Trailer Brake Controller > Page 9819 Trailer Brake Control Module: Technical Service Bulletins Brakes - Aftermarket Trailer Brake Controllers INFORMATION Bulletin No.: 06-08-45-008D Date: July 12, 2010 Subject: Information on Auxiliary Power Wire at Trailer and Installation of Aftermarket Trailer Brake Controller - Towing, Tow Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2011 HUMMER H2 Supercede: This bulletin is being revised to add the 2011 model year and information about the orientation of the ringlet. Please discard Corporate Bulletin Number 06-08-45-008C (Section 08 Body and Accessories). Important Installation of an electric brake controller and the wiring connections outlined in this bulletin are the responsibility of the dealership or customer. These repairs should never be charged to warranty. If you have any questions, please consult with your District Service Manager. Some customers may have questions on how to connect an electric trailer brake controller or where the brake controller pigtail harness is located. Starting with the new 2007 full-size utilities and pickups and 2008 HUMMER H2, there is no longer an electric trailer brake controller pigtail harness. An aftermarket brake controller will need to be installed/connected to the blunt wires under the left side of the IP for vehicles built without JL1 - Integrated Brake Controller (full-size utilities and pickups). The following steps should be used to complete the installation. 1. Locate the trailer brake control circuits that are looped and taped to the main harness under the instrument panel. 2. Pull the trailering wire harness down. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Accessories - Aftermarket Trailer Brake Controller > Page 9820 3. Match the vehicle harness label circuit functions to the trailer brake controller jumper harness functions. Important The color or wires to be joined together may not match. - Dark Blue Wire: switched power from controller to trailer brakes - Red with Black Stripe: fused vehicle power to electrical brake controller - Light Blue with White Stripe: Brake switch input to power electric brake controller - White: ground - Orange: CHMSL (Center High Mounted Stop Lamp) - not required with most systems 4. After completing the under dash connections to the electric brake controller, open the hood and locate the red wire that is taped to the harness between the underhood electrical center and the driver side front fender. 5. Break the tape on the red/black wire and pull it toward the front of vehicle. 6. Remove the lid from the electrical center. Important Ensure that the ringlets are not interfering with the UBEC cover. 7. Place the terminal on the larger of the two studs at the front of the electrical center and secure with an M8 nut. This is circuit #242 to stud #2, to power the aftermarket trailer brake controller. Important The fuse is already present in the vehicle to power the electrical trailer brake controller system. Auxiliary Power (Applies to All LD & 07-09 HD's Only) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Accessories - Aftermarket Trailer Brake Controller > Page 9821 Circuit #742 for Auxiliary Power at the 7-way trailer connector is no longer connected by the GM Assembly Plant. If the customer desires auxiliary power at the trailer connector location (i.e. refrigeration, battery charger or interior light in the trailer), complete the following steps to connect circuit #742: 1. Locate the red/black wire, looped and taped to the chassis harness, below the brake master cylinder. 2. Break the tape and route the wire to the front of the underhood electrical center. Important Ensure that the ringlets are not interfering with the UBEC cover. 3. Place the terminal on the smaller of the two studs on the electrical center and secure with an M6 fastener. This is circuit #742 to stud #1 for auxiliary power to the 7-way trailer connector. 4. ONLY for vehicles without RPO TP2 - Auxiliary Battery, install a 40 amp fuse to power the circuit. Important For vehicles equipped with RPO TP2 - Devices powered by this fuse will drain the vehicle battery if left connected with the vehicle not running. Warranty Information This installation procedure is to be performed at the customer's request and at their expense. It is not a warranty repair and a claim should not be submitted for reimbursement. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Page 9822 Trailer Brake Control Module: Diagrams Component Connector End Views Trailer Brake Control Module (JL1 except 31 Series) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Page 9823 Trailer Brake Control Module (JL1 with 31 Series) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Page 9824 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Page 9825 Fuel Pump/Trailer Brake Control Module (Gas with JL1 and except LU3, LY6 or LY6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Page 9826 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Page 9827 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Service and Repair > Trailer Brake Control Switch Replacement Trailer Brake Control Module: Service and Repair Trailer Brake Control Switch Replacement Trailer Brake Control Switch Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Trailer Brake Control Module > Component Information > Service and Repair > Trailer Brake Control Switch Replacement > Page 9830 Trailer Brake Control Module: Service and Repair Trailer Brake Control Module Replacement Trailer Brake Control Module Replacement (2500, 3500) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Booster Vacuum Sensor > Component Information > Diagrams Brake Booster Vacuum Sensor: Diagrams Component Connector End Views Brake Booster Vacuum Sensor (JL4 with 10 Series) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Booster Vacuum Sensor > Component Information > Diagrams > Page 9835 Brake Booster Vacuum Sensor: Service and Repair Power Brake Booster Vacuum Sensor Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Diagrams Brake Fluid Level Sensor/Switch: Diagrams Component Connector End Views Brake Fluid Level Switch Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Diagrams > Page 9839 Brake Fluid Level Sensor/Switch: Service and Repair Brake Fluid Level Indicator Switch Replacement (Non-Hybrid) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Diagrams Brake Fluid Pressure Sensor/Switch: Diagrams Component Connector End Views Brake Master Cylinder Pressure Sensor (JL1) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Diagrams > Page 9843 Brake Fluid Pressure Sensor/Switch: Service and Repair Brake Master Cylinder Pressure Sensor Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Service and Repair Braking Sensor/Switch: Service and Repair Brake Master Cylinder Primary Piston Position Sensor Replacement Removal Procedure Note: The ignition must be in the OFF position, without pausing at ACCESSORY, and without applying the brake pedal to ensure the brake modulator and high pressure accumulator (HPA) pressure relief occurs. This process will take approximately 1 to 3 minutes. 1. Turn the ignition to OFF, without pausing at ACCESSORY, and without applying the brake pedal. Remove the ignition key. 2. Wait approximately 1 to 3 minutes until the brake modulator and HPA pressure relief is complete. 3. Disconnect the brake master cylinder (BMC) primary piston position sensor electrical connector. 4. Remove the 2 BMC primary piston position sensor screws (1). 5. Remove the primary piston position sensor (2). Tilt the rear of the position sensor downward and remove the sensor. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Service and Repair > Page 9847 1. Install the BMC primary piston position sensor (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the 2 BMC primary piston position sensor screws (1) and tighten to 10 Nm (89 lb in). 3. Connect the primary piston position sensor electrical connector. 4. Inspect the battery state of charge. Refer to Battery Inspection/Test (See: Starting and Charging/Testing and Inspection/Component Tests and General Diagnostics). 5. If necessary, connect a battery charger to the 12V battery. Refer to Battery Charging (See: Starting and Charging/Battery/Service and Repair/Procedures) 6. Install a scan tool to the vehicle. Note: The ignition switch must remain in the ON position with the engine OFF during this procedure. 7. Turn the ignition ON with the engine OFF. 8. Using the scan tool, perform the following steps: 1. Select Diagnostics 2. Select the appropriate vehicle information 3. Select Chassis 4. Select Electronic Brake Control Module (EBCM) 5. Select Module Setup 6. Select BMC Primary Piston Position Relearn and follow the instructions on the scan tool Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Diagrams Lateral Accelerometer: Diagrams Component Connector End Views Yaw and Lateral Accelerometer Sensor (HP2) Yaw and Lateral Accelerometer Sensor (JL4 except 10 Series) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Diagrams > Page 9851 Yaw and Lateral Accelerometer Sensor (JL4 with 10 Series) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Diagrams > Page 9852 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Diagrams Parking Brake Warning Switch: Diagrams Component Connector End Views Park Brake Switch Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Diagrams > Page 9856 Parking Brake Warning Switch: Service and Repair Parking Brake Indicator Switch Replacement Removal Procedure Warning: Refer to Battery Disconnect Warning (See: Starting and Charging/Battery/Service Precautions). 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 2. Without disconnecting the electrical connectors, remove the left side instrument panel electrical center/junction block and position aside. Refer to Instrument Panel Electrical Center or Junction Block Replacement - Left Side (See: Maintenance/Fuses and Circuit Breakers/Fuse Block/Service and Repair/Removal and Replacement/Instrument Panel Electrical Center or Junction Block Replacement - Left Side). 3. Disconnect the park brake warning lamp switch electrical connector. 4. Remove the park brake warning lamp switch bolt. 5. Remove the park brake warning lamp switch. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Diagrams > Page 9857 1. Install the park brake warning lamp switch. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the park brake warning lamp switch bolt and tighten to 3 Nm (27 lb in). 3. Connect the park brake warning lamp switch electrical connector. 4. Install the left side instrument panel electrical center/junction block. Refer to Instrument Panel Electrical Center or Junction Block Replacement Left Side (See: Maintenance/Fuses and Circuit Breakers/Fuse Block/Service and Repair/Removal and Replacement/Instrument Panel Electrical Center or Junction Block Replacement - Left Side). 5. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams Wheel Speed Sensor: Diagrams Component Connector End Views Wheel Speed Sensor (WSS) - Left Front (10 Series) Wheel Speed Sensor (WSS) - Left Front (except 10 Series) Wheel Speed Sensor (WSS) - Left Rear (JL4 or HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Page 9861 Wheel Speed Sensor (WSS) - Right Front (10 Series) Wheel Speed Sensor (WSS) - Right Front (except 10 Series) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Page 9862 Wheel Speed Sensor (WSS) - Right Rear (JL4 or HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement Wheel Speed Sensor: Service and Repair Front Wheel Speed Sensor Replacement Non-Hybrid Less than 3900 kg (8600 lb) GVW Front Wheel Speed Sensor Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 9865 Non-Hybrid Greater than/Equal to 3900 kg (8600 lb) GVW Front Wheel Speed Sensor Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 9866 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 9867 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 9868 Wheel Speed Sensor: Service and Repair Rear Wheel Speed Sensor Replacement Non-Hybrid Less than 3900 kg (8600 lb) GVW Rear Wheel Speed Sensor Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 9869 Non-Hybrid Greater than/Equal to 3900 kg (8600 lb) GVW Rear Wheel Speed Sensor Replacement Removal Procedure Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 9870 2. Disconnect the wheel speed sensor electrical connector (1). 3. Release the wheel speed sensor electrical connector and sensor harness clips (2) from the inboard frame rail. 4. Remove the wheel speed sensor bolt (1). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 9871 5. Remove the wheel speed sensor (1) from the rear axle. Installation Procedure 1. Install the wheel speed sensor (1) to the rear axle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 9872 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the wheel speed sensor bolt (1) and tighten to 9 Nm (80 lb in). 3. Connect the wheel speed sensor electrical connector (1). 4. Install the wheel speed sensor electrical connector and sensor harness clips (2) to the inboard frame rail. 5. Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 9873 Wheel Speed Sensor: Service and Repair Rear Wheel Speed Sensor Ring Replacement Non-Hybrid Less than 3900 kg (8600 lb) GVW Rear Wheel Speed Sensor Ring Replacement Special Tools * J-8092 - Driver Handle * J-21128 - Axle Pinion Oil Seal Installer * J-23690 - Bearing Installer * J-2619-01 - Slide Hammer * J-45857 - Tone Wheel and/or Bearing Remover * J-45860 - Tone Ring Installer Removal Procedure 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair ). 3. Remove the rear wheel speed sensor. Refer to Rear Wheel Speed Sensor Replacement (See: Rear Wheel Speed Sensor Replacement/Non-Hybrid Less than 3900 kg (8600 lb) GVW). 4. Remove the rear axle housing cover. Refer to Rear Axle Housing Cover and Gasket Replacement (8.6, 9.5 Inch Axles) ()Rear Axle Housing Cover and Gasket Replacement (10.5/11.5 Inch Axle) (). 5. Remove the axle shaft. Refer to Rear Axle Shaft Replacement (See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft Assembly/Axle Shaft/Service and Repair). 6. Remove the axle shaft seal, the bearing and the wheel speed sensor ring from the axle housing using the J-2619-01 - Slide Hammer (1) and the J-45857 - Tone Wheel and/or Bearing Remover (2). Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 9874 1. Install the wheel speed sensor ring using the J-45860 - Tone Ring Installer (1) and the J-8092 Driver Handle (2). 2. Drive the wheel speed sensor ring into the axle housing until the tool bottoms against the tube. 3. Install the axle shaft bearing using the J-23690 - Bearing Installer (1) and the J-8092 - Driver Handle (2). 4. Drive the axle shaft bearing into the axle housing until the tool bottoms against the tube. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 9875 5. Install the axle shaft seal using the J-21128 - Axle Pinion Oil Seal Installer. 6. Drive the tool into the bore until the axle shaft seal bottoms flush with the tube. 7. Install the axle shaft. Refer to Rear Axle Shaft Replacement (See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft Assembly/Axle Shaft/Service and Repair). 8. Install the rear axle housing cover. Refer to Rear Axle Housing Cover and Gasket Replacement (8.6, 9.5 Inch Axles) ()Rear Axle Housing Cover and Gasket Replacement (10.5/11.5 Inch Axle) (). 9. Install the rear wheel speed sensor. Refer to Rear Wheel Speed Sensor Replacement (See: Rear Wheel Speed Sensor Replacement/Non-Hybrid Less than 3900 kg (8600 lb) GVW). 10. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 11. Fill the rear axle. Refer to Differential Oil Replacement (10.5 Inch Axle) (See: Maintenance/Fluids/Fluid - Differential/Service and Repair/Removal and Replacement)Differential Oil Replacement (11.5 Inch Axle) (See: Maintenance/Fluids/Fluid - Differential/Service and Repair/Removal and Replacement)Differential Oil Replacement (8.6 Inch Axle) (See: Maintenance/Fluids/Fluid - Differential/Service and Repair/Removal and Replacement)Differential Oil Replacement (9.5LD Inch Axle) (See: Maintenance/Fluids/Fluid - Differential/Service and Repair/Removal and Replacement). 12. Lower the vehicle. Non-Hybrid Greater than/Equal to 3900 kg (8600 lb) GVW Rear Wheel Speed Sensor Ring Replacement Removal Procedure Note: The wheel speed sensor ring is integral to the wheel hub and must be replaced as an assembly. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair ). 3. Remove the rear brake rotor. Refer to Rear Brake Rotor Replacement (JD9) (See: Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JD9))Rear Brake Rotor Replacement (JH6) (See: Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JH6))Rear Brake Rotor Replacement (JH7) (See: Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JH7)). 4. Remove the rear axle hub. Refer to Rear Axle Hub, Bearing, Cup, and/or Seal Replacement (See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Bearing/Service and Repair/Rear Axle Hub, Bearing, Cup, and/or Seal Replacement). Installation Procedure 1. Install the rear axle hub. Refer to Rear Axle Hub, Bearing, Cup, and/or Seal Replacement (See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Bearing/Service and Repair/Rear Axle Hub, Bearing, Cup, and/or Seal Replacement). 2. Install the rear brake rotor. Refer to Rear Brake Rotor Replacement (JD9) (See: Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JD9))Rear Brake Rotor Replacement (JH6) (See: Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JH6))Rear Brake Rotor Replacement (JH7) (See: Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor Replacement > Page 9876 Brake Rotor Replacement (JH7)). 3. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Diagrams Yaw Rate Sensor: Diagrams Component Connector End Views Yaw and Lateral Accelerometer Sensor (HP2) Yaw and Lateral Accelerometer Sensor (JL4 except 10 Series) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Diagrams > Page 9880 Yaw and Lateral Accelerometer Sensor (JL4 with 10 Series) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Diagrams > Page 9881 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Service and Repair > Non-Hybrid Less than 3900 kg (8600 lb) GVW Yaw Rate Sensor: Service and Repair Non-Hybrid Less than 3900 kg (8600 lb) GVW Vehicle Yaw Sensor with Vehicle Lateral Accelerometer Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Service and Repair > Non-Hybrid Less than 3900 kg (8600 lb) GVW > Page 9884 Yaw Rate Sensor: Service and Repair Non-Hybrid Greater than/Equal to 3900 kg (8600 lb) GVW Vehicle Yaw Sensor with Vehicle Lateral Accelerometer Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Current Sensor > Component Information > Diagrams Battery Current Sensor: Diagrams Component Connector End Views Battery Current Sensor (10 Series without MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Current Sensor > Component Information > Diagrams > Page 9890 Battery Current Sensor: Service and Repair Battery Current Sensor Replacement Removal Procedure 1. Remove the negative battery cable. Refer to Battery Negative Cable Replacement (V6) (See: Battery/Battery Cable/Negative/Service and Repair )Battery Negative Cable Replacement (V8) (See: Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Replacement (Diesel) (See: Battery/Battery Cable/Negative/Service and Repair). 2. Mark the location of the battery current sensor on the battery cable with tape for reference during installation. 3. Remove the tape securing the battery current sensor to the negative battery cable. 4. Mark the location of the negative battery cable clips (1) and remove the clips from the cable. 5. Squeeze the negative battery cable branches together. Important: Note the orientation of the battery current sensor prior to removal. 6. Slide the battery current sensor (2) off of the negative battery cable. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Current Sensor > Component Information > Diagrams > Page 9891 1. Squeeze the negative battery cable branches together. Important: Ensure the battery current sensor is installed in the correct direction and location on the negative battery cable. 2. Slide the NEW battery current sensor (2) up onto the negative battery cable to the location previously marked during removal. 3. Wrap electrical tape around the battery current sensor leg in order to secure the sensor to the negative battery cable. 4. Install the negative battery cable clips (1) to the cable to the locations previously marked during removal. 5. Install the negative battery cable. Refer to Battery Negative Cable Replacement (V6) (See: Battery/Battery Cable/Negative/Service and Repair )Battery Negative Cable Replacement (V8) (See: Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Replacement (Diesel) (See: Battery/Battery Cable/Negative/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder Case Replacement Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder Case Replacement Ignition Lock Cylinder Case Replacement Removal Procedure Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). 1. Remove the inflatable restraint steering wheel module coil. Refer to Steering Wheel Inflatable Restraint Module Coil Replacement (See: Restraint Systems/Air Bag Systems/Clockspring Assembly / Spiral Cable/Service and Repair/Removal and Replacement). 2. Remove the ignition/start switch. Refer to Ignition and Start Switch Replacement (See: Service and Repair). 3. Disconnect the park lock cable from the ignition lock cylinder case. 4. Disconnect the passlock and key buzzer from the ignition lock cylinder case. 5. Remove the 3 ignition lock cylinder case screws (2). 6. Remove the ignition lock cylinder case (1) from the vehicle. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder Case Replacement > Page 9897 1. Install the ignition lock cylinder case (1) to the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the 3 ignition lock cylinder case screws (2). Tighten the screws to 7 Nm (62 lb in). 3. Install the park lock cable into the lock cylinder housing. 4. Connect the passlock and key buzzer to the ignition lock cylinder case. 5. Install the ignition/start switch. Refer to Ignition and Start Switch Replacement (See: Service and Repair). 6. Install the inflatable restraint steering wheel module coil. Refer to Steering Wheel Inflatable Restraint Module Coil Replacement (See: Restraint Systems/Air Bag Systems/Clockspring Assembly / Spiral Cable/Service and Repair/Removal and Replacement). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder Case Replacement > Page 9898 Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder Replacement Ignition Lock Cylinder Replacement Removal Procedure Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). 1. Disable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair). 2. Remove the steering column shroud. Refer to Steering Column Shroud Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Column Shroud Replacement). 3. With the key installed hold it in the START position. 4. Install an allen wrench into the hole on top of the ignition lock cylinder case. Push down on the allen wrench to release the tab on the ignition lock cylinder inside the ignition lock cylinder case. 5. Slide the ignition lock cylinder out of the ignition lock cylinder case. Installation Procedure Note: The gears between the ignition/start switch and the ignition lock cylinder case must be in the correct position. Failure to do so will cause a misalignment of the gears in the ignition/start switch and the ignition lock cylinder case, which may result in a NO START or BATTERY DRAIN. 1. Use a screwdriver to rotate the ignition lock cylinder case gear clockwise to the start position allowing it to spring return into the RUN position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder Case Replacement > Page 9899 2. Install the key into the ignition lock cylinder. 3. Align the ignition lock cylinder and install it into the ignition lock cylinder case. 4. Install the steering column shroud. Refer to Steering Column Shroud Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Column Shroud Replacement). 5. Enable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Auxiliary Battery Relay > Component Information > Locations Auxiliary Battery Relay: Locations Harness Routing Views Auxiliary Battery Harness Routing (TP2) 1 - Fuse Holder 2 - Auxiliary Battery Run Relay 3 - Auxiliary Battery Harness 4 - Auxiliary Battery Relay 5 - X122 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Auxiliary Battery Relay > Component Information > Locations > Page 9904 Auxiliary Battery Relay: Diagrams Component Connector End Views Auxiliary Battery Relay X1 (TP2) Auxiliary Battery Relay X2 (TP2) Auxiliary Battery Relay X3 (TP2) Auxiliary Battery Run Relay (TP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Auxiliary Battery Relay > Component Information > Locations > Page 9905 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Auxiliary Battery Relay > Component Information > Locations > Page 9906 Auxiliary Battery Relay: Service and Repair Auxiliary Battery Relay Replacement Removal Procedure Warning: Refer to Battery Disconnect Warning (See: Battery/Service Precautions). 1. Disconnect the auxiliary battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Battery/Battery Cable/Negative/Service and Repair). 2. Reposition the auxiliary battery positive cable boot (5) from the auxiliary battery relay stud. 3. Remove the auxiliary battery positive cable nut (6) from the battery relay stud. 4. Remove the auxiliary battery positive cable from the auxiliary battery relay. 5. Disconnect the auxiliary battery positive cable electrical connector (1) from the battery relay. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Auxiliary Battery Relay > Component Information > Locations > Page 9907 6. Reposition the auxiliary battery positive cable boot (5) from the auxiliary battery relay stud. 7. Remove the auxiliary battery positive cable nut (4) from the battery relay stud. 8. Remove the auxiliary battery positive cable from the auxiliary battery relay. 9. Remove the auxiliary battery relay nuts and relay. Installation Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the auxiliary battery relay and nuts and tighten to 9 Nm (80 lb in). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Auxiliary Battery Relay > Component Information > Locations > Page 9908 2. Install the auxiliary battery positive cable to the auxiliary battery relay. 3. Install the auxiliary battery positive cable nut (4) to the battery relay stud and tighten to 9 Nm (80 lb in). 4. Position the auxiliary battery positive cable boot (5) to the auxiliary battery relay stud. 5. Connect the auxiliary battery positive cable electrical connector (1) to the battery relay. 6. Install the auxiliary battery positive cable to the auxiliary battery relay. 7. Install the auxiliary battery positive cable nut (6) to the battery relay stud and tighten to 9 Nm (80 lb in). 8. Position the auxiliary battery positive cable boot (5) to the auxiliary battery relay stud. 9. Connect the auxiliary battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Battery/Battery Cable/Negative/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Starter Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 9912 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 9913 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 9914 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 9915 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 9916 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 9917 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 9918 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Auxiliary Battery Relay > Component Information > Locations Auxiliary Battery Relay: Locations Harness Routing Views Auxiliary Battery Harness Routing (TP2) 1 - Fuse Holder 2 - Auxiliary Battery Run Relay 3 - Auxiliary Battery Harness 4 - Auxiliary Battery Relay 5 - X122 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Auxiliary Battery Relay > Component Information > Locations > Page 9923 Auxiliary Battery Relay: Diagrams Component Connector End Views Auxiliary Battery Relay X1 (TP2) Auxiliary Battery Relay X2 (TP2) Auxiliary Battery Relay X3 (TP2) Auxiliary Battery Run Relay (TP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Auxiliary Battery Relay > Component Information > Locations > Page 9924 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Auxiliary Battery Relay > Component Information > Locations > Page 9925 Auxiliary Battery Relay: Service and Repair Auxiliary Battery Relay Replacement Removal Procedure Warning: Refer to Battery Disconnect Warning (See: Service Precautions). 1. Disconnect the auxiliary battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Battery Cable/Negative/Service and Repair). 2. Reposition the auxiliary battery positive cable boot (5) from the auxiliary battery relay stud. 3. Remove the auxiliary battery positive cable nut (6) from the battery relay stud. 4. Remove the auxiliary battery positive cable from the auxiliary battery relay. 5. Disconnect the auxiliary battery positive cable electrical connector (1) from the battery relay. 6. Reposition the auxiliary battery positive cable boot (5) from the auxiliary battery relay stud. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Auxiliary Battery Relay > Component Information > Locations > Page 9926 7. Remove the auxiliary battery positive cable nut (4) from the battery relay stud. 8. Remove the auxiliary battery positive cable from the auxiliary battery relay. 9. Remove the auxiliary battery relay nuts and relay. Installation Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the auxiliary battery relay and nuts and tighten to 9 Nm (80 lb in). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Auxiliary Battery Relay > Component Information > Locations > Page 9927 2. Install the auxiliary battery positive cable to the auxiliary battery relay. 3. Install the auxiliary battery positive cable nut (4) to the battery relay stud and tighten to 9 Nm (80 lb in). 4. Position the auxiliary battery positive cable boot (5) to the auxiliary battery relay stud. 5. Connect the auxiliary battery positive cable electrical connector (1) to the battery relay. 6. Install the auxiliary battery positive cable to the auxiliary battery relay. 7. Install the auxiliary battery positive cable nut (6) to the battery relay stud and tighten to 9 Nm (80 lb in). 8. Position the auxiliary battery positive cable boot (5) to the auxiliary battery relay stud. 9. Connect the auxiliary battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Battery Cable/Negative/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Battery Negative Cable Disconnection and Connection (Single Battery) Negative: Service and Repair Battery Negative Cable Disconnection and Connection (Single Battery) Battery Negative Cable Disconnection and Connection (Single Battery) Disconnect Procedure Warning: Refer to Battery Disconnect Warning (See: Service Precautions). 1. Turn off all the lamps and accessories. 2. Turn the ignition OFF. 3. Open the hood. 4. Loosen the negative cable nut (1). 5. Reposition the negative battery cable away from the battery. Connect Procedure Warning: Refer to Battery Disconnect Warning (See: Service Precautions). Note: Clean any existing corrosion from the battery terminal and the battery cable end. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Battery Negative Cable Disconnection and Connection (Single Battery) > Page 9933 1. Position the negative battery cable to the battery. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the negative battery cable onto the battery terminal. 3. Tighten the negative cable clamp nut (1) to 5 Nm (44 lb in). 4. Close the hood. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Battery Negative Cable Disconnection and Connection (Single Battery) > Page 9934 Negative: Service and Repair Battery Negative Cable Disconnection and Connection (Dual Batteries) Battery Negative Cable Disconnection and Connection (Dual Batteries) Disconnect Procedure Warning: Refer to Battery Disconnect Warning (See: Service Precautions). 1. Turn off all the lamps and accessories. 2. Turn the ignition OFF. 3. Open the hood. 4. Loosen the primary battery negative cable clamp nut (1). 5. Remove and reposition the primary battery negative cable, away from the battery. 6. Loosen the auxiliary battery negative clamp nut (1). 7. Remove the auxiliary battery negative cable (2) from the auxiliary battery negative post. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Battery Negative Cable Disconnection and Connection (Single Battery) > Page 9935 8. Reposition the auxiliary negative battery cable away from the battery. Connect Procedure Warning: Refer to Battery Disconnect Warning (See: Service Precautions). Note: Clean any existing corrosion from the battery terminal and the battery cable end. 1. Install the auxiliary battery negative cable (2) onto the auxiliary battery negative post. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Tighten the auxiliary battery negative cable clamp nut (2) to 7.5 Nm (66 lb in). 3. Install the primary battery negative cable onto the primary battery negative post. 4. Tighten the primary battery negative cable clamp nut (1) to 5 Nm (44 lb in). 5. Close the hood. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Battery Negative Cable Disconnection and Connection (Single Battery) > Page 9936 Negative: Service and Repair Battery Negative Cable Disconnection and Connection (Auxiliary Battery) Battery Negative Cable Disconnection and Connection (Auxiliary Battery) Disconnect Procedure Warning: Refer to Battery Disconnect Warning (See: Service Precautions). 1. Turn off all the lamps and accessories. 2. Turn the ignition OFF. 3. Open the hood. 4. Loosen the primary battery negative cable clamp nut (1). 5. Remove the primary battery negative cable from the primary battery negative post. 6. Reposition the primary battery negative cable away from the battery. 7. Loosen the auxiliary battery negative cable clamp nut (1). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Battery Negative Cable Disconnection and Connection (Single Battery) > Page 9937 8. Loosen the auxiliary battery negative cable nut (3). 9. Remove the auxiliary battery negative cable (2) from the auxiliary battery negative post. 10. Reposition the auxiliary battery negative cable away from the battery. Connect Procedure Warning: Refer to Battery Disconnect Warning (See: Service Precautions). Note: Clean any existing corrosion from the battery terminal and the battery cable end. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the auxiliary battery negative cable (2) onto the auxiliary battery negative post. 2. Tighten the auxiliary battery negative cable clamp nut (1) to 7.5 Nm (66 lb in). 3. Install the primary battery negative cable onto the primary battery negative post. 4. Tighten the primary battery negative cable clamp nut (1) to 5 Nm (44 lb in). 5. Close the hood. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Battery Negative Cable Disconnection and Connection (Single Battery) > Page 9938 Negative: Service and Repair Battery Negative Cable REPLACEMENT Battery Negative Cable Replacement (Diesel) Removal Procedure 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: )Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: )Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: ). 2. Remove the negative battery cable clip (1) from the positive and negative cable bracket. 3. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 4. Remove the engine wiring harness ground bolt (3). 5. Reposition the engine wiring harness ground (4) and remove the negative battery cable (2) from the engine block. 6. Lower the vehicle. 7. Remove the negative battery cable from the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Battery Negative Cable Disconnection and Connection (Single Battery) > Page 9939 Installation Procedure 1. Install the negative battery cable to the vehicle. 2. Raise the vehicle. 3. Position the negative battery cable (2) to the engine block and position the engine wiring harness ground (4) on top of the negative battery cable terminal. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the engine wiring harness ground bolt (3) and tighten to 25 Nm (18 lb ft). 5. Lower the vehicle. 6. Install the negative battery cable clip (1) to the positive and negative cable bracket. 7. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: )Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: )Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: ). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Battery Negative Cable Disconnection and Connection (Single Battery) > Page 9940 Negative: Service and Repair Battery Negative Cable Disconnection and Connection (Single Battery) Battery Negative Cable Disconnection and Connection (Single Battery) Disconnect Procedure Warning: Refer to Battery Disconnect Warning (See: Service Precautions). 1. Turn off all the lamps and accessories. 2. Turn the ignition OFF. 3. Open the hood. 4. Loosen the negative cable nut (1). 5. Reposition the negative battery cable away from the battery. Connect Procedure Warning: Refer to Battery Disconnect Warning (See: Service Precautions). Note: Clean any existing corrosion from the battery terminal and the battery cable end. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Battery Negative Cable Disconnection and Connection (Single Battery) > Page 9941 1. Position the negative battery cable to the battery. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the negative battery cable onto the battery terminal. 3. Tighten the negative cable clamp nut (1) to 5 Nm (44 lb in). 4. Close the hood. Battery Negative Cable Disconnection and Connection (Dual Batteries) Battery Negative Cable Disconnection and Connection (Dual Batteries) Disconnect Procedure Warning: Refer to Battery Disconnect Warning (See: Service Precautions). 1. Turn off all the lamps and accessories. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Battery Negative Cable Disconnection and Connection (Single Battery) > Page 9942 2. Turn the ignition OFF. 3. Open the hood. 4. Loosen the primary battery negative cable clamp nut (1). 5. Remove and reposition the primary battery negative cable, away from the battery. 6. Loosen the auxiliary battery negative clamp nut (1). 7. Remove the auxiliary battery negative cable (2) from the auxiliary battery negative post. 8. Reposition the auxiliary negative battery cable away from the battery. Connect Procedure Warning: Refer to Battery Disconnect Warning (See: Service Precautions). Note: Clean any existing corrosion from the battery terminal and the battery cable end. 1. Install the auxiliary battery negative cable (2) onto the auxiliary battery negative post. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Battery Negative Cable Disconnection and Connection (Single Battery) > Page 9943 2. Tighten the auxiliary battery negative cable clamp nut (2) to 7.5 Nm (66 lb in). 3. Install the primary battery negative cable onto the primary battery negative post. 4. Tighten the primary battery negative cable clamp nut (1) to 5 Nm (44 lb in). 5. Close the hood. Battery Negative Cable Disconnection and Connection (Auxiliary Battery) Battery Negative Cable Disconnection and Connection (Auxiliary Battery) Disconnect Procedure Warning: Refer to Battery Disconnect Warning (See: Service Precautions). 1. Turn off all the lamps and accessories. 2. Turn the ignition OFF. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Battery Negative Cable Disconnection and Connection (Single Battery) > Page 9944 3. Open the hood. 4. Loosen the primary battery negative cable clamp nut (1). 5. Remove the primary battery negative cable from the primary battery negative post. 6. Reposition the primary battery negative cable away from the battery. 7. Loosen the auxiliary battery negative cable clamp nut (1). 8. Loosen the auxiliary battery negative cable nut (3). 9. Remove the auxiliary battery negative cable (2) from the auxiliary battery negative post. 10. Reposition the auxiliary battery negative cable away from the battery. Connect Procedure Warning: Refer to Battery Disconnect Warning (See: Service Precautions). Note: Clean any existing corrosion from the battery terminal and the battery cable end. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Battery Negative Cable Disconnection and Connection (Single Battery) > Page 9945 1. Install the auxiliary battery negative cable (2) onto the auxiliary battery negative post. 2. Tighten the auxiliary battery negative cable clamp nut (1) to 7.5 Nm (66 lb in). 3. Install the primary battery negative cable onto the primary battery negative post. 4. Tighten the primary battery negative cable clamp nut (1) to 5 Nm (44 lb in). 5. Close the hood. Battery Negative Cable REPLACEMENT Battery Negative Cable Replacement (Diesel) Removal Procedure 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: )Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: )Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: ). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Battery Negative Cable Disconnection and Connection (Single Battery) > Page 9946 2. Remove the negative battery cable clip (1) from the positive and negative cable bracket. 3. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 4. Remove the engine wiring harness ground bolt (3). 5. Reposition the engine wiring harness ground (4) and remove the negative battery cable (2) from the engine block. 6. Lower the vehicle. 7. Remove the negative battery cable from the vehicle. Installation Procedure 1. Install the negative battery cable to the vehicle. 2. Raise the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Battery Negative Cable Disconnection and Connection (Single Battery) > Page 9947 3. Position the negative battery cable (2) to the engine block and position the engine wiring harness ground (4) on top of the negative battery cable terminal. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the engine wiring harness ground bolt (3) and tighten to 25 Nm (18 lb ft). 5. Lower the vehicle. 6. Install the negative battery cable clip (1) to the positive and negative cable bracket. 7. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: )Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: )Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: ). Auxiliary Battery Negative Cable REPLACEMENT Auxiliary Battery Negative Cable Replacement Removal Procedure Warning: Refer to Battery Disconnect Warning (See: Service Precautions). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Battery Negative Cable Disconnection and Connection (Single Battery) > Page 9948 1. Disconnect the auxiliary battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: )Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: )Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: ). 2. Remove the auxiliary battery negative cable ground terminal bolt from the left cylinder head. 3. Remove the auxiliary battery negative cable from the vehicle. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Battery Negative Cable Disconnection and Connection (Single Battery) > Page 9949 1. Install the auxiliary battery negative cable to the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Position the auxiliary battery negative cable ground terminal to the left cylinder head and install the bolt and tighten to 25 Nm (18 lb ft). 3. Connect the auxiliary battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: )Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: )Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: ). Engine Ground Strap REPLACEMENT Engine Ground Strap Replacement (LMM) Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Battery Negative Cable Disconnection and Connection (Single Battery) > Page 9950 1. Remove the engine ground strap bolt (2) from the rear of the cylinder head. 2. Reposition the engine ground strap (1) from the cylinder head. 3. Remove the ground strap nut (1) from the stud on the plenum front panel. 4. Remove the ground strap (2) from the stud and the vehicle. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Battery Negative Cable Disconnection and Connection (Single Battery) > Page 9951 1. Install the ground strap (2) to the vehicle and the stud on the plenum front panel. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the ground strap nut (1) to the stud on the plenum front pane and tighten to 9 Nm (80 lb in). 3. Position the ground strap (1) to the cylinder head. 4. Install the ground strap bolt (2) to the cylinder head and tighten to 16 Nm (12 lb ft). Battery Negative Cable Disconnection and CONNECTION Battery Negative Cable Disconnection and Connection Disconnect Procedure Warning: Refer to Battery Disconnect Warning (See: Service Precautions). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Battery Negative Cable Disconnection and Connection (Single Battery) > Page 9952 Note: Do NOT disconnect the negative battery cable from the battery until a period of at least 1 minute after performing the following: Turning the ignition to OFF, without pausing at ACCESSORY, and without applying the brake pedal. These steps are necessary to allow the brake system pressure relief procedure to occur. Failure to follow these steps may result in warning lamps and/or DTCs being set pertaining to interruption of the pressure relief procedure. Other vehicle systems may also be affected by not allowing a 1 minute duration for power-down. 1. Turn off all lamps and accessories. 2. Turn the ignition OFF without pausing at ACCESSORY, and remove the ignition key. 3. Wait for at least 1 minute before disconnecting the negative battery cable from the battery, to allow for proper power-down procedures of certain vehicle systems. 4. Reposition the negative battery cable insulating cover (5) from the negative battery terminal. 5. Rotate the lever lock (4) counterclockwise in order to disconnect the negative battery cable from the battery. Connect Procedure Note: Clean any existing corrosion from the battery terminal and the battery cable. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Battery Negative Cable Disconnection and Connection (Single Battery) > Page 9953 1. Install the negative battery cable (6) to the battery. 2. Rotate the lever lock (4) clockwise until an audible click is heard in order to connect the negative battery cable to the battery. 3. Position the negative battery cable insulating cover (5) over the negative terminal. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Battery Positive Cable Replacement (Diesel) Positive: Service and Repair Battery Positive Cable Replacement (Diesel) Battery Positive Cable Replacement (Diesel) Removal Procedure 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Negative/Service and Repair). 2. Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair/Intake Manifold Cover Replacement). 3. Remove the underhood junction block cover. 4. Lift the junction block retainers from the locked position (3) and rotate the retainers to the open position (1). 5. Reposition the junction block. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Battery Positive Cable Replacement (Diesel) > Page 9958 6. Remove the positive battery cable connector (1) from the underhood bussed electrical center (UBEC). 7. Disconnect the positive battery cable (1) from the glow plug control module. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Battery Positive Cable Replacement (Diesel) > Page 9959 8. Remove the mega fuse cover. 9. Remove the positive battery cable to mega fuse nuts (1). 10. Remove the positive battery cable terminals from the mega fuse studs. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Battery Positive Cable Replacement (Diesel) > Page 9960 11. Remove the positive battery cable clip nuts (2) from the studs on the plenum front panel. 12. Remove the positive battery cable clip (1) from the stud on the plenum front panel. 13. Remove the positive battery cable clips (1) from the studs on the plenum front panel. 14. Remove the positive battery cable from the vehicle. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Battery Positive Cable Replacement (Diesel) > Page 9961 1. Install the positive battery cable to the vehicle. 2. Install the positive battery cable clips (1) onto the studs on the plenum front panel. 3. Install the positive battery cable clip (1) onto the stud on the plenum front panel. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the positive battery cable clip nuts (2) to the studs on the plenum front panel and tighten to 3 Nm (27 lb in). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Battery Positive Cable Replacement (Diesel) > Page 9962 5. Install the positive battery cable terminals onto the mega fuse studs. 6. Install the positive battery cable to mega fuse nuts (1) and tighten to 7.5 Nm (66 lb in). 7. Install the mega fuse cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Battery Positive Cable Replacement (Diesel) > Page 9963 8. Connect the positive battery cable (1) to the glow plug control module. 9. Install the positive battery cable connector (1) to the UBEC. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Battery Positive Cable Replacement (Diesel) > Page 9964 10. Ensure that the junction block retainers are in the open position (1). 11. Position and align the junction block to the 4 bracket pivots (2), once the pivots are engaged, push the retainers down into the locked position (3). 12. Install the underhood junction block cover. 13. Install the intake manifold cover. Refer to Intake Manifold Cover Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair/Intake Manifold Cover Replacement). 14. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Negative/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Battery Positive Cable Replacement (Diesel) > Page 9965 Positive: Service and Repair Auxiliary Battery Positive Cable Replacement Auxiliary Battery Positive Cable Replacement Removal Procedure 1. Disconnect the negative battery. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Negative/Service and Repair) 2. If equipped with dual generators,remove the mega fuse nut (1) on top of the auxiliary battery. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Battery Positive Cable Replacement (Diesel) > Page 9966 3. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Negative/Service and Repair). 4. Disconnect the generator battery jumper cable. Refer to Generator Battery Jumper Cable Replacement (See: Service and Repair/Generator Battery Jumper Cable Replacement) 5. Loosen the auxiliary battery positive clamp nut (1) and remove the clamp from the battery post. 6. Remove the cable retainers (2) along the top of the fan shroud. 7. Remove the auxiliary battery positive harness clips (1) from the condensor hose and the transmission cooler hose. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Battery Positive Cable Replacement (Diesel) > Page 9967 8. Remove the mega fuse block nut (1) and the auxiliary battery positive cable terminal (2), from the mega fuse block. Installation Procedure 1. If equipped with dual generators,connect the generator jumper cable (3) to the mega fuse holder with the nut (1) and tighten to 9 Nm (80 lb in) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Battery Positive Cable Replacement (Diesel) > Page 9968 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the auxiliary battery positive clamp to the battery post and tighten clamp nut (1) to 9 Nm (80 lb in) 3. Install the auxiliary battery positive cable retainers (2) along the cooling fan shroud. 4. Install the auxiliary battery positive cable clips (1) to the condensor hose and the transmission cooler hose. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Battery Positive Cable Replacement (Diesel) > Page 9969 5. Install the auxiliary battery positive cable terminal (2) to the mega fuse block and tighten the nut (1) to 9 Nm (80 lb in) 6. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Negative/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Battery Positive Cable Replacement (Diesel) > Page 9970 Positive: Service and Repair Auxiliary Battery Positive Cable Replacement - Battery to Battery Relay Auxiliary Battery Positive Cable Replacement - Battery to Battery Relay Removal Procedure 1. Disconnect the auxiliary battery. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Negative/Service and Repair). 2. Remove the underhood junction block cover. 3. Open the auxiliary battery positive cable post cover. 4. Loosen the auxiliary battery positive cable nut (2). 5. Remove the auxiliary battery positive cable from the battery positive post. 6. Remove the auxiliary battery positive cable nut (1) from the underhood junction block stud. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Battery Positive Cable Replacement (Diesel) > Page 9971 7. Remove the auxiliary battery positive cable terminal from the underhood junction block stud. 8. Reposition the auxiliary battery positive cable boot (5) at the auxiliary battery relay. 9. Remove the auxiliary battery positive cable nut (6) from the rely stud. 10. Remove the auxiliary battery positive cable terminal from the relay stud. 11. Remove the auxiliary battery positive cable clips (4) from the engine wiring harness and remove the cable from the vehicle. Installation Procedure 1. Install the auxiliary battery positive cable to the vehicle. 2. Install the auxiliary battery positive cable terminal to the relay stud. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the auxiliary battery positive cable nut (6) to the rely stud and tighten to 7.5 Nm (66 lb in). 4. Position the auxiliary battery positive cable boot (5) at the auxiliary battery relay. 5. Install the auxiliary battery positive cable to the battery positive post. 6. Tighten the auxiliary battery positive cable nut (2) and tighten to 7.5 Nm (66 lb in). 7. Install the auxiliary battery positive cable terminal to the underhood junction block stud. 8. Install the auxiliary battery positive cable nut (1) to the underhood junction block stud and tighten to 5 Nm (44 lb in). 9. Install the auxiliary battery positive cable clips (4) to the engine wiring harness. 10. Close the auxiliary battery positive cable post cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Battery Positive Cable Replacement (Diesel) > Page 9972 11. Install the underhood junction block cover. 12. Connect the auxiliary battery. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Negative/Service and Repair )Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Negative/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Battery Positive Cable Replacement (Diesel) > Page 9973 Positive: Service and Repair Battery Positive Cable Replacement (12V Battery to Auxiliary BEC) Battery Positive Cable Replacement (12V Battery to Auxiliary BEC) Removal Procedure 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (See: Negative/Service and Repair). 2. Reposition the positive battery cable insulating cover (2) from over the positive terminal. 3. Rotate the lever lock (1) counterclockwise in order to disconnect the positive battery cable. 4. Remove the positive battery cable terminal (3) from the battery. 5. Remove the auxiliary bussed electrical center (BEC) cover (1). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Battery Positive Cable Replacement (Diesel) > Page 9974 6. Remove the underhood junction block cover. 7. Lift the junction block retainers from the locked position (3) and rotate the retainers to the open position (1). 8. Remove the junction block. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Battery Positive Cable Replacement (Diesel) > Page 9975 9. Remove the positive battery cable nut (1) from the mega fuse stud. 10. Remove the positive battery cable nut (3) from the auxiliary BEC stud. 11. Disconnect the positive battery cable connector (2) from the underhood BEC. 12. Remove the positive battery cable assembly (1) from the vehicle. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Battery Positive Cable Replacement (Diesel) > Page 9976 1. Install the positive battery cable assembly (1) to the vehicle. 2. Install the positive battery cable leads to the mega fuse and auxiliary BEC studs. 3. Connect the positive battery cable connector (2) to the underhood BEC. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the positive battery cable nut (3) to the auxiliary BEC stud and tighten to 9 Nm (80 lb in). 5. Install the positive battery cable nut (1) to the mega fuse stud and tighten to 9 Nm (80 lb in). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Battery Positive Cable Replacement (Diesel) > Page 9977 6. Ensure that the junction block retainers are in the open position (1). 7. Position and align the junction block to the 4 bracket pivots (2), once the pivots are engaged, push the retainers down into the locked position (3). 8. Install the underhood junction block cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Battery Positive Cable Replacement (Diesel) > Page 9978 9. Install the auxiliary BEC cover (1). 10. Install the positive battery cable terminal (3) to the battery. 11. Rotate the lever lock (1) clockwise until an audible click is heard in order to connect the positive battery cable. 12. Position the positive battery cable insulating cover (2) over the positive terminal. 13. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (See: Negative/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Battery Positive Cable Replacement (Diesel) > Page 9979 Positive: Service and Repair Battery Positive Cable Replacement (Control Module to Auxiliary BEC) Battery Positive Cable Replacement (Control Module to Auxiliary BEC) Removal Procedure 1. Disable the high voltage system. Refer to High Voltage Disabling (). 2. Remove the auxiliary bussed electrical center (BEC) cover (1). 3. Remove the positive battery cable nut (1) from the mega fuse stud. 4. Remove the positive battery cable lead (5) from the mega fuse stud. 5. Remove the engine shield. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement). 6. Remove the positive battery cable clips (2, 3, and 4) from the frame crossmember. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Battery Positive Cable Replacement (Diesel) > Page 9980 7. Working through the wheel opening, remove the positive battery cable clip (2) from the brake pipe. 8. Working through the wheel opening, remove the positive battery cable clip (3) from the air cleaner adapter bracket 9. Lower the vehicle. 10. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair). 11. Remove the positive battery cable clip (4) from the air cleaner support bracket. 12. Remove the positive battery cable clip (5) from the fender inner panel. 13. Disconnect the positive battery cable electrical connector (1) from the drive motor generator control module. 14. Remove the positive battery cable (1) from the vehicle. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Battery Positive Cable Replacement (Diesel) > Page 9981 1. Install the positive battery cable (1) to the vehicle. 2. Connect the positive battery cable electrical connector (1) to the drive motor generator control module. 3. Install the positive battery cable clip (5) to the fender inner panel. 4. Install the positive battery cable clip (4) to the air cleaner support bracket. 5. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair). 6. Raise and suitably support the vehicle enough to work through the wheel opening. 7. Working through the wheel opening, install the positive battery cable clip (3) to air cleaner adapter bracket 8. Working through the wheel opening, install the positive battery cable clip (2) to the brake pipe. 9. Fully raise the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Battery Positive Cable Replacement (Diesel) > Page 9982 10. Install the positive battery cable clips (2, 3, and 4) to the frame crossmember. 11. Install the engine shield. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement). 12. Lower the vehicle. 13. Install the positive battery cable lead (5) to the mega fuse stud. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 14. Install the positive battery cable nut (1) to the mega fuse stud and tighten to 9 Nm (80 lb in). 15. Install the auxiliary BEC cover (1). 16. Enable the high voltage system. Refer to High Voltage Enabling (). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Current Sensor > Component Information > Diagrams Battery Current Sensor: Diagrams Component Connector End Views Battery Current Sensor (10 Series without MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Current Sensor > Component Information > Diagrams > Page 9986 Battery Current Sensor: Service and Repair Battery Current Sensor Replacement Removal Procedure 1. Remove the negative battery cable. Refer to Battery Negative Cable Replacement (V6) (See: Battery Cable/Negative/Service and Repair)Battery Negative Cable Replacement (V8) (See: Battery Cable/Negative/Service and Repair)Battery Negative Cable Replacement (Diesel) (See: Battery Cable/Negative/Service and Repair). 2. Mark the location of the battery current sensor on the battery cable with tape for reference during installation. 3. Remove the tape securing the battery current sensor to the negative battery cable. 4. Mark the location of the negative battery cable clips (1) and remove the clips from the cable. 5. Squeeze the negative battery cable branches together. Important: Note the orientation of the battery current sensor prior to removal. 6. Slide the battery current sensor (2) off of the negative battery cable. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Current Sensor > Component Information > Diagrams > Page 9987 1. Squeeze the negative battery cable branches together. Important: Ensure the battery current sensor is installed in the correct direction and location on the negative battery cable. 2. Slide the NEW battery current sensor (2) up onto the negative battery cable to the location previously marked during removal. 3. Wrap electrical tape around the battery current sensor leg in order to secure the sensor to the negative battery cable. 4. Install the negative battery cable clips (1) to the cable to the locations previously marked during removal. 5. Install the negative battery cable. Refer to Battery Negative Cable Replacement (V6) (See: Battery Cable/Negative/Service and Repair)Battery Negative Cable Replacement (V8) (See: Battery Cable/Negative/Service and Repair)Battery Negative Cable Replacement (Diesel) (See: Battery Cable/Negative/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Tray > Component Information > Service and Repair > Auxiliary Battery Tray Replacement Battery Tray: Service and Repair Auxiliary Battery Tray Replacement Auxiliary Battery Tray Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Tray > Component Information > Service and Repair > Auxiliary Battery Tray Replacement > Page 9992 Battery Tray: Service and Repair Battery Tray Replacement Battery Tray Replacement Removal Procedure 1. Remove the battery. Refer to Battery Replacement (See: Service and Repair/Removal and Replacement/Battery Replacement). 2. Remove the battery tray front support bolts. 3. Remove the battery tray front support. 4. Remove the nut securing the battery tray to the front fender inner panel. 5. Remove the 3 nuts securing the battery tray to the battery tray bracket. 6. Remove the battery tray from the vehicle. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Tray > Component Information > Service and Repair > Auxiliary Battery Tray Replacement > Page 9993 1. Install the battery tray to the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the 3 nuts securing the battery tray to the battery tray bracket and tighten to 20 Nm (15 lb ft). 3. Install the nut securing the battery tray to the front fender inner panel and tighten to 9 Nm (80 lb in). 4. Install the battery tray front support. 5. Install the battery tray front support bolts and tighten to 20 Nm (15 lb ft). 6. Install the battery. Refer to Battery Replacement (See: Service and Repair/Removal and Replacement/Battery Replacement). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications Alternator: Specifications Generator Usage Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Page 9998 Alternator: Diagrams Component Connector End Views Generator X1 (Diesel) Generator X2 (Diesel) Generator - Auxiliary X1 (Diesel with K76 or YF2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Page 9999 Generator - Auxiliary X2 (Diesel with K76 or YF2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator Bracket Replacement Alternator: Service and Repair Generator Bracket Replacement Generator Bracket Replacement (6.6L) Removal Procedure Warning: Refer to Battery Disconnect Warning (See: Battery/Service Precautions). 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Battery/Battery Cable/Negative/Service and Repair). 2. Remove the fan assembly. Refer to fan replacement Fan Replacement (Mechanical) (See: Engine, Cooling and Exhaust/Cooling System/Radiator Cooling Fan/Service and Repair)Fan Replacement (Diesel) (See: Engine, Cooling and Exhaust/Cooling System/Radiator Cooling Fan/Service and Repair). 3. Remove the intake air heater. Refer to Intake Air Heater Replacement (See: Powertrain Management/Fuel Delivery and Air Induction/Intake Air Heater/Service and Repair). 4. Remove the generator. Refer to Generator Replacement (V6) (See: )Generator Replacement (V8) (See: )Generator Replacement (6.6L) (See: ). 5. Remove the drive belt tensioner. Refer to Drive Belt Tensioner Replacement (See: Engine, Cooling and Exhaust/Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt Tensioner/Service and Repair). 6. Remove the engine wiring harness clip from the oil level indicator tube bracket (2). 7. Remove the oil level indicator tube bolt (3). 8. Remove the oil level indicator tube bracket bolts (1). 9. Remove the oil level indicator tube bracket (2). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator Bracket Replacement > Page 10002 10. Remove the heater inlet hose bracket nut (4) from the fuel filter adapter stud (1). 11. Remove the heater inlet hose bracket nut (3) from the generator bracket stud (2). 12. Reposition the heater inlet hose/pipe for clearance. 13. Remove the fuel feed pipe bracket bolts (1). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator Bracket Replacement > Page 10003 14. Remove the engine wiring harness clip bolt (1). 15. Reposition the engine wiring harness out of the way. 16. Remove the generator bracket bolts (1)and nuts. 17. Remove the generator bracket. 18. If replacing the generator bracket, remove the idler pulley bolts (2) and remove the pulleys from the generator bracket. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator Bracket Replacement > Page 10004 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. If the generator bracket was replaced, install the idler pulleys to the generator bracket and tighten the pulley bolts (2). Tighten the bolts to 50 Nm (37 lb ft). 2. Position the generator bracket to the engine and install the nuts and the bolts (1). Tighten the bolts to 50 Nm (37 lb ft). 3. Position the engine wiring harness and install the engine wiring harness clip bolt (1). Tighten the bolt to 10 Nm (89 lb in). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator Bracket Replacement > Page 10005 4. Install the fuel feed pipe bracket bolts (1). Tighten the bolts to 24 Nm (18 lb ft). 5. Position the heater inlet hose/pipe to the engine. 6. Install the heater inlet hose bracket to the generator bracket stud (2) and install the bracket nut (3). Tighten the nut to 9 Nm (80 lb in). 7. Install the heater inlet hose to the fuel filter adapter stud (1) and install the bracket nut (4). Tighten the nut to 9 Nm (80 lb in). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator Bracket Replacement > Page 10006 8. Install the oil level indicator tube bracket (2). 9. Install the oil level indicator tube bracket bolts (1). Tighten the bolts to 21 Nm (15 lb ft). 10. Install the oil level indicator tube bolt (3). Tighten the bolts to 21 Nm (15 lb ft). 11. Install the engine wiring harness clip to the oil level indicator tube bracket (2). 12. Install the drive belt tensioner. Refer to Drive Belt Tensioner Replacement (See: Engine, Cooling and Exhaust/Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt Tensioner/Service and Repair). 13. Install the generator. Refer to Generator Replacement (V6) (See: )Generator Replacement (V8) (See: )Generator Replacement (6.6L) (See: ). 14. Install the intake air heater. Refer to Intake Air Heater Replacement (See: Powertrain Management/Fuel Delivery and Air Induction/Intake Air Heater/Service and Repair). 15. Install the fan assembly. Refer to Fan Replacement (Mechanical) (See: Engine, Cooling and Exhaust/Cooling System/Radiator Cooling Fan/Service and Repair)Fan Replacement (Diesel) (See: Engine, Cooling and Exhaust/Cooling System/Radiator Cooling Fan/Service and Repair ). 16. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Battery/Battery Cable/Negative/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator Bracket Replacement > Page 10007 Alternator: Service and Repair Generator Bracket Replacement (V8) Generator Bracket Replacement (V8) Removal Procedure 1. Remove the generator. Refer to Generator Replacement (V6) (See: )Generator Replacement (V8) (See: )Generator Replacement (6.6L) (See: ). 2. Remove the power steering pump. Refer to Power Steering Pump Replacement (4.8L, 5.3L, 6.0L, and 6.2L) (See: Steering and Suspension/Steering/Power Steering/Power Steering Pump/Service and Repair)Power Steering Pump Replacement (4.3L) (See: Steering and Suspension/Steering/Power Steering/Power Steering Pump/Service and Repair)Power Steering Pump Replacement (6.6L) (See: Steering and Suspension/Steering/Power Steering/Power Steering Pump/Service and Repair). 3. Remove the engine wiring harness clip bolt (3) are reposition the clip (1) away from the generator bracket. 4. Remove the generator bracket bolts. 5. Remove the generator bracket. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator Bracket Replacement > Page 10008 1. Position the generator bracket to the engine. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the generator bracket bolts. Tighten the bolts to 50 Nm (37 lb ft). 3. Position the engine wiring harness clip (1) to the generator bracket and install the engine harness clip bolt (3). Tighten the bolt to 9 Nm (80 lb in). 4. Install the power steering pump. Refer to Power Steering Pump Replacement (4.8L, 5.3L, 6.0L, and 6.2L) (See: Steering and Suspension/Steering/Power Steering/Power Steering Pump/Service and Repair)Power Steering Pump Replacement (4.3L) (See: Steering and Suspension/Steering/Power Steering/Power Steering Pump/Service and Repair)Power Steering Pump Replacement (6.6L) (See: Steering and Suspension/Steering/Power Steering/Power Steering Pump/Service and Repair). 5. Install the generator. Refer to Generator Replacement (V6) (See: )Generator Replacement (V8) (See: )Generator Replacement (6.6L) (See: ). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator Bracket Replacement > Page 10009 Alternator: Service and Repair Auxiliary Generator Bracket Replacement (Diesel) Auxiliary Generator Bracket Replacement (Diesel) Removal Procedure 1. Remove the auxiliary generator. Refer to Auxiliary Generator Replacement (6.6L) (See: Auxiliary Generator Replacement (6.6L)). 2. Remove the auxiliary generator bracket bolt (2). 3. Remove the auxiliary generator bracket (1). Installation Procedure 1. Position the auxiliary generator bracket (2) to the air conditioning (A/C) bracket. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator Bracket Replacement > Page 10010 2. Install the auxiliary generator bracket bolt (1). Tighten the bolt to 50 Nm (37 lb ft). 3. Install the auxiliary generator. Refer to Auxiliary Generator Replacement (6.6L) (See: Auxiliary Generator Replacement (6.6L)). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator Bracket Replacement > Page 10011 Alternator: Service and Repair Generator Replacement Generator Replacement (6.6L) Removal Procedure Warning: Refer to Battery Disconnect Warning (See: Battery/Service Precautions). 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Battery/Battery Cable/Negative/Service and Repair). 2. Remove the drive belt. Refer to Drive Belt Replacement (See: Engine, Cooling and Exhaust/Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair). 3. Reposition the engine wiring harness boot (2) in order to access the terminal stud. 4. Remove the engine wiring harness nut (1). 5. Remove the engine wiring harness terminal (3) from the generator. 6. Reposition the engine wiring harness out of the way. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator Bracket Replacement > Page 10012 7. Disconnect the engine wiring harness electrical connector (1) from the generator (2). 8. Remove the generator bolts (1). 9. Remove the generator. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator Bracket Replacement > Page 10013 1. Install the generator. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the generator bolts (1). Tighten the bolts to 50 Nm (37 lb ft). 3. Connect the engine wiring harness electrical connector (1) to the generator (2). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator Bracket Replacement > Page 10014 4. Install the engine wiring harness terminal (3) to the generator. 5. Install the engine wiring harness nut (1). Tighten the nut to 9 Nm (80 lb in). 6. Position the engine wiring harness boot (2) in order to cover the terminal stud. 7. Install the drive belt. Refer to Drive Belt Replacement (See: Engine, Cooling and Exhaust/Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair). 8. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Battery/Battery Cable/Negative/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator Bracket Replacement > Page 10015 Alternator: Service and Repair Generator Bracket Replacement Generator Bracket Replacement (6.6L) Removal Procedure Warning: Refer to Battery Disconnect Warning (See: Battery/Service Precautions). 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Battery/Battery Cable/Negative/Service and Repair). 2. Remove the fan assembly. Refer to fan replacement Fan Replacement (Mechanical) (See: Engine, Cooling and Exhaust/Cooling System/Radiator Cooling Fan/Service and Repair)Fan Replacement (Diesel) (See: Engine, Cooling and Exhaust/Cooling System/Radiator Cooling Fan/Service and Repair). 3. Remove the intake air heater. Refer to Intake Air Heater Replacement (See: Powertrain Management/Fuel Delivery and Air Induction/Intake Air Heater/Service and Repair). 4. Remove the generator. Refer to Generator Replacement (V6) (See: )Generator Replacement (V8) (See: )Generator Replacement (6.6L) (See: ). 5. Remove the drive belt tensioner. Refer to Drive Belt Tensioner Replacement (See: Engine, Cooling and Exhaust/Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt Tensioner/Service and Repair). 6. Remove the engine wiring harness clip from the oil level indicator tube bracket (2). 7. Remove the oil level indicator tube bolt (3). 8. Remove the oil level indicator tube bracket bolts (1). 9. Remove the oil level indicator tube bracket (2). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator Bracket Replacement > Page 10016 10. Remove the heater inlet hose bracket nut (4) from the fuel filter adapter stud (1). 11. Remove the heater inlet hose bracket nut (3) from the generator bracket stud (2). 12. Reposition the heater inlet hose/pipe for clearance. 13. Remove the fuel feed pipe bracket bolts (1). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator Bracket Replacement > Page 10017 14. Remove the engine wiring harness clip bolt (1). 15. Reposition the engine wiring harness out of the way. 16. Remove the generator bracket bolts (1)and nuts. 17. Remove the generator bracket. 18. If replacing the generator bracket, remove the idler pulley bolts (2) and remove the pulleys from the generator bracket. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator Bracket Replacement > Page 10018 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. If the generator bracket was replaced, install the idler pulleys to the generator bracket and tighten the pulley bolts (2). Tighten the bolts to 50 Nm (37 lb ft). 2. Position the generator bracket to the engine and install the nuts and the bolts (1). Tighten the bolts to 50 Nm (37 lb ft). 3. Position the engine wiring harness and install the engine wiring harness clip bolt (1). Tighten the bolt to 10 Nm (89 lb in). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator Bracket Replacement > Page 10019 4. Install the fuel feed pipe bracket bolts (1). Tighten the bolts to 24 Nm (18 lb ft). 5. Position the heater inlet hose/pipe to the engine. 6. Install the heater inlet hose bracket to the generator bracket stud (2) and install the bracket nut (3). Tighten the nut to 9 Nm (80 lb in). 7. Install the heater inlet hose to the fuel filter adapter stud (1) and install the bracket nut (4). Tighten the nut to 9 Nm (80 lb in). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator Bracket Replacement > Page 10020 8. Install the oil level indicator tube bracket (2). 9. Install the oil level indicator tube bracket bolts (1). Tighten the bolts to 21 Nm (15 lb ft). 10. Install the oil level indicator tube bolt (3). Tighten the bolts to 21 Nm (15 lb ft). 11. Install the engine wiring harness clip to the oil level indicator tube bracket (2). 12. Install the drive belt tensioner. Refer to Drive Belt Tensioner Replacement (See: Engine, Cooling and Exhaust/Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt Tensioner/Service and Repair). 13. Install the generator. Refer to Generator Replacement (V6) (See: )Generator Replacement (V8) (See: )Generator Replacement (6.6L) (See: ). 14. Install the intake air heater. Refer to Intake Air Heater Replacement (See: Powertrain Management/Fuel Delivery and Air Induction/Intake Air Heater/Service and Repair). 15. Install the fan assembly. Refer to Fan Replacement (Mechanical) (See: Engine, Cooling and Exhaust/Cooling System/Radiator Cooling Fan/Service and Repair)Fan Replacement (Diesel) (See: Engine, Cooling and Exhaust/Cooling System/Radiator Cooling Fan/Service and Repair ). 16. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Battery/Battery Cable/Negative/Service and Repair). Generator Bracket Replacement (V8) Generator Bracket Replacement (V8) Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator Bracket Replacement > Page 10021 1. Remove the generator. Refer to Generator Replacement (V6) (See: )Generator Replacement (V8) (See: )Generator Replacement (6.6L) (See: ). 2. Remove the power steering pump. Refer to Power Steering Pump Replacement (4.8L, 5.3L, 6.0L, and 6.2L) (See: Steering and Suspension/Steering/Power Steering/Power Steering Pump/Service and Repair)Power Steering Pump Replacement (4.3L) (See: Steering and Suspension/Steering/Power Steering/Power Steering Pump/Service and Repair)Power Steering Pump Replacement (6.6L) (See: Steering and Suspension/Steering/Power Steering/Power Steering Pump/Service and Repair). 3. Remove the engine wiring harness clip bolt (3) are reposition the clip (1) away from the generator bracket. 4. Remove the generator bracket bolts. 5. Remove the generator bracket. Installation Procedure 1. Position the generator bracket to the engine. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator Bracket Replacement > Page 10022 2. Install the generator bracket bolts. Tighten the bolts to 50 Nm (37 lb ft). 3. Position the engine wiring harness clip (1) to the generator bracket and install the engine harness clip bolt (3). Tighten the bolt to 9 Nm (80 lb in). 4. Install the power steering pump. Refer to Power Steering Pump Replacement (4.8L, 5.3L, 6.0L, and 6.2L) (See: Steering and Suspension/Steering/Power Steering/Power Steering Pump/Service and Repair)Power Steering Pump Replacement (4.3L) (See: Steering and Suspension/Steering/Power Steering/Power Steering Pump/Service and Repair)Power Steering Pump Replacement (6.6L) (See: Steering and Suspension/Steering/Power Steering/Power Steering Pump/Service and Repair). 5. Install the generator. Refer to Generator Replacement (V6) (See: )Generator Replacement (V8) (See: )Generator Replacement (6.6L) (See: ). Auxiliary Generator Bracket Replacement (Diesel) Auxiliary Generator Bracket Replacement (Diesel) Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator Bracket Replacement > Page 10023 1. Remove the auxiliary generator. Refer to Auxiliary Generator Replacement (6.6L) (See: Auxiliary Generator Replacement (6.6L)). 2. Remove the auxiliary generator bracket bolt (2). 3. Remove the auxiliary generator bracket (1). Installation Procedure 1. Position the auxiliary generator bracket (2) to the air conditioning (A/C) bracket. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the auxiliary generator bracket bolt (1). Tighten the bolt to 50 Nm (37 lb ft). 3. Install the auxiliary generator. Refer to Auxiliary Generator Replacement (6.6L) (See: Auxiliary Generator Replacement (6.6L)). Generator Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator Bracket Replacement > Page 10024 Generator Replacement (6.6L) Removal Procedure Warning: Refer to Battery Disconnect Warning (See: Battery/Service Precautions). 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Battery/Battery Cable/Negative/Service and Repair). 2. Remove the drive belt. Refer to Drive Belt Replacement (See: Engine, Cooling and Exhaust/Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair). 3. Reposition the engine wiring harness boot (2) in order to access the terminal stud. 4. Remove the engine wiring harness nut (1). 5. Remove the engine wiring harness terminal (3) from the generator. 6. Reposition the engine wiring harness out of the way. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator Bracket Replacement > Page 10025 7. Disconnect the engine wiring harness electrical connector (1) from the generator (2). 8. Remove the generator bolts (1). 9. Remove the generator. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator Bracket Replacement > Page 10026 1. Install the generator. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the generator bolts (1). Tighten the bolts to 50 Nm (37 lb ft). 3. Connect the engine wiring harness electrical connector (1) to the generator (2). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator Bracket Replacement > Page 10027 4. Install the engine wiring harness terminal (3) to the generator. 5. Install the engine wiring harness nut (1). Tighten the nut to 9 Nm (80 lb in). 6. Position the engine wiring harness boot (2) in order to cover the terminal stud. 7. Install the drive belt. Refer to Drive Belt Replacement (See: Engine, Cooling and Exhaust/Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair). 8. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Battery/Battery Cable/Negative/Service and Repair). Generator Replacement (V8) Generator Replacement (V8) Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator Bracket Replacement > Page 10028 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Battery/Battery Cable/Negative/Service and Repair). 2. Remove the intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair). 3. Remove the accessory drive belt. Refer to Drive Belt Replacement - Accessory (). 4. Disconnect the engine harness electrical connector (3) from the generator. 5. Reposition the generator battery jumper cable boot (3). 6. Remove the generator battery jumper cable nut (2) from the generator. 7. Remove the generator battery jumper cable terminal (1) from the generator stud. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator Bracket Replacement > Page 10029 8. Remove the generator bolts. 9. Remove the generator. Installation Procedure 1. Install the generator. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the generator bolts. Tighten the bolts to 55 Nm (41 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator Bracket Replacement > Page 10030 3. Install the generator battery jumper cable terminal (1) to the generator stud. 4. Install the generator battery jumper cable nut (2) to the generator. Tighten the nut to 9 Nm (80 lb in). 5. Position the generator battery jumper cable boot (3). 6. Connect the engine harness electrical connector (3) to the generator. 7. Install the accessory drive belt. Refer to Drive Belt Replacement - Accessory (). 8. Install the intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair). 9. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Battery/Battery Cable/Negative/Service and Repair). Auxiliary Generator Replacement (6.6L) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator Bracket Replacement > Page 10031 Auxiliary Generator Replacement (6.6L) Removal Procedure Warning: Refer to Battery Disconnect Warning (See: Battery/Service Precautions). 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Battery/Battery Cable/Negative/Service and Repair). 2. Remove the drive belt. Refer to Drive Belt Replacement (See: Engine, Cooling and Exhaust/Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair). 3. Disconnect the engine wiring harness electrical connector (1) from the generator. 4. Reposition the engine wiring harness boot (4) in order to access the terminal stud. 5. Remove the engine wiring harness nut (3). 6. Remove the engine wiring harness terminal (2) from the generator. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator Bracket Replacement > Page 10032 7. Remove the generator bolts (1). 8. Remove the generator. Installation Procedure 1. Install the generator. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the generator bolts (1). Tighten the bolts to 50 Nm (37 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator Bracket Replacement > Page 10033 3. Install the engine wiring harness terminal (2) to the generator. 4. Install the engine wiring harness nut (3). Tighten the nut to 9 Nm (80 lb in). 5. Position the engine wiring harness boot (4) in order to cover the terminal stud. 6. Connect the engine wiring harness electrical connector (1) to the generator. 7. Install the drive belt. Refer to Drive Belt Replacement (See: Engine, Cooling and Exhaust/Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair). 8. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Battery/Battery Cable/Negative/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder Case Replacement Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder Case Replacement Ignition Lock Cylinder Case Replacement Removal Procedure Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). 1. Remove the inflatable restraint steering wheel module coil. Refer to Steering Wheel Inflatable Restraint Module Coil Replacement (See: Restraint Systems/Air Bag Systems/Clockspring Assembly / Spiral Cable/Service and Repair/Removal and Replacement). 2. Remove the ignition/start switch. Refer to Ignition and Start Switch Replacement (See: Service and Repair). 3. Disconnect the park lock cable from the ignition lock cylinder case. 4. Disconnect the passlock and key buzzer from the ignition lock cylinder case. 5. Remove the 3 ignition lock cylinder case screws (2). 6. Remove the ignition lock cylinder case (1) from the vehicle. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder Case Replacement > Page 10040 1. Install the ignition lock cylinder case (1) to the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the 3 ignition lock cylinder case screws (2). Tighten the screws to 7 Nm (62 lb in). 3. Install the park lock cable into the lock cylinder housing. 4. Connect the passlock and key buzzer to the ignition lock cylinder case. 5. Install the ignition/start switch. Refer to Ignition and Start Switch Replacement (See: Service and Repair). 6. Install the inflatable restraint steering wheel module coil. Refer to Steering Wheel Inflatable Restraint Module Coil Replacement (See: Restraint Systems/Air Bag Systems/Clockspring Assembly / Spiral Cable/Service and Repair/Removal and Replacement). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder Case Replacement > Page 10041 Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder Replacement Ignition Lock Cylinder Replacement Removal Procedure Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). 1. Disable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair). 2. Remove the steering column shroud. Refer to Steering Column Shroud Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Column Shroud Replacement). 3. With the key installed hold it in the START position. 4. Install an allen wrench into the hole on top of the ignition lock cylinder case. Push down on the allen wrench to release the tab on the ignition lock cylinder inside the ignition lock cylinder case. 5. Slide the ignition lock cylinder out of the ignition lock cylinder case. Installation Procedure Note: The gears between the ignition/start switch and the ignition lock cylinder case must be in the correct position. Failure to do so will cause a misalignment of the gears in the ignition/start switch and the ignition lock cylinder case, which may result in a NO START or BATTERY DRAIN. 1. Use a screwdriver to rotate the ignition lock cylinder case gear clockwise to the start position allowing it to spring return into the RUN position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder Case Replacement > Page 10042 2. Install the key into the ignition lock cylinder. 3. Align the ignition lock cylinder and install it into the ignition lock cylinder case. 4. Install the steering column shroud. Refer to Steering Column Shroud Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Column Shroud Replacement). 5. Enable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information Key: Technical Service Bulletins Locks - Key Code Security Rules and Information INFORMATION Bulletin No.: 10-00-89-010 Date: May 27, 2010 Subject: Key Code Security Rules and Information on GM KeyCode Look-Up Application (Canada Only) Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saturn and Saab 2002 and Prior Isuzu Attention: This bulletin has been created to address potential issues and questions regarding KeyCode security. This bulletin should be read by all parties involved in KeyCode activity, including dealer operator, partner security coordinator, sales, service and parts departments. A copy of this bulletin should be printed and maintained in the parts department for use as a reference. Important U.S. dealers should refer to Corporate Bulletin Number 10-00-89-009. Where Are Key Codes Located? General Motors provides access to KeyCodes through three sources when a vehicle is delivered to a dealer. Vehicle KeyCodes are located on the original vehicle invoice to the dealership. There is a small white bar coded tag sent with most new vehicles that also has the key code printed on it. Dealerships should make a practice of comparing the tag's keycode numbers to the keycode listed on the invoice. Any discrepancy should be reported immediately to the GM of Canada Key Code Inquiry Desk. Remember to remove the key tag prior to showing vehicles to potential customers. The third source for Key codes is through the GM KeyCode Look-Up feature within the OEConnection D2DLink application. KeyCode Look-Up currently goes back 17 previous model years from the current model year. When a vehicle is received by the dealership, care should be taken to safeguard the original vehicle invoice and KeyCode tag provided with the vehicle. Potential customers should not have access to the invoice or this KeyCode tag prior to the sale being completed. After a sale has been completed, the KeyCode information belongs to the customer and General Motors. Tip Only the original invoice contains key code information, a re-printed invoice does not. GM KeyCode Look-Up Application for GM of Canada Dealers All dealers should review the General Motors of Canada KeyCode Look-Up Policies and Procedures (Service Policy & Procedures Manual Section 3.1.6 "Replacement of VIN plates & keys"). Please note that the KeyCode Access site is restricted. Only authorized users should be using this application. Please see your Parts Manager for site authorized users. KeyCode Look-Up currently goes back 17 years from current model year. Important notes about security: - Users may not access the system from multiple computers simultaneously. - Users may only request one KeyCode at a time. - KeyCode information will only be available on the screen for 2 minutes. - Each user is personally responsible for maintaining and protecting their password. - Never share your password with others. - User Id's are suspended after 6 consecutive failed attempts. - User Id's are disabled if not used for 90 days. - Processes must be in place for regular dealership reviews. - The Parts Manager (or assigned management) must have processes in place for employee termination or life change events. Upon termination individuals access must be turned off immediately and access should be re-evaluated upon any position changes within the dealership. - If you think your password or ID security has been breached, contact Dealer Systems Support at 1-800-265-0573. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information > Page 10047 Each user will be required to accept the following agreement each time the KeyCode application is used. Key Code User Agreement - Key codes are proprietary information belonging to General Motors Corporation and to the vehicle owner. - Unauthorized access to, or use of, key code information is unlawful and may subject the user to criminal and civil penalties. - This information should be treated as strictly confidential and should not be disclosed to anyone unless authorized. I will ensure that the following information is obtained prior to releasing any Key Code information: 1. Government issued picture ID (Drivers License) 2. Registration or other proof of ownership. Registration should have normal markings from the Province that issued the registration and possibly the receipt for payment recorded as well. Important - GM takes this agreement seriously. Each user must be certain of vehicle ownership before giving out key codes. - When the ownership of the vehicle is in doubt, dealership personnel should not provide the information. Key code requests should never be received via a fax or the internet and key codes should never be provided to anyone in this manner. A face to face contact with the owner of the vehicle is the expected manner that dealers will use to release a key code or as otherwise stipulated in this bulletin or other materials. - Key codes should NEVER be sent via a fax or the internet. - Each Dealership should create a permanent file to document all KeyCode Look Up transactions. Requests should be filed by VIN and in each folder retain copies of the following: - Government issued picture ID (Drivers License) - Registration or other proof of ownership. - Copy of the paid customer receipt which has the name of the employee who cut and sold the key to the customer. - Do not put yourself or your Dealership in the position of needing to "explain" a KeyCode Look Up to either GM or law enforcement officials. - Dealership Management has the ability to review all KeyCode Look-Up transactions. - Dealership KeyCode documentation must be retained for two years. Frequently Asked Questions (FAQs) for GM of Canada Dealers How do I request a KeyCode for customer owned vehicle that is not registered? Scrapped, salvaged or stored vehicles that do not have a current registration should still have the ownership verified by requesting the vehicle title, current insurance policy and / or current lien holder information from the customers financing source. If you cannot determine if the customer is the owner of the vehicle, do not provide the key code information. In these cases, a short description of the vehicle (scrapped, salvaged, etc.) and the dealership location should be kept on file. Any clarifying explanation should be entered into the comments field. How do I document a KeyCode request for a vehicle that is being repossessed? The repossessor must document ownership of the vehicle by providing a court ordered repossession order and lien-holder documents prior to providing key code information. Copies of the repossessors Drivers License and a business card should be retained by the dealership for documentation. What do I do if the registration information is locked in the vehicle? Every effort should be made to obtain complete information for each request. Each Dealership will have to decide on a case by case basis if enough information is available to verify the customer's ownership of the vehicle. Other forms of documentation include vehicle title, insurance policy, and or current lien information from the customers financing source. Dealership Management must be involved in any request without complete information. If you cannot determine if the customer is the owner of the vehicle, do not provide the key code information. Can I get a print out of the information on the screen? It is important to note that the Key Code Look Up Search Results contain sensitive and/or proprietary information. For this reason GM recommends against printing it. If the Search Results must be printed, store and/or dispose of the printed copy properly to minimize the risk of improper or illegal use. Who in the dealership has access to the KeyCode application? Dealership Parts Manager (or assigned management) will determine, and control, who is authorized to access the KeyCode Look Up application. However, we anticipate that dealership parts and service management will be the primary users of the application. The KeyCode Look Up application automatically tracks each user activity session. Information tracked by the system includes: User name, User ID, all other entered data and the date/time of access. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information > Page 10048 What if I input the VIN incorrectly? If an incorrect VIN is entered into the system (meaning that the system does not recognize the VIN or that the VIN has been entered incorrectly) the system will return an error message. If I am an authorized user for the KeyCode application, can I access the application from home? Yes. What if I suspect key code misuse? Your dealership should communicate the proper procedures for requesting key codes. Any suspicious activity either within the dealership or externally should be reported to Dealer Systems Support at 1-800-265-0573 or GM of Canada Key Code Inquiry Desk at 1-905-644-4892. Whose key codes can I access through the system? At this time the following Canadian vehicle codes are available through the system: Chevrolet, Cadillac, Buick, Pontiac, GMC, HUMMER (H2 and H3 only), Oldsmobile, Saturn, Saab and Isuzu (up to 2002 model year) for a maximum of 17 model years. What should I do if I enter a valid VIN and the system does not produce any key code information? Occasionally, the KeyCode Look Up application may not produce a key code for a valid VIN. This may be the result of new vehicle information not yet available. In addition, older vehicle information may have been sent to an archive status. If you do not receive a key code returned for valid VIN, you should contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. How do I access KeyCodes if the KeyCode Look-up system is down? If the KeyCode Look-up system is temporarily unavailable, you can contact the original selling dealer who may have it on file or contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. If the customer is dealing with an emergency lock-out situation, you need to have the customer contact Roadside assistance, OnStar if subscribed, or 911. What should I do if the KeyCode from the look-up system does not work on the vehicle? On occasion a dealer may encounter a KeyCode that will not work on the vehicle in question. In cases where the KeyCode won't work you will need to verify with the manufacturer of the cutting equipment that the key has been cut correctly. If the key has been cut correctly you may be able to verify the proper KeyCode was given through the original selling dealer. When unable to verify the KeyCode through the original selling dealer contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. If the key has been cut correctly and the code given does not work, the lock cylinder may have been changed. In these situations following the proper SI document for recoding a key or replacing the lock cylinder may be necessary. How long do I have to keep KeyCode Records? Dealership KeyCode documentation must be retained for two years. Can I get a KeyCode changed in the Look-Up system? Yes, KeyCodes can be changed in the Look-Up system if a lock cylinder has been changed. Contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. What information do I need before I can provide a driver of a company fleet vehicle Keys or KeyCode information? The dealership should have a copy of the individual's driver's license, proof of employment and registration. If there is any question as to the customer's employment by the fleet company, the dealer should attempt to contact the fleet company for verification. If there is not enough information to determine ownership and employment, this information should not be provided. How do I document a request from an Independent Repair facility for a KeyCode or Key? The independent must provide a copy of their driver's license, proof of employment and signed copy of the repair order for that repair facility. The repair order must include customer's name, address, VIN, city, province and license plate number. Copies of this information must be included in your dealer KeyCode file. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information > Page 10049 Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Keyless Starting System > Keyless Start Transmitter > Component Information > Technical Service Bulletins > Keyless System - Remote Start Transmitter Diagnostic Tip Keyless Start Transmitter: Technical Service Bulletins Keyless System - Remote Start Transmitter Diagnostic Tip INFORMATION Bulletin No.: 09-08-52-004A Date: January 08, 2010 Subject: Diagnostic Tips/Recommendations on GM Accessory 2-Way Remote Start Transmitter When Transmitter Battery is Weak or Dead Models: 2007-2010 Buick Lucerne 2008-2010 Buick Enclave 2007-2010 Cadillac DTS, Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Cobalt, HHR, Impala, Silverado, Tahoe 2009-2010 Chevrolet Malibu, Traverse 2007-2010 GMC Acadia, Sierra, Yukon 2007-2009 Pontiac G5, G6, Solstice, Torrent 2008-2009 Pontiac G8 2007-2010 Saturn AURA, OUTLOOK, SKY, VUE 2007-2010 HUMMER H2 Supercede: This bulletin is being revised to update the models and model years. Please discard Corporate Bulletin Number 09-08-52-004 (Section 08 - Body and Accessories). Follow these procedures if a customer comments that their GM Accessory 2-way transmitter stopped communicating with the vehicle. About GM Accessory 2-Way Remote Start The GM Accessory 2-way transmitter has the ability to operate a second vehicle equipped with a 2-way advanced remote start system, but often the 2-way transmitter may only be coded to one vehicle. If the customer presses the left side button twice within one second, the 2-way transmitter will enter second vehicle mode and will not control the original vehicle until a subsequent double press of the left side button places the transmitter back in first vehicle mode. Each vehicle mode of the 2-way transmitter should be thought of as an individual transmitter with its own unique code. Test the Transmitter Battery Note This test should be performed prior to releasing the vehicle or transmitter to the customer. All transmitter batteries should be tested immediately after installation of a 2-way remote start kit or replacement of a transmitter battery using the following procedure. 1. Press the unlock button on the transmitter eight times consecutively. 2. After the eighth press of the unlock button, observe the battery gauge located in the upper right corner of the LCD display. The gauge should read full (three bars inside the battery icon). If after having a new battery installed, the battery goes dead within five months, the transmitter could have high sleep current, causing the battery to go dead. Replace the transmitter. Please follow this diagnostic or repair process thoroughly and complete each step. If the condition exhibited is resolved without completing every step, the remaining steps do not need to be performed. Determine if Transmitter is in Second Vehicle Mode 1. Press and release any of the face buttons on the 2-way transmitter and observe the display on power-up. 2. If the 2-way transmitter is in second vehicle mode, the second vehicle icon will be displayed on the left side of the transmitter display. Is the 2-way transmitter in second vehicle mode? If Yes, the 2-way transmitter is working properly. - Press and release the left side button twice within one second. The 2-way transmitter should exit second vehicle mode. - Press and release the lock button. Press and release the unlock button. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Keyless Starting System > Keyless Start Transmitter > Component Information > Technical Service Bulletins > Keyless System - Remote Start Transmitter Diagnostic Tip > Page 10055 - Confirm that the vehicle responds with the appropriate lock and unlock function. - If Yes , the 2-way transmitter was in mode B. - Press and release the left side button twice within one second. The 2-way transmitter should enter second vehicle mode. - Use the "next available slot" method in the scan tool to program the 2-way transmitter to the 2-way RCDLR. Refer to Remote Control Door Lock Transmitter Programming in SI. - Both vehicle modes of the 2-way transmitter should now be coded to the vehicle. If No: The 2-way transmitter is not exhibiting the failure mode addressed by this bulletin. Refer to normal diagnostic procedures. Parts Information For part numbers, usage and availability of 2-way remote start, refer to the Accessory Parts Catalog or Corporate Bulletin Number 09-00-89-025A. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Keyless Starting System > Keyless Start Transmitter > Component Information > Technical Service Bulletins > Keyless System - Remote Start Transmitter Diagnostic Tip > Page 10056 Keyless Start Transmitter: Technical Service Bulletins Keyless Start - 2-Way Advanced Remote Start INFORMATION Bulletin No.: 09-00-89-025A Date: October 26, 2009 Subject: GM Accessories: 2-Way Advanced Remote Start Systems Part Information Models: 2007-2010 Buick Lucerne 2008-2010 Buick Enclave 2007-2010 Cadillac Escalade ESV, EXT 2008-2010 Cadillac DTS 2007-2009 Chevrolet Equinox, HHR 2007-2010 Chevrolet Avalanche, Cobalt, Silverado, Tahoe 2008-2010 Chevrolet Impala, Malibu 2009-2010 Chevrolet Traverse 2007-2010 GMC Acadia, Sierra, Yukon 2008-2010 HUMMER H2 2007-2009 Pontiac Torrent 2007-2010 Pontiac G5, G6 2008-2010 Pontiac G8 2010 Pontiac Solstice 2007-2010 Saturn AURA, OUTLOOK 2009-2010 Saturn VUE 2010 Saturn SKY Attention: This bulletin does not apply to GMODC dealers. Supercede: This bulletin is being revised to add part numbers. Please discard Corporate Bulletin Number 09-00-89-025 (Section 00 - General Information). This bulletin is being published to provide information on locating service part numbers for GM Accessory, 2-Way Advanced Remote Start Systems. Dealers should consult the chart below and use the correct service part. Dealers should not use entire kit for warranty or repair work. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Keyless Starting System > Keyless Start Transmitter > Component Information > Technical Service Bulletins > Keyless System - Remote Start Transmitter Diagnostic Tip > Page 10057 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Keyless Starting System > Keyless Start Transmitter > Component Information > Technical Service Bulletins > Keyless System - Remote Start Transmitter Diagnostic Tip > Page 10058 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Keyless Starting System > Keyless Start Transmitter > Component Information > Technical Service Bulletins > Keyless System - Remote Start Transmitter Diagnostic Tip > Page 10059 Parts Information Service parts common to all 2-Way Advanced Remote Start Systems Transmitter Battery 12493150 Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams Starter Motor: Diagrams Component Connector End Views Starter Motor X1 (Diesel) Starter Motor X2 (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Page 10063 Starter Motor: Service and Repair Starter Replacement (6.6L) Removal Procedure Warning: Refer to Battery Disconnect Warning (See: Battery/Service Precautions). 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Battery/Battery Cable/Negative/Service and Repair). 2. Remove the wheelhouse liner. Refer to Front Wheelhouse Liner Replacement - Right Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side)Front Wheelhouse Liner Replacement - Right Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side). 3. Working through the wheelhouse, remove the starter solenoid cable nut (6) from the starter. 4. Remove the starter solenoid cable (7) from the starter. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Page 10064 5. Working through the wheelhouse, remove the engine wiring harness lead nut (3). 6. Remove the engine wiring harness lead (2) from the starter motor. 7. Remove the exhaust manifold-to-catalytic converter pipe. Refer to Catalytic Converter Replacement (LY6 with Exhaust Flange) (See: Engine, Cooling and Exhaust/Exhaust System/Catalytic Converter/Service and Repair)Catalytic Converter Replacement (L9H with Exhaust Flange) (See: Engine, Cooling and Exhaust/Exhaust System/Catalytic Converter/Service and Repair)Catalytic Converter Replacement (Gen IV Engines with Exhaust Clamp) (See: Engine, Cooling and Exhaust/Exhaust System/Catalytic Converter/Service and Repair)Catalytic Converter Replacement (LFA with Exhaust Clamp) (See: Engine, Cooling and Exhaust/Exhaust System/Catalytic Converter/Service and Repair)Catalytic Converter Replacement (LMM) (See: Engine, Cooling and Exhaust/Exhaust System/Catalytic Converter/Service and Repair). 8. From under the vehicle, remove the starter motor bolts (1). 9. Remove the starter motor. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Page 10065 1. Install the starter motor. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the starter motor bolts (1). Tighten the bolts to 85 Nm (63 lb ft). 3. Install the exhaust manifold-to-catalytic converter pipe. Refer to Catalytic Converter Replacement (LY6 with Exhaust Flange) (See: Engine, Cooling and Exhaust/Exhaust System/Catalytic Converter/Service and Repair)Catalytic Converter Replacement (L9H with Exhaust Flange) (See: Engine, Cooling and Exhaust/Exhaust System/Catalytic Converter/Service and Repair)Catalytic Converter Replacement (Gen IV Engines with Exhaust Clamp) (See: Engine, Cooling and Exhaust/Exhaust System/Catalytic Converter/Service and Repair)Catalytic Converter Replacement (LFA with Exhaust Clamp) (See: Engine, Cooling and Exhaust/Exhaust System/Catalytic Converter/Service and Repair)Catalytic Converter Replacement (LMM) (See: Engine, Cooling and Exhaust/Exhaust System/Catalytic Converter/Service and Repair). 4. Install the engine wiring harness lead (2) to the starter motor. 5. Install the engine wiring harness lead nut (3). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Page 10066 Tighten the nut to 3.4 Nm (30 lb in). 6. Install the starter solenoid cable (7) to the starter. 7. Install the starter solenoid cable nut (6) to the starter. Tighten the nut to 9 Nm (80 lb in). 8. Install the wheelhouse liner. Refer to Front Wheelhouse Liner Replacement - Right Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side)Front Wheelhouse Liner Replacement - Right Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side). 9. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Battery/Battery Cable/Negative/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations Starter Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 10070 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 10071 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 10072 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 10073 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 10074 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 10075 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 10076 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Service and Repair Starter Solenoid: Service and Repair Starter Solenoid Switch Replacement (Diesel) Removal Procedure 1. Remove the starter motor. Refer to Starter Replacement (V8) (See: Starter Motor/Service and Repair)Starter Replacement (V6) (See: Starter Motor/Service and Repair)Starter Replacement (6.6L) (See: Starter Motor/Service and Repair). 2. Reposition the M-terminal stud weather cover (1). 3. Clean the epoxy coating (2) from the M-terminal stud. 4. Loosen the M-terminal stud nut. 5. Remove the cable from the M-terminal stud. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Service and Repair > Page 10080 6. Remove the solenoid bolts (1). 7. Separate the solenoid from the housing and unhook the solenoid plunger (2) from the drive gear lever (1). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Service and Repair > Page 10081 8. Note that the spring (3) is positioned against the drive gear lever (1) and the drive gear lever is placed inside the solenoid plunger loop (2). 9. Remove the solenoid housing. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Service and Repair > Page 10082 10. If necessary, remove the solenoid plunger and spring. Installation Procedure 1. If necessary, install the solenoid plunger and spring. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Service and Repair > Page 10083 2. Using Three Bond silicone 1207B, GM P/N 97720043, seal the starter solenoid attachment area. Note: Ensure that the drive gear lever (1) is properly installed into the solenoid plunger (2) loop. Improper installation of the drive gear lever will cause an abnormal or no operation condition of the starter. 3. Install the solenoid, making sure to insert the drive gear lever (1) into the solenoid plunger (2) loop, perform the following: 1. Pull the gear lever (1) out away from the starter housing and pull the plunger (2) out away from the solenoid. 2. Tip the solenoid and insert the lever into the loop, push the solenoid against the housing. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Service and Repair > Page 10084 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the solenoid bolts (1). Tighten the bolts to 10 Nm (89 lb in). 5. Wipe the excess silicone pressed out during the solenoid installation from around the base of the solenoid to make a weather proof seal. 6. Install the cable to the M-terminal stud between the washers and terminal nut. 7. Tighten the M-terminal stud nut. Tighten the nut to 8 Nm (71 lb in). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Service and Repair > Page 10085 8. Using Three Bond silicone 1207B, GM P/N 97720043, seal the M-terminal stud connection (2). 9. Reposition the M-terminal stud weather cover (1). 10. Bench test the starter in a free-run condition prior to installation. 11. Install the starter motor. Refer to Starter Replacement (V8) (See: Starter Motor/Service and Repair)Starter Replacement (V6) (See: Starter Motor/Service and Repair)Starter Replacement (6.6L) (See: Starter Motor/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions Auxiliary Power Outlet: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Schematic Symbols Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10091 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10092 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10093 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10094 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10095 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10096 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10097 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10098 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10099 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10100 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10101 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10102 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10103 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10104 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10105 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10106 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10107 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10108 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10109 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10110 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10111 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10112 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10113 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10114 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10115 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10116 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10117 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10118 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10119 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10120 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10121 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10122 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10123 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10124 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10125 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10126 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10127 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10128 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10129 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10130 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10131 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10132 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10133 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10134 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10135 Auxiliary Power Outlet: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed with Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10136 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10137 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Connector Test Adapters) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10138 Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Test Lamp) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Fused Jumper Wires) * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage Drop) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Frequency) * Testing Ground and Low Reference Circuits (See: Testing and Inspection/Component Tests and General Diagnostics/Testing Ground and Low Reference Circuits) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fuses) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Circuit Breakers) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fusible Links) Troubleshooting with a Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Testing for a Short to Voltage Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10139 Testing for a Short to Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure tests for a short to voltage in a circuit. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the Digital Multimeter (DMM) to the V (DC) position. 4. Connect the positive lead of the DMM to one end of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. Turn ON the ignition and operate all accessories. 7. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Special Tools J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure). Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents). Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10140 The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the frequency of a signal. Note: Connecting the Digital Multimeter (DMM) to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Set to Hz on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10141 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the Digital Multimeter (DMM). 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the difference in voltage potential between 2 points. 1. Set the Digital Multimeter (DMM) to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10142 Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Backprobe Note: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10143 (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for Continuity Testing for Continuity Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures verify good continuity in a circuit. With a Digital Multimeter (DMM) 1. Set the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Select the MIN MAX function on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10144 Testing for Electrical Intermittents Testing for Electrical Intermittents Special Tools J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. Note: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions). 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10145 visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing for Terminal Fretting Some intermittent conditions can be caused by wire terminal fretting corrosion. Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can pile up enough at the electrical contact spots that the electrical resistance across the connection increases. Movement between the contacting surfaces as small as 10 to 100 microns can cause fretting. To put this in perspective, a sheet of paper is about 100 microns thick, so fretting motion is small and hard to see. Vibration and thermal expansion/contraction are the main sources that create fretting motion. Since vehicles vibrate and can experience large temperature swings, they are a good source for fretting motion. Tin, copper, nickel, and iron surfaces are all susceptible to fretting corrosion. Fretting corrosion can be difficult to see but it looks like small, dark smudges on the terminals contact surface. To correct a fretting condition disconnect the suspect connector and add Nyogel lubricant 760G (dielectric grease) to both sides of the connector terminals. Then reconnect the connector and wipe away any excess lubricant. This will correct the additional terminal contact resistance due to the terminal fretting corrosion. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10146 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Power Distribution Schematics). * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Ground Distribution Schematics). Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Checking Aftermarket Accessories). * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10147 Note: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures test for a short to ground in a circuit. With a Digital Multimeter (DMM) 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohms position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Danger: High voltage circuits should only be tested using a digital multimeter (DMM) and test leads with at least a CAT III rating, such as the J 39200-A Digital Multimeter. Failure to follow the procedures exactly as written may result in serious injury or death. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Digital Multimeter (DMM) Basic Requirements Service information is validated using digital multimeters that meet or exceed the following requirements. Using a multimeter that does not meet these basic requirements may give inaccurate readings which could lead to an incorrect diagnosis. Display and Settings 1. Four digits displayed 2. Voltage, amperage, resistance, frequency, diode test settings, and min-max function 3. Display positive and negative values Voltage 1. Have at least 10 M ohm input impedance Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10148 2. Test a DC voltage range of 0.1-1000 V. 3. Test an AC voltage range of 0.1-1000 V. Amperage 1. Test a DC amperage range of 0.1µA-10 A. 2. Test an AC amperage range of 0.1µA-10 A. Resistance Test a resistance range of 0.1 ohm-40 Mohm and displays infinite for a value greater than 40 M ohm (O.L. (Over-load)) Frequency Test for a frequency range of 0.5 HZ-199 K HZ Diode Test 1. Apply at least 1 mA when performing the diode bias test 2. Display the break over voltage drop (0-3 V) of a forward biased diode 3. Display infinite (O.L. (Over-load)) when a diode is reverse biased Min-Max Readings 1. Can update at a 1 ms sample rate 2. Saves and displays minimum and maximum values Note: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Probe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors). * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the EL-38125-580 GM Approved Terminal Release Tool Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the EL-38125-580 GM Approved Terminal Release Tool Kit , ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the EL-38125-580 GM Approved Terminal Release Tool Kit label on the inside of the EL-38125-580 GM Approved Terminal Release Tool Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10149 Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/EPC Connectors AFL/EPC Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10150 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 3. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10151 View showing depressing of the lever lock release tab. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10152 6. Release the rear lower half of the wiredress cover. 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10153 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10154 Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Bosch Connectors (ECM) Bosch Connectors (ECM) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10155 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. 2. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10156 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-bladed tool to release the locking tabs and remove the dress cover. 4. The terminal positive assurance (TPA) is located in the front of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10157 5. Use a small flat-blade tool to remove TPA from the connector. 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10158 Note: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10159 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10160 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Terminal Replacement Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10161 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10162 5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Position Assurance Locks) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Terminal Position Assurance Locks) * AFL/EPC Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/AFL/EPC Connectors) * Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (BSK))Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (0.64))Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (2.8 JPT))Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (ECM)) * Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Weather Pack))Delphi Connectors (Push To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Push to Seat))Delphi Connectors Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10163 (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Pull to Seat))Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro-Pack 100W))Delphi Connectors (Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro .64))Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (12-Way)) * FCI Connectors (Lever Lock) (See: General Electrical Diagnostic Procedures/Connector Repairs/FCI Connectors (Lever Lock)) * JST Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/JST Connectors) * Kostal Connectors (Glow Plug Control Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Glow Plug Control Module))Kostal Connectors (Transmission) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Transmission)) * Molex Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Molex Connectors) * Sumitomo Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Sumitomo Connectors) * Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (CM 42-Way))Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Sensor))Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (0.25 Cap))Tyco/AMP Connectors (43-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (43-Way))Tyco/AMP Connectors (Door Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Door Module))Tyco/AMP Connectors (102-Way Inline) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (102-Way Inline))Tyco/AMP Connectors (Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Seat))Tyco/AMP Connectors (SIR) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (SIR)) * Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (2-Way))Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (16-Way)) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10164 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10165 * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10166 * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10167 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10168 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10169 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Push to Seat) Delphi Connectors (Push To Seat) Special Tools J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10170 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs). 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Terminated Lead Repair 1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice sleeves depending on the gauge size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Delphi Connectors (Pull to Seat) Delphi Connectors (Pull To Seat) Special Tools Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10171 J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Note: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10172 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. View of a typical Micro 64 connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10173 Depress the lock and pull the lever over and past the lock. View of the connector when released from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10174 View of another type of Micro 64 connector. Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10175 View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10176 Note: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10177 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10178 Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Note: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10179 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10180 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10181 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10182 1. Cut the wire as close to the terminal as possible. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10183 Terminal Replacement Procedure After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Special Tools J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Note: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals). 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12-Way) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10184 Delphi Connectors (12-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10185 4. Release the lower wire dress cover locking tab. 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10186 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10187 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors (Lever Lock) FCI Connectors (Lever Lock) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10188 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. The release tab is located on the top of the wiredress cover. 3. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10189 6. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10190 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10191 1. While depressing the lock, remove the connector from the component. 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10192 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. 4. View of the TPA when removed from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10193 5. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Glow Plug Control Module) Kostal Connectors (Glow Plug Control Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10194 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10195 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10196 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. Note: The front TPA cannot be removed from the connector. Only move it to the preset position. 6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm). 7. Use a small flat-blade tool to completely remove the rear TPA from the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10197 8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Transmission) Kostal Connectors (Transmission) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10198 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10199 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Terminal Replacement Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10200 After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10201 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10202 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10203 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10204 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10205 3. To assemble the connector, reverse the connector disassembly procedure. Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10206 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10207 7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10208 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10209 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10210 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10211 Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10212 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10213 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10214 6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (102-Way Inline) Tyco/AMP Connectors (102-Way Inline) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10215 View of a typical connector in the assembled position. 1. Pull the locking lever to the 90 degree position from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10216 2. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal. 3. Slide the male connector body out away from the guide plates. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10217 Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 4. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. 5. Using terminal release tool J 38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10218 6. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 7. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10219 8. The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool J-38125-11A or equivalent to release the locking tab and slide the connector off the female body. 9. Move the locking lever 180 degrees from the connected position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10220 10. With the locking lever in the 180 degree position the guide plates can be removed from the connector body. Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 11. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10221 12. Using terminal release tool J 38125-216, lift the terminal plate past the terminals and out of the connector body cavity. 13. Terminal plate will bind slightly on each corner. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10222 14. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 15. Using terminal release tool J 38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10223 16. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 17. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10224 18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever. 19. Slide the male connector body back inward toward the guide plates. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10225 20. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly. 21. Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Seat) Tyco/AMP Connectors (Seat) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10226 Removal Procedure 1. Grasp the locking slide lever and pull outward from the end of the connector. 2. As the slide lever is pulled out the mating connector is lifted from the seated position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10227 Note: TPA is keyed and can only be inserted in one direction. 3. Using terminal release tool J 38125-11A or equivalent, push the TPA tabs into the connector body. 4. Pull the TPA from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10228 5. Using terminal release tool J 38125-11A or equivalent, release the connector wire dress cover locking tab. 6. With the lock tab released, lift the connector wire dress cover from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10229 7. Using terminal release tool J 38125-212, press the prongs into the holes each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 8. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10230 9. Using terminal release tool J 38125-556, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (SIR) Tyco/AMP Connectors (SIR) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10231 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10232 3. Using terminal tool J-38125-11A or equivalent, release the wire dress cover locking tabs. 4. Pivot connector wire dress cover while removing from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10233 5. Using terminal tool J-38125-11A or equivalent, remove the TPA by lifting straight off the connector body. 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals Repairing Connector Terminals Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10234 Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gauge size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10235 2. Disconnect the connector from the component. 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10236 4. Relieve the tension on the nose piece retainers by inserting J 38125-12A into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. 5. Once the nose piece retainers are relaxed, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10237 6. On the opposite side of the nose piece, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10238 8. Insert the J 38125-553 tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10239 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. If the TPA is removed, be sure to reinstall it before reconnecting the connector. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10240 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Special Tools Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10241 J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Note: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10242 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10243 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10244 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10245 1. While depressing the lock, pull the two connector halves apart. Note: The TPA is fragile and may break if not done carefully. 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. 3. View of the male half of the connector with female terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10246 4. View of the female half of the connector with male terminals. 5. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. View of the female half of the connector with male terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10247 7. View of the male half of the connector with female terminals. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10248 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are a one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine if the element in the fuse is broken (2). If not broken (1), also check for continuity using a Digital Multimeter (DMM) or a continuity tester. If the element is broken or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a Digital Multimeter (DMM) at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gauge size. Repairing a Fusible Link Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10249 Flat Wire Repairs The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Special Tools J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool * J 38125-5 Ultra Torch Special Tool The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Note: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation). GMLAN Connector Terminal Repair Note: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) for the appropriate connector repair procedure. GMLAN Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10250 Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10251 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Special Tools J-38125 Terminal Repair Kit Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10252 repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs High Temperature Wiring Repairs Special Tools J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gauge size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10253 splice. Note: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10254 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10255 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the wire insulation has been chafed, or broken, enough to show the conductive portion of the wire, and the wire is not damaged, determine the length of insulation that needs to be repaired. If the repair is less than 280 mm (11 in), cut the wire within the damaged area. Then slide the appropriate heat shrink tubing (listed below) over the wire, and repair the wire by splicing the wires together. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Once the wire is spliced together slide heat shrink tubing over the damaged area and apply heat to seal the repaired wire. If the wire is damaged, or the damaged area is larger than 280 mm (11 in), then replace the damaged wire by splicing in a new section of wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10256 SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Special Tools J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10257 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10258 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10259 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Special Tools J-38125 Terminal Repair Kit Note: Use only DuraSeal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use DuraSeal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use DuraSeal splice sleeves where there are special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10260 * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10261 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10262 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the instructions for Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Staggering the splices by 65 mm (2.5 in) is recommended. Note: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product AL-36FR to replace the damaged mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Flat Wire Repairs) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/GMLAN Wiring Repairs) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Heated Oxygen Sensor Wiring Repairs) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves) * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Twisted or Shielded Cable) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Inline Harness Diodes) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/SIR/SRS Wiring Repairs) US English/Metric Conversion US English/Metric Conversion Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10263 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10264 Testing Ground and Low Reference Circuits Testing Ground and Low Reference Circuits Because a test lamp can light with up to 200 ohm in a ground or low reference circuit they are not recommended to be used for this type of test. A low impedance test lamp can light and indicate the circuit is good when there is as much as 20-30 ohm present, while a high impedance test lamp can light with up to 200 ohm present in the circuit. This is why the Digital Multi-Meter (DMM) is used when validating a ground or low reference circuit continuity. When using the DMM there are many vehicle conditions that can affect the ground and low reference continuity testing. If these conditions are not met, a ground or low reference circuit test can fail on a good circuit. This may cause longer diagnosis time and incorrect component replacement. Any current flow through a ground or low reference circuit, while being tested, will skew the DMM continuity reading, or display a reading higher than when there is no current flowing. Performing a ground or low reference circuit continuity test, in reference to the vehicles battery negative terminal, will have the highest risk of failing a good ground or low reference circuit test than any other ground reference point. The best ground test points would be a control module housing (if the control modules housing is metal and grounded), door jamb striker (if attached to metal), under dash metal frame work, engine block, or body ground studs (other than where the negative battery cable is attached). A typical DMM ground or low reference circuit continuity reading can be as high as 100 ohm with the ignition ON, and drop to 15-25 ohm after the ignition is turned OFF. The reading will drop below 10 ohm after 30-40 seconds, then below 5 ohm after 60 seconds. Once the vehicle completely goes to sleep (generally 3-10 minutes) the reading will drop below 0.3 ohm. The following list of conditions may need to be met to ensure a valid continuity reading on a ground or low reference circuit: * Ignition OFF * Key out of the ignition switch (when not equipped with keyless entry and remote start) * Retained Accessory Power (RAP) OFF (open and close the driver door after ignition OFF) * Battery charger set at a 2 A or less charge rate * Scan tool not communicating with any vehicle control module (in some cases it may need to be disconnected from the DLC) * All entry doors closed * Headlamps OFF (auto headlamps disabled) * Any delay lighting OFF * HVAC after blow OFF * Any accessory that can work when the ignition is OFF * Wait up to 60 seconds (after all other listed conditions are met) Activating the DOOR LOCK function with a key fob can greatly reduce the time to achieve a valid ground or low reference continuity test result. Terminal Removal Terminal Removal Special Tools * EL-38125-580 - Terminal Release Tool Kit * EL-35616 - Connector Test Adapter Kit For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repair procedures. 1. Find the appropriate connector end view within the connector end view section. The connector end view has the following information: Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10265 * Diagnostic probe tool * Terminal release tool * Terminal/terminated lead part numbers Note: Not using the proper test kit probe may cause damage to the terminal(s) that are probed. 2. Determine if a terminal is damaged. * Locate the diagnostic probe tool from the connector end view. The connector end view describes the color and part number to help the technician find and use the correct tool. * Connect the probe tool to the Digital Multimeter. * Insert the probe tool into the cavity and follow the procedures from the Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter). 3. Disconnect the connector body to perform the repair. 4. Use the following procedure to remove the terminal from the connector body. Note: Several procedures for specific connector bodies are called out in the Wiring Repairs section. * The terminal position assurance (TPA) and connector position assurance (CPA) should be removed before releasing the terminal for the connector body. * Look at the connector end view to locate the cavity of the damaged terminal and find the proper terminal release tool from the terminal release tool kit. Note: Using the incorrect terminal release tool can damage the connector body. * Insert the terminal release tool into the cavity. Note: Some terminals have a lever that must be disengaged before the terminal can be released. 5. Gently pull the wire out of the back of the connector. 6. Repair the terminal by following the Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) procedure. 7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminated Lead Repair Terminated Lead Repair Special Tools * J-38125-8 - Splice Sleeve Crimp Tool Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10266 * J-38125-5 - Ultra Torch For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) procedures. Terminated leads are terminals that are crimped onto wires. The terminated lead can be used throughout the vehicle since it is designed for temperatures up to 150°C. The length of the wire is 450 mm. The DuraSeal splice sleeve has the following 2 critical features: * A special heat shrink tubing that environmentally seals the splice. The shrink tubing contains a sealing adhesive inside the shrink tubing. * A cross hatched (knurled) core crimp that provides the necessary contact integrity for sensitive low energy circuits. 1. Use the connector end view to identify the correct terminated lead. 2. The terminated lead package should include a DuraSeal splice sleeve. If not, use the chart to identify the correct part. 3. Open the harness by removing any tape: Use a sewing seam ripper, or a comparable tool, to cut open the harness, to avoid wire insulation damage. 4. Depending on how many terminals need repairs, cut the terminal and wire back at least 40 mm. Try to keep the harness wire length the same. If more than one terminated lead is required, stagger the lengths by 40 mm. This helps reduce the bundle size of the wire harness. 5. Use the EL-38125-10 - tool in order to position the DuraSeal splice sleeve in the proper color nest of the splice sleeve crimp tool. The crimp tool has four nests, one for each color. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10267 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the J-38125-5 - ultra torch , apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10268 Auxiliary Power Outlet: Connector Views Component Connector End Views Accessory Power Outlet - Center Console (D07) Accessory Power Outlet - Center Console Compartment (D07) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10269 Accessory Power Outlet - Center Seat (AZ3) Accessory Power Outlet - I/P 1 Accessory Power Outlet - I/P 2 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10270 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 10271 Auxiliary Power Outlet: Electrical Diagrams Cigar Lighter/Power Outlet Schematics Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 10272 Auxiliary Power Outlet: Description and Operation Power Outlets Description and Operation 12 Volt Power Outlet Receptacle Description and Operation The accessory power receptacles are supplied battery voltage at all times. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Testing and Inspection > Symptoms - Power Outlets Auxiliary Power Outlet: Testing and Inspection Symptoms - Power Outlets Symptoms - Power Outlets Visual/Physical Inspection * Inspect for aftermarket devices which can affect the operation of the power outlets. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Checking Aftermarket Accessories) * Inspect the accessible system components or the visible system components for obvious damage or for obvious conditions which can cause the symptom. Intermittent Electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) Symptom List Refer to Power Outlet Receptacle Malfunction (See: Power Outlet Receptacle Inoperative (120 VAC)) in order to diagnose the system. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Testing and Inspection > Symptoms - Power Outlets > Page 10275 Auxiliary Power Outlet: Testing and Inspection Power Outlet Receptacle Inoperative (120 VAC) Power Outlet Receptacle Malfunction Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions )provides an overview of each diagnostic category. Diagnostic Fault Information Circuit/System Description The accessory power receptacles are supplied B+ all the time. Reference Information Schematic Reference Cigar Lighter/Power Outlet Schematics (See: Diagrams/Electrical Diagrams) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views) Description and Operation Power Outlets Description and Operation (See: Description and Operation) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) Circuit/System Testing 1. Ignition OFF, disconnect the harness connector at the appropriate X80 accessory power receptacle. 2. Test for less than 5 ohm between the ground circuit terminal C and ground. ‹› If greater than the specified range, test the ground circuit for an open/high resistance. 3. Verify that a test lamp illuminate between the B+ circuit terminal A and ground. ‹› If the test lamp does not illuminate, test the B+ circuit for a short to ground or an open/high resistance. 4. If all circuits test normal, test or replace the X80 accessory power receptacle. Repair Instructions Perform the Diagnostic Repair Verification (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Testing and Inspection > Symptoms - Power Outlets > Page 10276 Cigar Lighter Receptacle or 12-Volt Accessory Power Receptacle Replacement (See: Service and Repair) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Testing and Inspection > Page 10277 Auxiliary Power Outlet: Service and Repair Cigar Lighter Receptacle or 12-Volt Accessory Power Receptacle Replacement Tools Required J 42059 Cigar Lighter Socket Remover Removal Procedure 1. Remove the auxiliary power outlet fuse from the fuse block. 2. Remove the receptacle: 1. Look into the receptacle. There are two 3 mm (0.11 in) tab windows 12 mm (0.47 in) from the front of the receptacle. The J 42059 pushes the plastic latches from these tab windows and the receptacle can be pulled straight out. 2. Place one side of the "T" portion of the J 42059 into the tab window. The J 42059 will not fit straight into the receptacle. Angle the J 42059 slightly for insertion into the receptacle. 3. Insert the other side of the "T" into the opposite tab window. You must move the J 42059 handle toward horizontal to engage the other tab window. 4. Use the J 42059 to pull the receptacle straight out. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Testing and Inspection > Page 10278 3. If J 42059 tool fails to release the lighter socket from the retainer, perform the following alternate method: 1. Insert a small grinding tool with a cutoff wheel into the socket. 2. Remove the plastic latches in the 3 mm (0.11 in) square windows. 3. Use the J 42059 as directed above to remove the socket. Installation Procedure 1. Route the connector through the retainer. Align the accessory power receptacle retainer to the slot in the opening. 2. Install the retainer by pressing into place fully seated. 3. Connect the electrical connector to the receptacle. 4. Align the tabs on the receptacle to the slots in the retainer. Install the accessory power receptacle by pressing into place until fully seated. 5. Install the accessory power receptacle fuse. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Testing and Inspection > Page 10279 Auxiliary Power Outlet: Tools and Equipment Special Tools Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 07-08-46-002D > Jul > 09 > Audio System - Noise When Using OnStar(R) Electronic Noise Suppressor: Customer Interest Audio System - Noise When Using OnStar(R) TECHNICAL Bulletin No.: 07-08-46-002D Date: July 29, 2009 Subject: Audio Whine Noise from Radio Speakers When Using OnStar(R) (Install Noise Suppression Filter) Models: 2007-2010 GM Passenger Cars and Trucks (Including Saturn) 2007-2010 HUMMER H2, H3 2007-2009 Saab 9-7X Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update the Warranty Information. Please discard Corporate Bulletin Number 07-08-46-002C (Section 08 - Body and Accessories). Condition Some customers may comment on an audio whine coming from the radio speakers when using the OnStar(R) system. The amplitude and frequency of the whine will change with an increase or decrease in engine speed. Cause This condition may be caused by electrical noise on the OnStar(R) Vehicle Communication Interface Module (VCIM) battery feed wire being passed to the microphone output pins at the radio. Correction Technicians are to install a noise suppression filter, P/N 1224205, into the OnStar(R) battery voltage circuit, a few centimeters (inches) from the VCIM. The filter package has three attached wires - a single yellow wire at one end with a yellow wire and a black wire at the other. Install the single yellow wire side into the battery voltage circuit towards the VCIM. Install the remaining single yellow wire into the battery voltage circuit toward the fuse and the black wire to ground. Important The noise suppression filter is polarity sensitive. The filter is designed to be most effective when the end with the capacitor ground is connected towards the source of the electrical noise. Install the filter in this polarity first. If the noise level is still not satisfactory, try disconnecting the capacitor ground. In some cases, if the first installation does not correct the noise, try reversing the filter polarity (removing the filter, turning it end for end and then reinstalling it) and grounding the capacitor lead. Parts Information Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table above. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 07-08-46-002D > Jul > 09 > Audio System - Noise When Using OnStar(R) > Page 10288 Warranty Information (Saab U.S. Models) Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 07-08-46-002D > Jul > 09 > Audio System - Noise When Using OnStar(R) Electronic Noise Suppressor: All Technical Service Bulletins Audio System - Noise When Using OnStar(R) TECHNICAL Bulletin No.: 07-08-46-002D Date: July 29, 2009 Subject: Audio Whine Noise from Radio Speakers When Using OnStar(R) (Install Noise Suppression Filter) Models: 2007-2010 GM Passenger Cars and Trucks (Including Saturn) 2007-2010 HUMMER H2, H3 2007-2009 Saab 9-7X Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update the Warranty Information. Please discard Corporate Bulletin Number 07-08-46-002C (Section 08 - Body and Accessories). Condition Some customers may comment on an audio whine coming from the radio speakers when using the OnStar(R) system. The amplitude and frequency of the whine will change with an increase or decrease in engine speed. Cause This condition may be caused by electrical noise on the OnStar(R) Vehicle Communication Interface Module (VCIM) battery feed wire being passed to the microphone output pins at the radio. Correction Technicians are to install a noise suppression filter, P/N 1224205, into the OnStar(R) battery voltage circuit, a few centimeters (inches) from the VCIM. The filter package has three attached wires - a single yellow wire at one end with a yellow wire and a black wire at the other. Install the single yellow wire side into the battery voltage circuit towards the VCIM. Install the remaining single yellow wire into the battery voltage circuit toward the fuse and the black wire to ground. Important The noise suppression filter is polarity sensitive. The filter is designed to be most effective when the end with the capacitor ground is connected towards the source of the electrical noise. Install the filter in this polarity first. If the noise level is still not satisfactory, try disconnecting the capacitor ground. In some cases, if the first installation does not correct the noise, try reversing the filter polarity (removing the filter, turning it end for end and then reinstalling it) and grounding the capacitor lead. Parts Information Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table above. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 07-08-46-002D > Jul > 09 > Audio System - Noise When Using OnStar(R) > Page 10294 Warranty Information (Saab U.S. Models) Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Center Instrument Panel Fuse Block - Owners Manual Fuse: Locations Center Instrument Panel Fuse Block - Owners Manual CENTER INSTRUMENT PANEL FUSE BLOCK The center instrument panel fuse block is located underneath the instrument panel, to the left of the steering column. TOP VIEW HARNESS CONNECTOR - USAGE BODY 2 ............................................................................................................................................... ................................... Body Harness Connector 2 BODY 1 ............................................................... ................................................................................................................... Body Harness Connector 1 BODY 3 ............................................................................................................................................ ...................................... Body Harness Connector 3 HEADLINER 3 .................................................. .............................................................................................................. Headliner Harness Connector 3 HEADLINER 2 ................................................................................................................ ................................................ Headliner Harness Connector 2 HEADLINER 1 ................................. ............................................................................................................................... Headliner Harness Connector 1 SEO/UPFITTER .......................................................................................................................... Special Equipment Option Upfitter Harness Connector CIRCUIT BREAKER - USAGE CB1 ......................................................................................................................................................... Passenger Side Power Window Circuit Breaker CB2 ......................................................................... .......................................................................................................... Passenger Seat Circuit Breaker CB3 ...................................................................................................................................................... .................................. Driver Seat Circuit Breaker CB4 ....................................................................... .......................................................................................................................... Rear Sliding Window Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Center Instrument Panel Fuse Block - Owners Manual > Page 10299 Fuse: Locations Instrument Panel Fuse Block - Owners Manual INSTRUMENT PANEL FUSE BLOCK The instrument panel fuse block access door is located on the driver side edge of the instrument panel. Pull off the cover to access the fuse block. The vehicle may not use all of the fuses shown. FUSES ................................................................................................................................................. ..................................................................... USAGE Fuse 1 .................................................................................................................................................. .............................................................. Rear Seats Fuse 2 ................................................................ .................................................................................................................. Rear Accessory Power Outlet Fuse 3 ....................................................................................................................................... ................................... Steering Wheel Controls Backlight Fuse 4 ...................................................... .......................................................................................................................................... Driver Door Module Fuse 5 ..................................................................................................................................... ............................... Dome Lamps, Driver Side Turn Signal Fuse 6 .................................................... ...................................................................................................................... Driver Side Turn Signal, Stoplamp Fuse 7 ................................................................................................................................. .............................................. Instrument Panel Back Lighting Fuse 8 ................................................ .................................................................................................................... Passenger Side Turn Signal, Stoplamp Fuse 9 ..................................................................................................................... ............................................. Passenger Door Module, Driver Unlock Fuse 10 .................................. ................................................................................................................................. Power Door Lock 2 (Unlock Feature) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Center Instrument Panel Fuse Block - Owners Manual > Page 10300 Fuse 11 ................................................................................................................................................ ....................... Power Door Lock 2 (Lock Feature) Fuse 12 ......................................................................................................................................................... Stoplamps, Center-High Mounted Stoplamp Fuse 13 ......................................................................... .................................................................................................................. Rear Climate Controls Fuse 14 ................................................................................................................................................ ......................................................... Power Mirror Fuse 15 ................................................................ ............................................................................................................... Body Control Module (BCM) Fuse 16 ................................................................................................................................................ ....................................... Accessory Power Outlets Fuse 17 .............................................................. ......................................................................................................................................... Interior Lamps Fuse 18 .................................................................................................................................... ............................... Power Door Lock 1 (Unlock Feature) Fuse 19 .................................................... .................................................................................................................................... Rear Seat Entertainment Fuse 20 ..................................................................................................................................................... Ultrasonic Rear Parking Assist, Power Liftgate Fuse 21 ..................................................................... .................................................................................................. Power Door Lock 1 (Lock Feature) Fuse 22 ................................................................................................................................................ ........................... Driver Information Center (DIC) Fuse 23 ................................................................. ............................................................................................................................................ Rear Wiper Fuse 24 ..................................................................................................................................... ..................................................................... Cooled Seats Fuse 25 .............................................................................................................................................. Driver Seat Module, Remote Keyless Entry System Fuse 26 ........................................................................................................................................................... Driver Power Door Lock (Unlock Feature) CIRCUIT BREAKER ............................................................................................................................ ................................................................ USAGE LT DR .......................................................................................................................................................... Driver Side Power Window Circuit Breaker HARNESS CONNECTOR ................................................................................................................... ................................................................. USAGE LT DR .................................................................................................................................................. .......................... Driver Door Harness Connection BODY .................................................................. ................................................................................................................................ Harness Connector BODY ................................................................................................................................. ................................................................. Harness Connector Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood Fuse: Application and ID Fuse Block - Underhood Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 10303 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 10304 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 10305 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 10306 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 10307 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 10308 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 10309 Fuse Block - Underhood Top View - Diesel Fuse Block - Underhood Top View - Gas Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 10310 Fuse Block - Underhood Bottom View Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 10311 Fuse Block - Underhood X1 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 10312 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 10313 Fuse Block - Underhood X2 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 10314 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 10315 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 10316 Fuse Block - Underhood X3 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 10317 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 10318 Fuse Block - Underhood X4 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 10319 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 10320 Fuse Block - Underhood X5 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 10321 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 10322 Fuse Block - Underhood X6 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 10323 Fuse Block - Underhood X7 (except TP2) Fuse Block - Underhood X7 (TP2) Fuse Block - Underhood X8 (except JL1) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 10324 Fuse Block - Underhood X8 (JL1) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 10325 Fuse: Application and ID Fuse Block - I/P Electrical Center Identification Views Fuse Block - I/P Label Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 10326 Fuse Block - I/P Top View Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 10327 Fuse Block - I/P Bottom View Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 10328 Fuse Block - I/P X1 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 10329 Fuse Block - I/P X2 (except MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 10330 Fuse Block - I/P X3 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 10331 Fuse Block - I/P X4 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 10332 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 10333 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 10334 Fuse: Application and ID Fuse Block - Mobile Radio Electrical Center Identification Views Fuse Block - Mobile Radio, Top View (9L4) Fuse Block - Mobile Radio (9L4) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 10335 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 10336 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 10337 Fuse: Application and ID Fuse Holder Electrical Center Identification Views Fuse Block - Auxiliary, Fuse Holder (HP2) Fuse Block - Auxiliary, Fuse Holder (HP2) Fuse Holder X1 (Gas except 9L4) Fuse Holder X1 (Diesel or Gas with 9L4) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 10338 Fuse Holder X2 (Gas with TP2) Fuse Holder X2 (Diesel or Gas except LU3) Fuse Holder X2 (LU3) Fuse Holder X2 (Gas except LU3) Fuse Holder X2 (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 10339 Fuse Holder X3 (9L4) Fuse Holder X3 (Diesel) Fuse Holder X4 (TP2) Fuse Holder X4 (Diesel) Fuse Holder X4 (Diesel with K76 or YF2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 10340 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 10341 Fuse: Application and ID Junction Block Electrical Center Identification Views Junction Block - Left I/P, Label Junction Block - Left I/P, Top View Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 10342 Junction Block - Left I/P, Bottom View Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 10343 Junction Block - Left I/P X1 (except MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 10344 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 10345 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 10346 Junction Block - Left I/P X2 (except MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 10347 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 10348 Junction Block - Left I/P X3 (except MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 10349 Junction Block - Left I/P X4 (except MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 10350 Junction Block - Left I/P X5 (SPO Alarm or SPO Heated Seats) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 10351 Junction Block - Left I/P X7 (JF4) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 10352 Junction Block - Left I/P X8 (except MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 10353 Junction Block - Left I/P X9 (except MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 10354 Junction Block - Left I/P X10 (except MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 10355 Junction Block - Left I/P X11 (except MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 10356 Junction Block - Left I/P X12 (except MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 10357 Junction Block - Left I/P X13 (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 10358 Junction Block - Left I/P X14 (5X7, 5Y0, 9L4, SPO DVD or SPO Heated Seats) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 10359 Junction Block - Right I/P, Top View Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 10360 Junction Block - Right I/P (Wire Entry) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 10361 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 10362 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 10363 Junction Block - Right I/P X2 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 10364 Junction Block - Right I/P X3 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 10365 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 10366 Junction Block - Right I/P X4 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 10367 Junction Block - Right I/P X5 Junction Block - Right I/P X6 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 10368 Junction Block - Rear Lamps Junction Block - Rear Lamps X1 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 10369 Junction Block - Rear Lamps X2 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 10370 Junction Block - Rear Lamps X3 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 10371 Junction Block - Rear Lamps X4 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations Fuse Block: Component Locations Fuse Block - I/P Electrical Center Identification Views Fuse Block - I/P Label Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 10376 Fuse Block - I/P Top View Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 10377 Fuse Block - I/P Bottom View Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 10378 Fuse Block - I/P X1 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 10379 Fuse Block - I/P X2 (except MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 10380 Fuse Block - I/P X3 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 10381 Fuse Block - I/P X4 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 10382 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 10383 Fuse Block - Underhood Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 10384 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 10385 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 10386 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 10387 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 10388 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 10389 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 10390 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 10391 Fuse Block - Underhood Top View - Diesel Fuse Block - Underhood Top View - Gas Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 10392 Fuse Block - Underhood Bottom View Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 10393 Fuse Block - Underhood X1 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 10394 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 10395 Fuse Block - Underhood X2 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 10396 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 10397 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 10398 Fuse Block - Underhood X3 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 10399 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 10400 Fuse Block - Underhood X4 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 10401 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 10402 Fuse Block - Underhood X5 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 10403 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 10404 Fuse Block - Underhood X6 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 10405 Fuse Block - Underhood X7 (except TP2) Fuse Block - Underhood X7 (TP2) Fuse Block - Underhood X8 (except JL1) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 10406 Fuse Block - Underhood X8 (JL1) Fuse Block - Mobile Radio Electrical Center Identification Views Fuse Block - Mobile Radio, Top View (9L4) Fuse Block - Mobile Radio (9L4) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 10407 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 10408 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 10409 Fuse Block: Connector Locations Harness Routing Views Chassis Harness Routing (Except LY6/LMM/HP2) 1 - X300 2 - X408 (UD7) 3 - G401 4 - J423 (except LU3) 5 - J331 6 - Fuse Block - Underhood X3 7 - X115 8 - X102 (JL1) 9 - J338 (except LU3/LMG) 10 - J300 11 - G300 Chassis Harness Routing (LY6/LMM except 31 Series) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 10410 1 - X300 2 - X408 (UD7) 3 - Trailer Connector (UY7) 4 - J411 (JL1) 5 - G401 6 - J331 7 - Fuse Block - Underhood X3 8 - X115 9 - X102 (JL1) 10 - J300 11 - G300 Chassis Harness - Front Engine Compartment (31 Series) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 10411 1 - X102 (JL1) 2 - Fuel Pump Relay - Secondary (LY6 without NQZ) 3 - Fuse Block - Underhood 4 X126 Driver Door Harness Routing Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 10412 1 - Door Frame 2 - Fuse Block - I/P X4 3 - J502 (YE9 without AN3) 4 - X500 (YE9 without AN3/DL3) 5 - X502 (ASF without YE9 or with AN3) Engine Harness Routing - Left Side (4.3L) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 10413 1 - Throttle Body 2 - G107 3 - Transmission 4 - X300 5 - X109 6 - X110 (NQG/NQH) 7 - Fuse Block - Underhood X2 Engine Harness Routing - Left Front Side (4.8L/5.3L/6.0L/6.2L except LFA/HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 10414 1 - Air Intake Duct 2 - X111 3 - Fuse Block - Underhood X2 4 - X109 5 - X110 (NQF/NQG/NQH) 6 Engine Control Module (ECM) X2 7 - Engine Control Module (ECM) X1 8 - G102 9 - J105 Engine Chassis Harness Routing - Top Front (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 10415 1 - Battery - Right 2 - Fuse Holder 3 - X127 4 - X108 5 - X107 6 - X123 (PTO) 7 - Fuse Block Underhood 8 - X109 9 - Battery - Left 10 - Engine Control Module (ECM) 11 - Transmission Control Module (TCM) I/P Harness Routing - Engine Compartment (Except HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 10416 1 - G110 (XA7) 2 - J113 (NQH) 3 - Fuse Block - Underhood X5 4 - Fuse Block - Underhood X4 5 Left Front Fender 6 - X103 7 - X109 8 - X115 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Schematic Symbols Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10419 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10420 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10421 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10422 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10423 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10424 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10425 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10426 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10427 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10428 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10429 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10430 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10431 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10432 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10433 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10434 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10435 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10436 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10437 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10438 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10439 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10440 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10441 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10442 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10443 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10444 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10445 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10446 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10447 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10448 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10449 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10450 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10451 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10452 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10453 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10454 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10455 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10456 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10457 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10458 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10459 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10460 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10461 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10462 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10463 Fuse Block: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed with Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10464 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10465 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Connector Test Adapters) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10466 Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Test Lamp) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Fused Jumper Wires) * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage Drop) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Frequency) * Testing Ground and Low Reference Circuits (See: Testing and Inspection/Component Tests and General Diagnostics/Testing Ground and Low Reference Circuits) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fuses) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Circuit Breakers) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fusible Links) Troubleshooting with a Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Testing for a Short to Voltage Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10467 Testing for a Short to Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure tests for a short to voltage in a circuit. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the Digital Multimeter (DMM) to the V (DC) position. 4. Connect the positive lead of the DMM to one end of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. Turn ON the ignition and operate all accessories. 7. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Special Tools J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure). Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents). Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10468 The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the frequency of a signal. Note: Connecting the Digital Multimeter (DMM) to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Set to Hz on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10469 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the Digital Multimeter (DMM). 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the difference in voltage potential between 2 points. 1. Set the Digital Multimeter (DMM) to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10470 Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Backprobe Note: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10471 (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for Continuity Testing for Continuity Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures verify good continuity in a circuit. With a Digital Multimeter (DMM) 1. Set the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Select the MIN MAX function on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10472 Testing for Electrical Intermittents Testing for Electrical Intermittents Special Tools J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. Note: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions). 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10473 visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing for Terminal Fretting Some intermittent conditions can be caused by wire terminal fretting corrosion. Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can pile up enough at the electrical contact spots that the electrical resistance across the connection increases. Movement between the contacting surfaces as small as 10 to 100 microns can cause fretting. To put this in perspective, a sheet of paper is about 100 microns thick, so fretting motion is small and hard to see. Vibration and thermal expansion/contraction are the main sources that create fretting motion. Since vehicles vibrate and can experience large temperature swings, they are a good source for fretting motion. Tin, copper, nickel, and iron surfaces are all susceptible to fretting corrosion. Fretting corrosion can be difficult to see but it looks like small, dark smudges on the terminals contact surface. To correct a fretting condition disconnect the suspect connector and add Nyogel lubricant 760G (dielectric grease) to both sides of the connector terminals. Then reconnect the connector and wipe away any excess lubricant. This will correct the additional terminal contact resistance due to the terminal fretting corrosion. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10474 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Power Distribution Schematics). * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Ground Distribution Schematics). Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Checking Aftermarket Accessories). * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10475 Note: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures test for a short to ground in a circuit. With a Digital Multimeter (DMM) 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohms position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Danger: High voltage circuits should only be tested using a digital multimeter (DMM) and test leads with at least a CAT III rating, such as the J 39200-A Digital Multimeter. Failure to follow the procedures exactly as written may result in serious injury or death. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Digital Multimeter (DMM) Basic Requirements Service information is validated using digital multimeters that meet or exceed the following requirements. Using a multimeter that does not meet these basic requirements may give inaccurate readings which could lead to an incorrect diagnosis. Display and Settings 1. Four digits displayed 2. Voltage, amperage, resistance, frequency, diode test settings, and min-max function 3. Display positive and negative values Voltage 1. Have at least 10 M ohm input impedance Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10476 2. Test a DC voltage range of 0.1-1000 V. 3. Test an AC voltage range of 0.1-1000 V. Amperage 1. Test a DC amperage range of 0.1µA-10 A. 2. Test an AC amperage range of 0.1µA-10 A. Resistance Test a resistance range of 0.1 ohm-40 Mohm and displays infinite for a value greater than 40 M ohm (O.L. (Over-load)) Frequency Test for a frequency range of 0.5 HZ-199 K HZ Diode Test 1. Apply at least 1 mA when performing the diode bias test 2. Display the break over voltage drop (0-3 V) of a forward biased diode 3. Display infinite (O.L. (Over-load)) when a diode is reverse biased Min-Max Readings 1. Can update at a 1 ms sample rate 2. Saves and displays minimum and maximum values Note: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Probe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors). * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the EL-38125-580 GM Approved Terminal Release Tool Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the EL-38125-580 GM Approved Terminal Release Tool Kit , ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the EL-38125-580 GM Approved Terminal Release Tool Kit label on the inside of the EL-38125-580 GM Approved Terminal Release Tool Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10477 Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/EPC Connectors AFL/EPC Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10478 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 3. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10479 View showing depressing of the lever lock release tab. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10480 6. Release the rear lower half of the wiredress cover. 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10481 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10482 Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Bosch Connectors (ECM) Bosch Connectors (ECM) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10483 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. 2. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10484 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-bladed tool to release the locking tabs and remove the dress cover. 4. The terminal positive assurance (TPA) is located in the front of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10485 5. Use a small flat-blade tool to remove TPA from the connector. 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10486 Note: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10487 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10488 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Terminal Replacement Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10489 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10490 5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Position Assurance Locks) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Terminal Position Assurance Locks) * AFL/EPC Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/AFL/EPC Connectors) * Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (BSK))Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (0.64))Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (2.8 JPT))Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (ECM)) * Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Weather Pack))Delphi Connectors (Push To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Push to Seat))Delphi Connectors Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10491 (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Pull to Seat))Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro-Pack 100W))Delphi Connectors (Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro .64))Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (12-Way)) * FCI Connectors (Lever Lock) (See: General Electrical Diagnostic Procedures/Connector Repairs/FCI Connectors (Lever Lock)) * JST Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/JST Connectors) * Kostal Connectors (Glow Plug Control Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Glow Plug Control Module))Kostal Connectors (Transmission) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Transmission)) * Molex Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Molex Connectors) * Sumitomo Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Sumitomo Connectors) * Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (CM 42-Way))Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Sensor))Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (0.25 Cap))Tyco/AMP Connectors (43-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (43-Way))Tyco/AMP Connectors (Door Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Door Module))Tyco/AMP Connectors (102-Way Inline) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (102-Way Inline))Tyco/AMP Connectors (Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Seat))Tyco/AMP Connectors (SIR) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (SIR)) * Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (2-Way))Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (16-Way)) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10492 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10493 * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10494 * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10495 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10496 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10497 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Push to Seat) Delphi Connectors (Push To Seat) Special Tools J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10498 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs). 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Terminated Lead Repair 1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice sleeves depending on the gauge size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Delphi Connectors (Pull to Seat) Delphi Connectors (Pull To Seat) Special Tools Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10499 J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Note: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10500 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. View of a typical Micro 64 connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10501 Depress the lock and pull the lever over and past the lock. View of the connector when released from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10502 View of another type of Micro 64 connector. Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10503 View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10504 Note: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10505 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10506 Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Note: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10507 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10508 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10509 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10510 1. Cut the wire as close to the terminal as possible. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10511 Terminal Replacement Procedure After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Special Tools J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Note: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals). 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12-Way) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10512 Delphi Connectors (12-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10513 4. Release the lower wire dress cover locking tab. 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10514 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10515 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors (Lever Lock) FCI Connectors (Lever Lock) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10516 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. The release tab is located on the top of the wiredress cover. 3. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10517 6. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10518 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10519 1. While depressing the lock, remove the connector from the component. 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10520 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. 4. View of the TPA when removed from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10521 5. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Glow Plug Control Module) Kostal Connectors (Glow Plug Control Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10522 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10523 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10524 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. Note: The front TPA cannot be removed from the connector. Only move it to the preset position. 6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm). 7. Use a small flat-blade tool to completely remove the rear TPA from the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10525 8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Transmission) Kostal Connectors (Transmission) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10526 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10527 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Terminal Replacement Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10528 After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10529 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10530 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10531 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10532 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10533 3. To assemble the connector, reverse the connector disassembly procedure. Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10534 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10535 7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10536 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10537 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10538 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10539 Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10540 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10541 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10542 6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (102-Way Inline) Tyco/AMP Connectors (102-Way Inline) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10543 View of a typical connector in the assembled position. 1. Pull the locking lever to the 90 degree position from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10544 2. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal. 3. Slide the male connector body out away from the guide plates. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10545 Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 4. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. 5. Using terminal release tool J 38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10546 6. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 7. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10547 8. The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool J-38125-11A or equivalent to release the locking tab and slide the connector off the female body. 9. Move the locking lever 180 degrees from the connected position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10548 10. With the locking lever in the 180 degree position the guide plates can be removed from the connector body. Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 11. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10549 12. Using terminal release tool J 38125-216, lift the terminal plate past the terminals and out of the connector body cavity. 13. Terminal plate will bind slightly on each corner. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10550 14. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 15. Using terminal release tool J 38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10551 16. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 17. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10552 18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever. 19. Slide the male connector body back inward toward the guide plates. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10553 20. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly. 21. Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Seat) Tyco/AMP Connectors (Seat) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10554 Removal Procedure 1. Grasp the locking slide lever and pull outward from the end of the connector. 2. As the slide lever is pulled out the mating connector is lifted from the seated position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10555 Note: TPA is keyed and can only be inserted in one direction. 3. Using terminal release tool J 38125-11A or equivalent, push the TPA tabs into the connector body. 4. Pull the TPA from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10556 5. Using terminal release tool J 38125-11A or equivalent, release the connector wire dress cover locking tab. 6. With the lock tab released, lift the connector wire dress cover from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10557 7. Using terminal release tool J 38125-212, press the prongs into the holes each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 8. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10558 9. Using terminal release tool J 38125-556, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (SIR) Tyco/AMP Connectors (SIR) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10559 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10560 3. Using terminal tool J-38125-11A or equivalent, release the wire dress cover locking tabs. 4. Pivot connector wire dress cover while removing from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10561 5. Using terminal tool J-38125-11A or equivalent, remove the TPA by lifting straight off the connector body. 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals Repairing Connector Terminals Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10562 Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gauge size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10563 2. Disconnect the connector from the component. 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10564 4. Relieve the tension on the nose piece retainers by inserting J 38125-12A into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. 5. Once the nose piece retainers are relaxed, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10565 6. On the opposite side of the nose piece, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10566 8. Insert the J 38125-553 tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10567 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. If the TPA is removed, be sure to reinstall it before reconnecting the connector. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10568 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Special Tools Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10569 J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Note: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10570 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10571 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10572 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10573 1. While depressing the lock, pull the two connector halves apart. Note: The TPA is fragile and may break if not done carefully. 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. 3. View of the male half of the connector with female terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10574 4. View of the female half of the connector with male terminals. 5. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. View of the female half of the connector with male terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10575 7. View of the male half of the connector with female terminals. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10576 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are a one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine if the element in the fuse is broken (2). If not broken (1), also check for continuity using a Digital Multimeter (DMM) or a continuity tester. If the element is broken or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a Digital Multimeter (DMM) at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gauge size. Repairing a Fusible Link Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10577 Flat Wire Repairs The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Special Tools J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool * J 38125-5 Ultra Torch Special Tool The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Note: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation). GMLAN Connector Terminal Repair Note: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) for the appropriate connector repair procedure. GMLAN Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10578 Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10579 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Special Tools J-38125 Terminal Repair Kit Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10580 repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs High Temperature Wiring Repairs Special Tools J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gauge size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10581 splice. Note: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10582 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10583 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the wire insulation has been chafed, or broken, enough to show the conductive portion of the wire, and the wire is not damaged, determine the length of insulation that needs to be repaired. If the repair is less than 280 mm (11 in), cut the wire within the damaged area. Then slide the appropriate heat shrink tubing (listed below) over the wire, and repair the wire by splicing the wires together. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Once the wire is spliced together slide heat shrink tubing over the damaged area and apply heat to seal the repaired wire. If the wire is damaged, or the damaged area is larger than 280 mm (11 in), then replace the damaged wire by splicing in a new section of wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10584 SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Special Tools J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10585 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10586 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10587 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Special Tools J-38125 Terminal Repair Kit Note: Use only DuraSeal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use DuraSeal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use DuraSeal splice sleeves where there are special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10588 * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10589 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10590 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the instructions for Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Staggering the splices by 65 mm (2.5 in) is recommended. Note: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product AL-36FR to replace the damaged mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Flat Wire Repairs) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/GMLAN Wiring Repairs) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Heated Oxygen Sensor Wiring Repairs) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves) * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Twisted or Shielded Cable) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Inline Harness Diodes) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/SIR/SRS Wiring Repairs) US English/Metric Conversion US English/Metric Conversion Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10591 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10592 Testing Ground and Low Reference Circuits Testing Ground and Low Reference Circuits Because a test lamp can light with up to 200 ohm in a ground or low reference circuit they are not recommended to be used for this type of test. A low impedance test lamp can light and indicate the circuit is good when there is as much as 20-30 ohm present, while a high impedance test lamp can light with up to 200 ohm present in the circuit. This is why the Digital Multi-Meter (DMM) is used when validating a ground or low reference circuit continuity. When using the DMM there are many vehicle conditions that can affect the ground and low reference continuity testing. If these conditions are not met, a ground or low reference circuit test can fail on a good circuit. This may cause longer diagnosis time and incorrect component replacement. Any current flow through a ground or low reference circuit, while being tested, will skew the DMM continuity reading, or display a reading higher than when there is no current flowing. Performing a ground or low reference circuit continuity test, in reference to the vehicles battery negative terminal, will have the highest risk of failing a good ground or low reference circuit test than any other ground reference point. The best ground test points would be a control module housing (if the control modules housing is metal and grounded), door jamb striker (if attached to metal), under dash metal frame work, engine block, or body ground studs (other than where the negative battery cable is attached). A typical DMM ground or low reference circuit continuity reading can be as high as 100 ohm with the ignition ON, and drop to 15-25 ohm after the ignition is turned OFF. The reading will drop below 10 ohm after 30-40 seconds, then below 5 ohm after 60 seconds. Once the vehicle completely goes to sleep (generally 3-10 minutes) the reading will drop below 0.3 ohm. The following list of conditions may need to be met to ensure a valid continuity reading on a ground or low reference circuit: * Ignition OFF * Key out of the ignition switch (when not equipped with keyless entry and remote start) * Retained Accessory Power (RAP) OFF (open and close the driver door after ignition OFF) * Battery charger set at a 2 A or less charge rate * Scan tool not communicating with any vehicle control module (in some cases it may need to be disconnected from the DLC) * All entry doors closed * Headlamps OFF (auto headlamps disabled) * Any delay lighting OFF * HVAC after blow OFF * Any accessory that can work when the ignition is OFF * Wait up to 60 seconds (after all other listed conditions are met) Activating the DOOR LOCK function with a key fob can greatly reduce the time to achieve a valid ground or low reference continuity test result. Terminal Removal Terminal Removal Special Tools * EL-38125-580 - Terminal Release Tool Kit * EL-35616 - Connector Test Adapter Kit For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repair procedures. 1. Find the appropriate connector end view within the connector end view section. The connector end view has the following information: Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10593 * Diagnostic probe tool * Terminal release tool * Terminal/terminated lead part numbers Note: Not using the proper test kit probe may cause damage to the terminal(s) that are probed. 2. Determine if a terminal is damaged. * Locate the diagnostic probe tool from the connector end view. The connector end view describes the color and part number to help the technician find and use the correct tool. * Connect the probe tool to the Digital Multimeter. * Insert the probe tool into the cavity and follow the procedures from the Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter). 3. Disconnect the connector body to perform the repair. 4. Use the following procedure to remove the terminal from the connector body. Note: Several procedures for specific connector bodies are called out in the Wiring Repairs section. * The terminal position assurance (TPA) and connector position assurance (CPA) should be removed before releasing the terminal for the connector body. * Look at the connector end view to locate the cavity of the damaged terminal and find the proper terminal release tool from the terminal release tool kit. Note: Using the incorrect terminal release tool can damage the connector body. * Insert the terminal release tool into the cavity. Note: Some terminals have a lever that must be disengaged before the terminal can be released. 5. Gently pull the wire out of the back of the connector. 6. Repair the terminal by following the Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) procedure. 7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminated Lead Repair Terminated Lead Repair Special Tools * J-38125-8 - Splice Sleeve Crimp Tool Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10594 * J-38125-5 - Ultra Torch For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) procedures. Terminated leads are terminals that are crimped onto wires. The terminated lead can be used throughout the vehicle since it is designed for temperatures up to 150°C. The length of the wire is 450 mm. The DuraSeal splice sleeve has the following 2 critical features: * A special heat shrink tubing that environmentally seals the splice. The shrink tubing contains a sealing adhesive inside the shrink tubing. * A cross hatched (knurled) core crimp that provides the necessary contact integrity for sensitive low energy circuits. 1. Use the connector end view to identify the correct terminated lead. 2. The terminated lead package should include a DuraSeal splice sleeve. If not, use the chart to identify the correct part. 3. Open the harness by removing any tape: Use a sewing seam ripper, or a comparable tool, to cut open the harness, to avoid wire insulation damage. 4. Depending on how many terminals need repairs, cut the terminal and wire back at least 40 mm. Try to keep the harness wire length the same. If more than one terminated lead is required, stagger the lengths by 40 mm. This helps reduce the bundle size of the wire harness. 5. Use the EL-38125-10 - tool in order to position the DuraSeal splice sleeve in the proper color nest of the splice sleeve crimp tool. The crimp tool has four nests, one for each color. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10595 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the J-38125-5 - ultra torch , apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10596 Fuse Block: Connector Views Electrical Center Identification Views Junction Block - Left I/P, Label Junction Block - Left I/P, Top View Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10597 Junction Block - Left I/P, Bottom View Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10598 Junction Block - Left I/P X1 (except MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10599 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10600 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10601 Junction Block - Left I/P X2 (except MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10602 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10603 Junction Block - Left I/P X3 (except MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10604 Junction Block - Left I/P X4 (except MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10605 Junction Block - Left I/P X5 (SPO Alarm or SPO Heated Seats) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10606 Junction Block - Left I/P X7 (JF4) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10607 Junction Block - Left I/P X8 (except MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10608 Junction Block - Left I/P X9 (except MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10609 Junction Block - Left I/P X10 (except MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10610 Junction Block - Left I/P X11 (except MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10611 Junction Block - Left I/P X12 (except MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10612 Junction Block - Left I/P X13 (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10613 Junction Block - Left I/P X14 (5X7, 5Y0, 9L4, SPO DVD or SPO Heated Seats) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10614 Junction Block - Right I/P, Top View Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10615 Junction Block - Right I/P (Wire Entry) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10616 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10617 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10618 Junction Block - Right I/P X2 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10619 Junction Block - Right I/P X3 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10620 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10621 Junction Block - Right I/P X4 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10622 Junction Block - Right I/P X5 Junction Block - Right I/P X6 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10623 Junction Block - Rear Lamps Junction Block - Rear Lamps X1 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10624 Junction Block - Rear Lamps X2 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10625 Junction Block - Rear Lamps X3 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 10626 Junction Block - Rear Lamps X4 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Procedures Fuse Block: Procedures Ground Repair Electrical Grounds Proper electrical system function relies on secure, positive, corrosion-free ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacements. In general, electrical ground connections are accomplished using one, or a combination of, three attachment methods: * Welded M6 stud and nut * Welded M6 nut and bolt * Welded M8 nut and bolt Caution: Use GM approved replacement fasteners with conductive finish for electrical ground repair. Determine which attachment method is used, and carry out the appropriate repair. M6 Weld Stud Replacement 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note: Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Carefully remove paint and primer from the area surrounding the rivet stud flange until bare metal is visible. Caution: Use GM approved replacement fasteners with conductive finish for electrical ground repair. 5. Select a replacement conductive M6 rivet stud. Refer to GM parts catalog for the correct part number and application. 6. Using a rivet stud installer, install the replacement conductive M6 rivet stud. 7. Ensure the new rivet stud is securely fastened, with no detectable movement. Note: The rivet stud and surrounding panel area must be properly refinished prior to the installation of the ground terminal and nut to maintain positive electrical grounding. 8. Completely wrap the threads of the rivet stud with painters tape or equivalent. 9. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair (). 10. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 11. Remove the painters tape or equivalent from the rivet stud threads. 12. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 13. Carefully remove any corrosion from the electrical ground wire terminal. Refer to Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections). 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the new conductive M6 rivet stud threads. 15. Install the ground terminal to the new rivet stud. 16. Select a new, conductive M6 nut. Refer to GM parts catalog for the correct part number and application. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 17. Install the M6 nut and tighten to 8 Nm (71 lb in). 18. Check for proper system operation. M6 Weld Nut Caution: Use GM approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a new, conductive self-threading M7 bolt may be used to secure the ground terminal. Refer to GM parts catalog for the correct part number and application. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the new, conductive, self-threading M7 bolt Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Procedures > Page 10629 threads. 5. Carefully remove any corrosion from the electrical ground terminal. Refer to Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections). 6. Install the electrical ground terminal to the new, conductive M7 bolt. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 7. Install the M7 bolt and tighten to 9 Nm (80 lb in). 8. Check for proper system operation. M6 Weld Nut (Alternative Repair) Caution: Use GM approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a conductive M6 bolt and a conductive M6 nut may be used to secure the electrical ground terminal. Refer to GM parts catalog for the correct part number and application. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 ) clearance behind the panel surface and 20 mm (0.79 ) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note: Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Carefully remove paint and primer from the area surrounding the new ground site until bare metal is visible. 6. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the new, conductive M6 bolt threads. 7. Carefully remove any corrosion from the electrical ground terminal. Refer to Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections). 8. Install the electrical ground terminal and new, conductive M6 bolt to the ground location. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 9. Install the conductive M6 nut and tighten to 8 Nm (71 lb in). Note: The repair area must be properly refinished to maintain positive electrical grounding. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair (). 11. Check for proper system operation. M8 Weld Nut Caution: Use GM approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a conductive M8 bolt and a conductive M8 nut may be used to secure the ground terminal. Refer to GM parts catalog for the correct part numbers and application. 2. Select a location adjacent to M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note: Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Carefully remove paint and primer from the area surrounding the new ground site until bare metal is visible. 6. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the new, conductive M8 bolt threads. 7. Carefully remove any corrosion from the electrical ground terminal. Refer to Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections). 8. Install the electrical ground terminal and new, conductive M8 bolt to the ground location. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 9. Install the conductive M8 nut and tighten to 22 Nm (16 lb ft). Note: The repair area must be properly refinished to maintain positive electrical grounding. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Procedures > Page 10630 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair (). 11. Check for proper system operation. M8 Weld Nut (Alternative Repair) Caution: Use GM approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a conductive M6 rivet stud and a conductive M6 nut may be used to secure the ground terminal. Refer to GM parts catalog for the correct part numbers and application. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new, conductive M6 rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note: Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Carefully remove paint and primer from the area surrounding the rivet stud flange until bare metal is visible. 6. Using a rivet stud installer, install the replacement conductive M6 rivet stud. 7. Ensure the new rivet stud is securely fastened, with no detectable movement. Note: The rivet stud and surrounding panel area must be properly refinished prior to the installation of the ground terminal and nut to maintain positive electrical grounding. 8. Completely wrap the threads of the rivet stud with painters tape or equivalent. 9. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair (). 10. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 11. Remove the painters tape or equivalent from the rivet stud threads. 12. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 13. Carefully remove any corrosion from the electrical ground wire terminal. Refer to Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections). 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the new conductive M6 rivet stud threads. 15. Install the ground terminal to the new, conductive M6 rivet stud. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 16. Install the conductive M6 nut and tighten to 8 Nm (71 lb in). 17. Check for proper system operation. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Procedures > Page 10631 Fuse Block: Removal and Replacement 175 Amp Mega Fuse Replacement (Diesel) 175 Amp Mega Fuse Replacement (Diesel) Removal Procedure 1. Disconnect the auxiliary battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Battery/Battery Cable/Negative/Service and Repair). 2. Remove the mega fuse cover (3). 3. Remove the starter solenoid cable nut (1) from the fuse stud. 4. Remove the starter solenoid cable terminal (2) from the fuse stud. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Procedures > Page 10632 5. Remove the auxiliary battery positive cable nut (1) from the mega fuse holder. 6. Remove the generator battery jumper cable to fuse nut (3). 7. Remove the generator battery jumper cable terminal (2) from the fuse stud. 8. Remove the auxiliary battery positive cable from the fuse studs. 9. Remove the upper mega fuse nut (1), if necessary. 10. Remove the appropriate mega fuse (2). Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Procedures > Page 10633 1. Install the appropriate mega fuse (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the upper mega fuse nut (1), if necessary. Tighten the nut to 15 Nm (11 lb ft). 3. Install the auxiliary battery positive cable to the fuse studs. 4. Install the generator battery jumper cable terminal (2) to the fuse stud. 5. Install the generator battery jumper cable to fuse nut (3). Tighten the nut to 9 Nm (80 lb in). 6. Install the auxiliary battery positive cable nut (1) to the mega fuse holder. Tighten the nut to 15 Nm (11 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Procedures > Page 10634 7. Install the starter solenoid cable terminal (2) to the fuse stud. 8. Install the starter solenoid cable nut (1) to the fuse stud. Tighten the nut to 15 Nm (11 lb ft). 9. Install the mega fuse cover (3). 10. Connect the auxiliary battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Battery/Battery Cable/Negative/Service and Repair). 175 Amp Mega Fuse Replacement (Single Battery) 175 Amp Mega Fuse Replacement (Single Battery) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Procedures > Page 10635 175 Amp Mega Fuse Replacement (Auxiliary Battery) 175 Amp Mega Fuse Replacement (Auxiliary Battery) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Procedures > Page 10636 200 Amp Mega Fuse and Auxiliary Electrical Center 12VDC Junction Block Replacement 200 Amp Mega Fuse and Auxiliary Electrical Center 12VDC Junction Block Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Procedures > Page 10637 Instrument Panel Electrical Center or Junction Block Replacement - Left Side Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Procedures > Page 10638 Instrument Panel Electrical Center or Junction Block Replacement - Left Side Body Wiring Harness Junction Block Replacement Body Wiring Harness Junction Block Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Procedures > Page 10639 Underhood Electrical Center or Junction Block Replacement Underhood Electrical Center or Junction Block Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Procedures > Page 10640 Underhood Electrical Center or Junction Block Bracket Replacement Underhood Electrical Center or Junction Block Bracket Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Procedures > Page 10641 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair Grounding Point: Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 10646 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 10647 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 10648 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 10649 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 10650 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 10651 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Customer Interest for Multiple Junction Connector: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm Multiple Junction Connector: Customer Interest Seats - Driver/Passenger Heated Seats Inop./Slow to Warm TECHNICAL Bulletin No.: 10-08-50-008B Date: January 13, 2011 Subject: Driver or Passenger Heated Seat Inoperative, Slow to Warm, DTC(s) Set (Repair Connector, Re-Route Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Silverado, Suburban, Tahoe 2011 Chevrolet Silverado Heavy Duty 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2011 GMC Sierra Heavy Duty All Equipped with Heated Front Seat (RPO AN3, KA1) or Heated and Cooled Seat (RPO KB6) and/or Luxury Package (RPO PCK) Supercede: This bulletin is being revised to update the RPOs. Please discard Corporate Bulletin Number 10-08-50-008A (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger heated seat system exhibits the following symptoms: - Heated seat turns on and then turns off within 1 to 10 minutes (at any 60 second interval). - The system doesn't get warm enough, or gets warm very slowly. - The heated seat system is completely inoperative. Upon further review, DTCs B2430 0D and/or B2180 0D may be set as a current or history code if the vehicle is equipped with heated seats only (RPO KA1). Also, the LED indicator for the heated seats may come On and then flash after approximately 1 minute, then go out. If the vehicle is equipped with heated and cooled seats (KB6), the switch LED indicator may stay On, but the heated and cooled seat is inoperative. The fan will continue to blow air. Cause Heated Seats (RPO AN3, KA1) The heated seat control circuit terminal and/or ground terminal in harness connector X1 to the memory seat module (MSM) may have lost tension and is loose. The reduced terminal tension increases resistance in the connector, which may result in the symptoms described above. Heated and Cooled Seats (RPO KB6) The thermo-electric device (TED) in the seat cushion/seat back ventilation heating and cooling module may have become inoperative. Correction Heated Seats (RPO AN3, KA1) Follow the steps below to correct the concern with the heated seats. Note This repair requires a unique anti-abrasion electrical tape and harness clip from Kent Automotive. Refer to the Parts Information below. 1. Access and remove the seat bolts/nuts. 2. Adjust the seat rearward about halfway. Adjust the seat recline full forward. 3. Tilt the seat backward to access the bottom of the seat. Prop the seat up with a suitable tool if required. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Customer Interest for Multiple Junction Connector: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 10660 4. Disconnect seat harness connectors (1) X1, X2, X3 and X4 from the MSM. 5. Identify connector X1. Refer to Component Connector End Views in SI. 6. Perform a terminal drag test on connector X1, paying special attention to terminals 1, 4, 6, 11 and 14. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Refer to Testing for Intermittent Conditions and Poor Connections in SI. 7. Replace any terminal in question including connector X1 terminals 1, 4, 6, 11 and 14 if necessary. Refer to Repairing Connector Terminals in SI. 8. Identify connector X4. Refer to Component Connector End Views in SI. 9. Perform the terminal drag test described in step 6, paying special attention to terminal 14. 10. Replace any terminal in question including connector X4 terminal 14 if necessary. Refer to Repairing Connector Terminals in SI. 11. Remove the harness clip (1) from the plastic carrier. 12. Cut the electrical tape holding the harness in the plastic carrier using a sharp utility knife in the area shown (1). 13. Free the harness from the carrier back to the area shown (1). 14. Obtain "*Woven Polyester (PET) Electrical Tape" (Special Order P/N RZ97156A00) from Kent Automotive. Refer to Parts Information below. Important Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Customer Interest for Multiple Junction Connector: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 10661 DO NOT substitute with vinyl electrical tape or friction tape. Use only the tape specified above. 15. Tape the harness starting at the MSM connectors (1) extending back to the new break-out location (2) in the plastic carrier. 16. Install a plastic tie strap around the harness and the plastic carrier at the break-out point (1). 17. Install the new harness edge clip (1) 10 mm (0.4 in) further from the connectors and the existing harness clip. Ensure the clip is installed in the orientation shown. 18. Install the harness with the new harness clip in the location shown (1). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Customer Interest for Multiple Junction Connector: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 10662 19. Reinstall the harness connectors (1) to the MSM. 20. Reinstall the seat to the vehicle. Heated and Cooled Seats (RPO KB6) Follow the steps below to correct the concern with the heated and cooled seats. 1. Inspect the ventilation heating and cooling module for a concern with the TED. Refer to Seat Heating and Cooling, Diagnostic Information and Procedures in SI. Note If the heated and cooled seat function is inoperative, but the heat switch indicators are On, the MSM is functioning properly and the concern is with the TED. 2. If the TED is found to be the concern, replace the seat cushion or seat back ventilation heating and cooling module. Refer to Driver or Passenger Seat Back Ventilation Heating and Cooling Blower Replacement or Driver or Passenger Seat Cushion Ventilation Heating and Cooling Blower Replacement in SI. If the TED is not the concern, follow normal diagnostics and repair in SI. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Use the appropriate Labor Operation based on the repair completed. Heated Seats (RPO AN3, KA1) For vehicles repaired under warranty, use: Heated and Cooled Seats (RPO KB6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Customer Interest for Multiple Junction Connector: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 10663 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Customer Interest for Multiple Junction Connector: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power Multiple Junction Connector: Customer Interest Electrical - Intermittent MIL/DTC P2138/Reduced Power TECHNICAL Bulletin No.: 07-06-04-019D Date: June 28, 2010 Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced Engine Power (Repair Instrument Panel (IP) to Body Harness Connector) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years and warranty information. Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion System) Condition - Some customers may comment on an intermittent malfunction indicator lamp (MIL) being Illuminated with a message or an indicator that displays Reduced Engine Power. - The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP) Sensor 1-2 Correlation set as Current or in History. Cause This condition may be caused by water intrusion into the instrument panel (IP) to body harness connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value for more than a calibrated period of time, setting P2138. Correction Note Aftermarket equipment can generate DTC P2138 and/or other DTCs. 1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or low reference circuits or to any other ECM/PCM 5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI. 2. Perform the Diagnostic System Check - Vehicle. ‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any 5V reference DTCs are not set, proceed to Step 3. 3. Locate the IP to body harness connector, which may be located in and around the left hand kick panel area or inside the IP. Depending on the vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI. Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped) and windshield/cowl sealing. 4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the leak. Refer to General Information > Water Leaks in SI. ‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair. 5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for Intermittent Conditions and Poor Connections in SI. ‹› If any corrosion and/or debris is observed, repair as necessary. 6. After completing the repair, verify the proper operation of the system. Depending on the vehicle and model year, perform the Diagnostic Repair Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Customer Interest for Multiple Junction Connector: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power > Page 10668 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the appropriate labor operation for the source of the water leak Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm Multiple Junction Connector: All Technical Service Bulletins Seats - Driver/Passenger Heated Seats Inop./Slow to Warm TECHNICAL Bulletin No.: 10-08-50-008B Date: January 13, 2011 Subject: Driver or Passenger Heated Seat Inoperative, Slow to Warm, DTC(s) Set (Repair Connector, Re-Route Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Silverado, Suburban, Tahoe 2011 Chevrolet Silverado Heavy Duty 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2011 GMC Sierra Heavy Duty All Equipped with Heated Front Seat (RPO AN3, KA1) or Heated and Cooled Seat (RPO KB6) and/or Luxury Package (RPO PCK) Supercede: This bulletin is being revised to update the RPOs. Please discard Corporate Bulletin Number 10-08-50-008A (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger heated seat system exhibits the following symptoms: - Heated seat turns on and then turns off within 1 to 10 minutes (at any 60 second interval). - The system doesn't get warm enough, or gets warm very slowly. - The heated seat system is completely inoperative. Upon further review, DTCs B2430 0D and/or B2180 0D may be set as a current or history code if the vehicle is equipped with heated seats only (RPO KA1). Also, the LED indicator for the heated seats may come On and then flash after approximately 1 minute, then go out. If the vehicle is equipped with heated and cooled seats (KB6), the switch LED indicator may stay On, but the heated and cooled seat is inoperative. The fan will continue to blow air. Cause Heated Seats (RPO AN3, KA1) The heated seat control circuit terminal and/or ground terminal in harness connector X1 to the memory seat module (MSM) may have lost tension and is loose. The reduced terminal tension increases resistance in the connector, which may result in the symptoms described above. Heated and Cooled Seats (RPO KB6) The thermo-electric device (TED) in the seat cushion/seat back ventilation heating and cooling module may have become inoperative. Correction Heated Seats (RPO AN3, KA1) Follow the steps below to correct the concern with the heated seats. Note This repair requires a unique anti-abrasion electrical tape and harness clip from Kent Automotive. Refer to the Parts Information below. 1. Access and remove the seat bolts/nuts. 2. Adjust the seat rearward about halfway. Adjust the seat recline full forward. 3. Tilt the seat backward to access the bottom of the seat. Prop the seat up with a suitable tool if required. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 10674 4. Disconnect seat harness connectors (1) X1, X2, X3 and X4 from the MSM. 5. Identify connector X1. Refer to Component Connector End Views in SI. 6. Perform a terminal drag test on connector X1, paying special attention to terminals 1, 4, 6, 11 and 14. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Refer to Testing for Intermittent Conditions and Poor Connections in SI. 7. Replace any terminal in question including connector X1 terminals 1, 4, 6, 11 and 14 if necessary. Refer to Repairing Connector Terminals in SI. 8. Identify connector X4. Refer to Component Connector End Views in SI. 9. Perform the terminal drag test described in step 6, paying special attention to terminal 14. 10. Replace any terminal in question including connector X4 terminal 14 if necessary. Refer to Repairing Connector Terminals in SI. 11. Remove the harness clip (1) from the plastic carrier. 12. Cut the electrical tape holding the harness in the plastic carrier using a sharp utility knife in the area shown (1). 13. Free the harness from the carrier back to the area shown (1). 14. Obtain "*Woven Polyester (PET) Electrical Tape" (Special Order P/N RZ97156A00) from Kent Automotive. Refer to Parts Information below. Important Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 10675 DO NOT substitute with vinyl electrical tape or friction tape. Use only the tape specified above. 15. Tape the harness starting at the MSM connectors (1) extending back to the new break-out location (2) in the plastic carrier. 16. Install a plastic tie strap around the harness and the plastic carrier at the break-out point (1). 17. Install the new harness edge clip (1) 10 mm (0.4 in) further from the connectors and the existing harness clip. Ensure the clip is installed in the orientation shown. 18. Install the harness with the new harness clip in the location shown (1). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 10676 19. Reinstall the harness connectors (1) to the MSM. 20. Reinstall the seat to the vehicle. Heated and Cooled Seats (RPO KB6) Follow the steps below to correct the concern with the heated and cooled seats. 1. Inspect the ventilation heating and cooling module for a concern with the TED. Refer to Seat Heating and Cooling, Diagnostic Information and Procedures in SI. Note If the heated and cooled seat function is inoperative, but the heat switch indicators are On, the MSM is functioning properly and the concern is with the TED. 2. If the TED is found to be the concern, replace the seat cushion or seat back ventilation heating and cooling module. Refer to Driver or Passenger Seat Back Ventilation Heating and Cooling Blower Replacement or Driver or Passenger Seat Cushion Ventilation Heating and Cooling Blower Replacement in SI. If the TED is not the concern, follow normal diagnostics and repair in SI. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Use the appropriate Labor Operation based on the repair completed. Heated Seats (RPO AN3, KA1) For vehicles repaired under warranty, use: Heated and Cooled Seats (RPO KB6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 10677 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power Multiple Junction Connector: All Technical Service Bulletins Electrical - Intermittent MIL/DTC P2138/Reduced Power TECHNICAL Bulletin No.: 07-06-04-019D Date: June 28, 2010 Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced Engine Power (Repair Instrument Panel (IP) to Body Harness Connector) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years and warranty information. Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion System) Condition - Some customers may comment on an intermittent malfunction indicator lamp (MIL) being Illuminated with a message or an indicator that displays Reduced Engine Power. - The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP) Sensor 1-2 Correlation set as Current or in History. Cause This condition may be caused by water intrusion into the instrument panel (IP) to body harness connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value for more than a calibrated period of time, setting P2138. Correction Note Aftermarket equipment can generate DTC P2138 and/or other DTCs. 1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or low reference circuits or to any other ECM/PCM 5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI. 2. Perform the Diagnostic System Check - Vehicle. ‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any 5V reference DTCs are not set, proceed to Step 3. 3. Locate the IP to body harness connector, which may be located in and around the left hand kick panel area or inside the IP. Depending on the vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI. Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped) and windshield/cowl sealing. 4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the leak. Refer to General Information > Water Leaks in SI. ‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair. 5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for Intermittent Conditions and Poor Connections in SI. ‹› If any corrosion and/or debris is observed, repair as necessary. 6. After completing the repair, verify the proper operation of the system. Depending on the vehicle and model year, perform the Diagnostic Repair Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power > Page 10682 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the appropriate labor operation for the source of the water leak Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Page 10683 Multiple Junction Connector: Locations Harness Routing Views Rear Bumper Harness Routing 1 - Rear Bumper 2 - J403 (UD7) 3 - J404 (UD7) 4 - Junction Block - Rear Lamps Connector 5 X408 (UD7) Brake Clutch Harness Routing Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Page 10684 1 - Driver Door Frame 2 - X205 3 - X102 (JL1) 4 - Accelerator Pedal Position (APP) Sensor Connector 5 - Junction Block - Left I/P (except MEX) Chassis Harness (31 Series) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Page 10685 1 - Trailer Brake Control Relay (JL1) 2 - J422 (JL1) 3 - Trailer Connector 4 - J331 (Diesel without NQZ/LY6) 5 - X300 (LY6) 6 - X300 (Diesel) 7 - J411 (JL1) 8 - Junction Block - Rear Lamps 9 G401 10 - J338 (JL1) 11 - G300 12 - J300 (LY6 without NQZ) Passenger Door Harness Routing Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Page 10686 1 - J604 (YE9 without AN3/DL3) 2 - Junction Block - Right I/P X3 3 - Door Frame 4 - X601 (ASF) 5 - X600 (YE9 without AN3/DL3) 6 - J603 (YE9 without AN3/DL3) I/P Harness Routing - Passenger Compartment (Except HP2) - 1 of 2 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Page 10687 1 - X201 2 - X205 3 - Junction Block - Right I/P 4 - X200 5 - X202 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name Multiple Junction Connector: Diagrams Connector End Views By Name Ai - Ba Component Connector End Views (continued) Air Temperature Actuator - Left (CJ2) Air Temperature Actuator - Right (CJ2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10690 Air Temperature Actuator (C67 or C42) Air Temperature Sensor - Inside (CJ2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10691 Air Temperature Sensor - Lower Left (CJ2) Air Temperature Sensor - Lower Right (CJ2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10692 Air Temperature Sensor - Upper Left (CJ2) Air Temperature Sensor - Upper Right (CJ2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10693 Ambient Air Temperature Sensor (CJ2 or C67) Ambient Light Sensor (C67, C42 or MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10694 Ambient Light/Sunload Sensor (CJ2) Audio Amplifier X1 (UQA with Y91) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10695 Audio Amplifier X1 (UQA without Y91) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10696 Audio Amplifier X2 (UQA) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10697 Audio Amplifier X3 (UQA) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10698 Audio/Video Adapter (U42) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10699 Automatic Transmission Auxiliary Fluid Pump Control Module X1 (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10700 Automatic Transmission Auxiliary Fluid Pump Control Module X2 (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10701 Automatic Transmission Fluid Temperature (TFT) Sensor (M30) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10702 Automatic Transmission Input Shaft Speed (ISS) Sensor (M30) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10703 Automatic Transmission Internal Mode Switch (MW7) Automatic Transmission Shift Lever (M30, MYC, MYD, M99 or MW7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10704 Automatic Transmission Shift Lock Control Solenoid Automatic Transmission Turbine Speed Sensor (MW7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10705 Auxiliary Battery Relay X1 (TP2) Auxiliary Battery Relay X2 (TP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10706 Auxiliary Battery Relay X3 (TP2) Auxiliary Battery Run Relay (TP2) Auxiliary Body Control Module (XBCM) X1 (EXP) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10707 Auxiliary Body Control Module (XBCM) X2 (EXP) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10708 Backup Alarm (8S3) Backup Lamp - Left Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10709 Backup Lamp - Right Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10710 Backup Lamp Switch (TZ0) Barometric Pressure (BARO) Sensor (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10711 Battery - Left (-) (Auxiliary Battery Negative Cable) (6A6) Battery - Left (-) (Auxiliary Battery Negative Cable) (TP2) Battery - Left (-) (Battery Negative Cable) (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10712 Battery - Left (+) (Auxiliary Battery Positive Cable) (TP2) Battery - Left (+) (Starter Cable) (6A6 or Diesel) Battery - Right (-) (Battery Negative Cable) (Gas) Battery - Right (-) (Starter Cable) (Diesel) Ba - Da Component Connector End Views (continued) Battery - Right (+) (Diesel or 9L4) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10713 Battery - Right (+) (Gas without 9L4) Battery (+) (Battery Positive Cable) (HP2) Battery (+) (Battery Positive Cable) (HP2) Battery Current Sensor (10 Series without MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10714 Battery Module 1 (HP2) Battery Module 21 (HP2) Battery Module 22 (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10715 Battery Module 40 (HP2) Blower Motor Blower Motor Control Module X1 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10716 Blower Motor Control Module X2 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10717 Body Control Module (BCM) X1 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10718 Body Control Module (BCM) X2 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10719 Body Control Module (BCM) X3 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10720 Body Control Module (BCM) X4 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10721 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10722 Body Control Module (BCM) X5 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10723 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10724 Body Control Module (BCM) X6 Body Control Module (BCM) X7 (except MEX or A52) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10725 Brake Booster Vacuum Sensor (JL4 with 10 Series) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10726 Brake Fluid Level Switch Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10727 Brake Master Cylinder Piston Position Sensor (HP2) Brake Master Cylinder Pressure Sensor (JL1) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10728 Camshaft Position (CMP) Actuator Solenoid Valve (LZ1, LY6, L96 or L9H) Camshaft Position (CMP) Sensor (LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10729 Camshaft Position (CMP) Sensor (Gas except LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10730 Camshaft Position (CMP) Sensor (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10731 Cellular Telephone Microphone (UE1, UUL or UUK) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10732 Center High Mounted Stop Lamp (CHMSL) X1 Center High Mounted Stop Lamp (CHMSL) X2 Center High Mounted Stop Lamp (CHMSL) X3 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10733 Center High Mounted Stop Lamp (CHMSL) X4 Central Sequential Fuel Injection (Central SFI) X1-X6 (LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10734 Central Sequential Fuel Injection (Central SFI) X7 (LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10735 Chime Module (UL5) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10736 Clutch Pedal Position (CPP) Switch (TZ0) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10737 Control Solenoid Valve Assembly X1 (MYC, MYD or M99) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10738 Control Solenoid Valve Assembly X2 (MYC, MYD or M99) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10739 Control Solenoid Valve Assembly X3 (MYC, MYD or M99) Crankshaft Position (CKP) Sensor (LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10740 Crankshaft Position (CKP) Sensor (Gas except LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10741 Crankshaft Position (CKP) Sensor (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10742 Data Link Connector (DLC) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10743 Da - Dr Component Connector End Views (continued) Data Link Resistor Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10744 Data Link Resistor 2 (HP2) Digital Radio Receiver (U2K) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10745 Digital Video Disc (DVD) Control Module X1 (SPO DVD) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10746 Digital Video Disc (DVD) Control Module X2 (SPO DVD) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10747 Digital Video Disc (DVD) Control Module X3 (SPO DVD) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10748 Digital Video Disc (DVD) Control Module X4 (SPO DVD) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10749 Digital Video Disc (DVD) Control Module X5 (SPO DVD) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10750 Digital Video Disc (DVD) Control Module X6 (SPO DVD) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10751 Digital Video Disc (DVD) Display - Driver Seat Headrest X1 (SPO DVD) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10752 Digital Video Disc (DVD) Display - Driver Seat Headrest X2 (SPO DVD) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10753 Digital Video Disc (DVD) Display - Passenger Seat Headrest X1 (SPO DVD) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10754 Digital Video Disc (DVD) Display - Passenger Seat Headrest X2 (SPO DVD) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10755 Dome/Reading Lamps - Front Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10756 Dome/Reading Lamps - Rear (Crew Cab or Extended Cab) Door Latch - Driver (AU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10757 Door Latch - Driver (except AU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10758 Door Latch - Left Rear (Crew Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10759 Door Latch - Passenger Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10760 Door Latch - Right Rear (Crew Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10761 Door Lock Switch - Driver (AU3 without AN3 or DL3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10762 Door Lock Switch - Passenger (AU3 without AN3 or DL3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10763 Door Lock/Window Switch - Driver X1 (AN3 or DL3) Door Lock/Window Switch - Driver X2 (AN3 or DL3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10764 Door Lock/Window Switch - Driver X3 (AN3 or DL3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10765 Door Lock/Window Switch - Driver X4 (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10766 Door Lock/Window Switch - Driver X7 (AN3 or DL3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10767 Door Lock/Window Switch - Passenger X1 (AN3 or DL3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10768 Door Lock/Window Switch - Passenger X2 (AN3 or DL3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10769 Door Lock/Window Switch - Passenger X3 (AN3 or DL3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10770 Door Lock/Window Switch - Passenger X4 (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10771 Door Lock/Window Switch - Passenger X7 (AN3 or DL3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10772 Drive Motor Battery Cable Terminal Extension Cover (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10773 Drive Motor Battery Current Sensor (HP2) Drive Motor Battery High Voltage Manual Disconnect Lever X2 (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10774 Drive Motor Battery High Voltage Manual Disconnect Lever X3 (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10775 Drive Motor Battery Negative High Voltage Contactor Relay X1 (HP2) Drive Motor Battery Negative High Voltage Contactor Relay X2 (HP2) Drive Motor Battery Negative High Voltage Contactor Relay X3 (HP2) Drive Motor Battery Positive High Voltage Contactor Relay X1 (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10776 Drive Motor Battery Positive High Voltage Contactor Relay X2 (HP2) Drive Motor Battery Positive High Voltage Contactor Relay X3 (HP2) Drive Motor Generator Battery (-) (Drive Motor Battery Positive and Negative Cable Assembly) (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10777 Drive Motor Generator Battery (+) (Drive Motor Battery Positive and Negative Cable Assembly) (HP2) Drive Motor Generator Battery Control Module X1 (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10778 Drive Motor Generator Battery Control Module X2 (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10779 Drive Motor Generator Battery Control Module X3 (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10780 Drive Motor Generator Battery Control Module X4 (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10781 Drive Motor Generator Battery Control Module X5 (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10782 Dr - En Component Connector End Views (continued) Drive Motor Generator Battery X1 (HP2) Drive Motor Generator Battery X2 (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10783 Drive Motor Generator Power Inverter Module Cover (HP2) Drive Motor Generator Power Inverter Module X1 (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10784 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10785 Drive Motor Generator Power Inverter Module X2 (HP2) Drive Motor Generator Power Inverter Module X3 (HP2) Drive Motor Generator Power Inverter Module X4 (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10786 Drive Motor Generator Power Inverter Module X5 (HP2) Drive Motor Generator Power Inverter Module X6 (HP2) Drive Motor Generator Power Inverter Module X7 (HP2) Drive Motor Generator Power Inverter Module X8 (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10787 Drive Motor Generator Power Inverter Module X9 (HP2) Drive Motor Generator Power Inverter Module X10 (HP2) Drive Motor Generator Power Inverter Module X11 (HP2) Drive Motor Generator Power Inverter Module X12 (HP2) Drive Motor Power Inverter Current Limit Relay X1 (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10788 Drive Motor Power Inverter Current Limit Relay X2 (HP2) Driver Information Center (DIC) Switch (except MEX or 8S8) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10789 Electronic Adjustable Pedal (EAP) Assembly (JF4) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10790 Electronic Brake Control Module (EBCM) (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10791 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10792 Electronic Brake Control Module (EBCM) (JF3 or JF7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10793 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10794 Electronic Brake Control Module (EBCM) (JH6 or JH7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10795 Electronic Brake Control Module (EBCM) (JL4 except 10 Series) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10796 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10797 Electronic Brake Control Module (EBCM) (JL4 with 10 Series) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10798 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10799 Electronic Compass Module (YE9) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10800 Electronic Power Steering Motor Control Module X1 (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10801 Electronic Power Steering Motor Control Module X3 (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10802 Electronic Power Steering Motor Control Module X4 (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10803 Emergency Vehicle Roof Lamp Relay (5Y0) Engine Control Module (ECM) X1 (LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10804 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10805 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10806 Engine Control Module (ECM) X1 (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10807 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10808 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10809 Engine Control Module (ECM) X1 (LY2, LMG, LC9, LY5, LH6, L76 or L9H) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10810 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10811 Engine Control Module (ECM) X1 (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10812 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10813 Engine Control Module (ECM) X1 (LY6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10814 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10815 Engine Control Module (ECM) X2 (LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10816 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10817 En - Fu Component Connector End Views (continued) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10818 Engine Control Module (ECM) X2 (LY2, LY6 or L9H with Y91) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10819 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10820 Engine Control Module (ECM) X2 (LMG, LC9, LY5, LH6, L76 or L9H without Y91) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10821 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10822 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10823 Engine Control Module (ECM) X2 (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10824 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10825 Engine Control Module (ECM) X2 (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10826 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10827 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10828 Engine Control Module (ECM) X3 (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10829 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10830 Engine Coolant Level Switch (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10831 Engine Coolant Temperature (ECT) Sensor (Diesel) Engine Coolant Temperature (ECT) Sensor (Gas) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10832 Engine Cooling Fan - Left (Gas except LY6) Engine Cooling Fan - Right (Gas except LY6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10833 Engine Cooling Fan Resistor - Left (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10834 Engine Cooling Fan Resistor - Right (HP2) Engine Oil Level (EOL) Switch (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10835 Engine Oil Pressure (EOP) Sensor (Diesel) Engine Oil Pressure (EOP) Sensor (Gas except LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10836 Engine Oil Pressure (EOP) Sensor (LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10837 Evaporative Emission (EVAP) Canister Purge Solenoid Valve (Gas) Evaporative Emission (EVAP) Canister Vent Solenoid Valve (Gas) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10838 Evaporator Temperature Sensor (except HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10839 Exhaust Gas Recirculation (EGR) Temperature Sensor 1 (Diesel) Exhaust Gas Recirculation (EGR) Temperature Sensor 2 (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10840 Exhaust Gas Recirculation (EGR) Valve (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10841 Exhaust Pressure Differential Sensor (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10842 Exhaust Temperature Sensor 1 (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10843 Exhaust Temperature Sensor 2 (Diesel) Fog Lamp - Left Front (T96) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10844 Fog Lamp - Right Front (T96) Front Drive Axle Actuator (NQF, NQG or NQH) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10845 Fuel Heater (Diesel) Fuel Injector 1 (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10846 Fuel Injector 1 (Gas except LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10847 Fuel Injector 1 (LU3) Fuel Injector 2 (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10848 Fuel Injector 2 (Gas except LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10849 Fuel Injector 2 (LU3) Fuel Injector 3 (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10850 Fuel Injector 3 (Gas except LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10851 Fuel Injector 3 (LU3) Fuel Injector 4 (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10852 Fuel Injector 4 (Gas except LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10853 Fuel Injector 4 (LU3) Fuel Injector 5 (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10854 Fu - He Component Connector End Views (continued) Fuel Injector 5 (Gas except LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10855 Fuel Injector 5 (LU3) Fuel Injector 6 (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10856 Fuel Injector 6 (Gas except LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10857 Fuel Injector 6 (LU3) Fuel Injector 7 (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10858 Fuel Injector 7 (Gas except LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10859 Fuel Injector 8 (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10860 Fuel Injector 8 (Gas except LU3) Fuel Level Sensor - Primary (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10861 Fuel Level Sensor - Secondary (Diesel with 31 Series without NQZ) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10862 Fuel Pressure Regulator (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10863 Fuel Pressure Sensor (Gas except LU3 or LY6) Fuel Pump/Trailer Brake Control Module (Gas with JL1 and except LU3, LY6 or LY6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10864 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10865 Fuel Pump (Diesel with 31 Series without NQZ) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10866 Fuel Pump and Sender Assembly - Front (Gas except MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10867 Fuel Pump and Sender Assembly - Front (MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10868 Fuel Pump and Sender Assembly - Rear (LY6 except MEX and without NQZ) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10869 Fuel Pump and Sender Assembly - Rear (LY6 with MEX and without NQZ) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10870 Fuel Pump Flow Control Module (Gas except JL1 and except LU3, LY6 or LY6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10871 Fuel Pump Relay - Secondary (LY6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10872 Fuel Rail Pressure (FRP) Sensor (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10873 Fuel Tank Pressure (FTP) Sensor (Gas) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10874 Fuel Temperature Sensor (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10875 Garage Door Opener (GDO) (UG1) Generator - Auxiliary X1 (Diesel with K76 or YF2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10876 Generator - Auxiliary X2 (Diesel with K76 or YF2) Generator Battery Vent Fan (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10877 Generator Battery Vent Fan Relay (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10878 Generator Control Module Coolant Pump - Left (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10879 Generator Control Module Coolant Pump - Right (HP2) Generator Control Module Temperature Sensor (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10880 Generator X1 (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10881 Generator X1 (Gas) Generator X2 (Diesel) Generator X2 (LU3) Generator X2 (Gas except LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10882 Glow Plug Control Module (GPCM) X1 (Diesel) Glow Plug Control Module (GPCM) X2 (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10883 Headlamp - Left High Beam Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10884 Headlamp - Left Low Beam Headlamp - Right High Beam Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10885 Headlamp - Right Low Beam Headlamp and Panel Dimmer Switch Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10886 Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 (LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10887 He - In Component Connector End Views (continued) Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 (Gas except LU3 and except ZW9) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10888 Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 (LY6 or L96 with ZW9) Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 2 (LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10889 Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 2 (Gas except LU3) Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 (LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10890 Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 (Gas except LU3 and except ZW9) Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 (LY6 or L96 with ZW9) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10891 Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 2 (LU3) Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 2 (Gas except LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10892 Heated Seat Control Module X1 (SPO Heated Seats) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10893 Heated Seat Control Module X2 (SPO Heated Seats) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10894 Heated Seat Control Module X3 (SPO Heated Seats) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10895 Heated Seat Control Module X4 (SPO Heated Seats) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10896 Heated Seat Element - Driver Back (AN3 without KB6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10897 Heated Seat Element - Driver Back (SPO Heated Seats) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10898 Heated Seat Element - Driver Cushion (AN3 without KB6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10899 Heated Seat Element - Driver Cushion (SPO Heated Seats) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10900 Heated Seat Element - Passenger Back (AN3 without KB6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10901 Heated Seat Element - Passenger Back (SPO Heated Seats) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10902 Heated Seat Element - Passenger Cushion (AN3 without KB6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10903 Heated Seat Element - Passenger Cushion (SPO Heated Seats) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10904 Heated Seat Switch - Driver (SPO Heated Seats) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10905 Heated Seat Switch - Passenger (SPO Heated Seats) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10906 Heated Steering Wheel (KA9) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10907 Heater Coolant Pump (HP2) High Voltage Circuit Impact Detection Sensor (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10908 Hood Ajar Switch (AP3, AP8 or PTO) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10909 Horn - Left Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10910 Horn - Right (Z71, YE9 or HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10911 HVAC Control Module X1 (CJ2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10912 HVAC Control Module X2 (C67, C42 or MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10913 HVAC Control Module X2 (CJ2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10914 HVAC Control Module X3 (C67, C42, CJ2 or MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10915 Ignition Coil 1 (Gas except LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10916 Ignition Coil 2 (Gas except LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10917 Ignition Coil 3 (Gas except LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10918 Ignition Coil 4 (Gas except LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10919 Ignition Coil 5 (Gas except LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10920 Ignition Coil 6 (Gas except LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10921 Ignition Coil 7 (Gas except LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10922 Ignition Coil 8 (Gas except LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10923 Ignition Control Module (ICM) (LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10924 Ignition Switch Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10925 Inflatable Restraint Front End Sensor - Left (10 Series) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10926 Inflatable Restraint Front End Sensor - Right (10 Series) Inflatable Restraint Front End Sensor (except 10 Series) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10927 Inflatable Restraint I/P Module (10 Series except MEX) Inflatable Restraint I/P Module (20/30/31 Series or MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10928 Inflatable Restraint I/P Module Disable Switch (C99 or MEX) Inflatable Restraint I/P Module Indicator (AL0 or C99 except MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10929 Inflatable Restraint Passenger Presence System (PPS) Module (AL0) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10930 Inflatable Restraint Roof Rail Module - Driver (Crew Cab with ASF) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10931 Inflatable Restraint Roof Rail Module - Driver (Extended Cab with ASF) In - Ob Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10932 Component Connector End Views (continued) Inflatable Restraint Roof Rail Module - Driver (Regular Cab with ASF) Inflatable Restraint Roof Rail Module - Passenger (Crew Cab with ASF) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10933 Inflatable Restraint Roof Rail Module - Passenger (Extended Cab with ASF) Inflatable Restraint Roof Rail Module - Passenger (Regular Cab with ASF) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10934 Inflatable Restraint Seat Position Sensor - Driver (10 Series except MEX) Inflatable Restraint Seat Position Sensor - Passenger (10 Series except Crew Cab or MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10935 Inflatable Restraint Sensing and Diagnostic Module (SDM) X1 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10936 Inflatable Restraint Sensing and Diagnostic Module (SDM) X2 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10937 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10938 Inflatable Restraint Side Impact Module - Left (10 Series except HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10939 Inflatable Restraint Side Impact Module - Left (HP2) Inflatable Restraint Side Impact Module - Right (10 Series except HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10940 Inflatable Restraint Side Impact Module - Right (HP2) Inflatable Restraint Side Impact Sensor (SIS) - Left Front (ASF) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10941 Inflatable Restraint Side Impact Sensor (SIS) - Left Rear (Extended or Crew Cab with ASF) Inflatable Restraint Side Impact Sensor (SIS) - Right Front (ASF) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10942 Inflatable Restraint Side Impact Sensor (SIS) - Right Rear (Extended or Crew Cab with ASF) Inflatable Restraint Steering Wheel Module Coil X1 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10943 Inflatable Restraint Steering Wheel Module Coil X2 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10944 Inflatable Restraint Steering Wheel Module X1 (10 Series) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10945 Inflatable Restraint Steering Wheel Module X2 (10 Series) Inflatable Restraint Steering Wheel Module (except 10 Series) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10946 Infrared Transmitter (U42) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10947 Inside Rearview Mirror (ISRVM) (except MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10948 Instrument Panel Cluster (IPC) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10949 Intake Air Heater (IAH) X1 (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10950 Intake Air Heater X2 (Diesel) Intake Air Temperature (IAT) Sensor 2 (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10951 Intake Air Valve (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10952 Knock Sensor (KS) 1 (Gas) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10953 Knock Sensor (KS) 2 (Gas) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10954 License Lamp - Left License Lamp - Right Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10955 Manifold Absolute Pressure (MAP) Sensor (LU3) Manifold Absolute Pressure (MAP) Sensor (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10956 Manifold Absolute Pressure (MAP) Sensor (Gas except LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10957 Marker Lamp - Tailgate (RO5) Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10958 Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (Gas) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10959 Memory Seat Module (MSM) X1 (AN3) Memory Seat Module (MSM) X2 (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10960 Memory Seat Module (MSM) X3 (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10961 Memory Seat Module (MSM) X4 (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10962 Memory Seat Module (MSM) X5 (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10963 Memory Seat Module (MSM) X6 (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10964 Memory Seat Module (MSM) X7 (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10965 Mode Actuator (C67, C42 or CJ2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10966 Modulated Main Pressure Control (PC) Solenoid Valve (MW7) Multifunction Switch - I/P (except MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10967 Noise Compensation Microphone (UQA with Y91) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10968 Object Alarm Sensor - Left Rear Corner (UD7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10969 Ob - Se Component Connector End Views (continued) Object Alarm Sensor - Left Rear Middle (UD7) Object Alarm Sensor - Right Rear Corner (UD7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10970 Object Alarm Sensor - Right Rear Middle (UD7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10971 Output Speed Sensor (OSS) (M99) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10972 Outside Rearview Mirror - Driver (DL3, DL8 or DPN) Outside Rearview Mirror - Passenger (DL3, DL8 or DPN) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10973 Outside Rearview Mirror Switch (DL8 or DPN) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10974 Park Brake Switch Park/Neutral Position (PNP) Switch (M30) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10975 Park/Turn Signal Lamp - Lower Left Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10976 Park/Turn Signal Lamp - Lower Right Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10977 Park/Turn Signal Lamp - Upper Left Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10978 Park/Turn Signal Lamp - Upper Right Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10979 Power Steering Assist Motor X1 (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10980 Power Steering Assist Motor X2 (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10981 Power Take Off (PTO) Module (PTO) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10982 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10983 Power Take Off (PTO) Relay (PTO) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10984 Power Take-Off (PTO) Switch (PTO) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10985 Pressure Control (PC) Solenoid Valve (M30) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10986 Pressure Control (PC) Solenoid Valve 1 (MW7) Pressure Control (PC) Solenoid Valve 2 (MW7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10987 Pressure Switch Manifold (PSM) (MW7) Radio X1 (except Y91) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10988 Radio X1 (Y91 or 8S8) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10989 Radio X2 (except Y91 or 8S8) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10990 Radio X2 (Y91 or 8S8) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10991 Radio X3 (U42) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10992 Radio X4 (UUL or UUK) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10993 Rear Fender Clearance Lamp - Left Front (RO5) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10994 Rear Fender Clearance Lamp - Left Rear (RO5) Rear Fender Clearance Lamp - Right Front (RO5) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10995 Rear Fender Clearance Lamp - Right Rear (RO5) Rear Object Sensor Control Module X1 (UD7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10996 Rear Object Sensor Control Module X2 (UD7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10997 Rear Seat Audio (RSA) Control X1 (UK6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10998 Rear Seat Audio (RSA) Control X2 (UK6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 10999 Rear Window Defogger Grid X1 (C49) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11000 Rear Window Defogger Grid X2 (C49) Rearview Camera (SPO Rearview Camera) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11001 Rearview Camera Image Display Module X1 (UVC) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11002 Rearview Camera Image Display Module X2 (UVC) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11003 Recirculation Actuator (C67 or CJ2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11004 Remote Control Door Lock Receiver (RCDLR) (AP3 or AP8) Roof Beacon Relay (TRW) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11005 Roof Beacon Switch (5X7, 5Y0 or TRW) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11006 Roof Clearance Lamp - Left Front Outer (U01) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11007 Roof Clearance Lamp - Front Middle (U01) Roof Clearance Lamp - Right Front Outer (U01) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11008 Seat Adjuster Motor Assembly - Driver (AG1 without AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11009 Seat Adjuster Motor Assembly - Driver X1 (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11010 Se - Sp Component Connector End Views (continued) Seat Adjuster Motor Assembly - Driver X2 (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11011 Seat Adjuster Motor Assembly - Passenger (AG2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11012 Seat Adjuster Switch - Driver (AG1 without AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11013 Seat Adjuster Switch - Driver (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11014 Seat Adjuster Switch - Passenger (AG2 without AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11015 Seat Adjuster Switch - Passenger (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11016 Seat Back Ventilation Heating and Cooling Module - Driver (KB6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11017 Seat Back Ventilation Heating and Cooling Module - Passenger (KB6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11018 Seat Belt Buckle - Driver Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11019 Seat Belt Buckle - Passenger X1 (10 Series without MEX) Seat Belt Buckle - Passenger X2 (AL0) Seat Belt Pretensioner - Driver Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11020 Seat Belt Pretensioner - Passenger Seat Climate Control Module X1 (KB6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11021 Seat Climate Control Module X2 (KB6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11022 Seat Climate Control Module X3 (KB6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11023 Seat Cushion Ventilation Heating and Cooling Module - Driver (KB6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11024 Seat Cushion Ventilation Heating and Cooling Module - Passenger (KB6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11025 Seat Front Vertical Motor - Driver (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11026 Seat Front Vertical Motor - Passenger (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11027 Seat Horizontal Motor - Driver (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11028 Seat Horizontal Motor - Passenger (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11029 Seat Lumbar Horizontal Motor - Driver (AN3) Seat Lumbar Horizontal Motor - Passenger (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11030 Seat Lumbar Horizontal Motor Position Sensor - Driver (AN3) Seat Lumbar Switch - Driver (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11031 Seat Lumbar Switch - Passenger (AN3) Seat Lumbar Vertical Motor - Driver (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11032 Seat Lumbar Vertical Motor - Passenger (AN3) Seat Lumbar Vertical Motor Position Sensor - Driver (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11033 Seat Rear Vertical Motor - Driver (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11034 Seat Rear Vertical Motor - Passenger (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11035 Seat Recline Motor - Driver (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11036 Seat Recline Motor - Passenger (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11037 Seat Recline Position Sensor - Driver (AN3) Security Indicator Lamp (SPO Alarm) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11038 Serial Data Gateway (SDG) Module X1 (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11039 Serial Data Gateway (SDG) Module X2 (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11040 Shift Solenoid (SS) Valve 1 (MW7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11041 Shift Solenoid (SS) Valve 2 (MW7) Shift Solenoid (SS) Valve 3 (MW7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11042 Side Marker Lamp - Left Front (Z88) Side Marker Lamp - Left Rear (Z88) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11043 Side Marker Lamp - Right Front (Z88) Side Marker Lamp - Right Rear (Z88) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11044 Sliding Rear Window Close Relay (A48) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11045 Sliding Rear Window Motor (A48) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11046 Sliding Rear Window Open Relay (A48) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11047 Sliding Rear Window Switch (A48) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11048 Speaker - Center I/P (UQA with Y91) Speaker - Left Front (UQ3) Speaker - Left Front (UQ5) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11049 Speaker - Left Front (UQA) Sp - Tr Component Connector End Views (continued) Speaker - Left Front Tweeter (except MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11050 Speaker - Left Rear (Extended Cab or Crew Cab with UQ3 or UQ5) Speaker - Left Rear (Extended Cab or Crew Cab with UQA) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11051 Speaker - Left Rear (Regular Cab) Speaker - Right Front (UQ3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11052 Speaker - Right Front (UQ5) Speaker - Right Front (UQA) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11053 Speaker - Right Front Tweeter (except MEX) Speaker - Right Rear (Extended Cab or Crew Cab with UQ3 or UQ5) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11054 Speaker - Right Rear (Extended Cab or Crew Cab with UQA) Speaker - Right Rear (Regular Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11055 Speaker - Subwoofer (UQA) Starter Motor X1 (5X7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11056 Starter Motor X1 (LU3 without 9L4) Starter Motor X1 (6A6) Starter Motor X1 (9L4 or Gas except LU3) Starter Motor X1 (Diesel) Starter Motor X2 (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11057 Starter Motor X2 (Gas) Steering Angle Sensor (JL4) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11058 Steering Wheel Control Switch - Left (K34 or KA9) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11059 Steering Wheel Control Switch - Right (UK3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11060 Stop Lamp Switch Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11061 Sunroof Control Module (CF5) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11062 Sunroof Switch (CF5) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11063 Sunshade - Left (DH6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11064 Sunshade - Right (DH6) Tail/Stop and Turn Signal Lamp - Lower Left Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11065 Tail/Stop and Turn Signal Lamp - Lower Right Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11066 Tail/Stop and Turn Signal Lamp - Upper Left Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11067 Tail/Stop and Turn Signal Lamp - Upper Right Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11068 Theft Deterrent Module (TDM) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11069 Throttle Body (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11070 Throttle Body (Gas except HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11071 Torque Converter Clutch (TCC) Pressure Control (PC) Solenoid Valve (MW7) Torque Converter Clutch (TCC) Pulse Width Modulated (PWM) Solenoid Valve (M30) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11072 Torque Converter Clutch (TCC) Solenoid Valve (M30) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11073 Wiring Diagram Trailer Brake Control Module (JL1 except 31 Series) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11074 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11075 Trailer Brake Control Module (JL1 with 31 Series) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11076 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11077 Trailer Brake Control Relay (JL1) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11078 Trailer Brake Control Switch (JL1) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11079 Trailer Connector (except MEX or EXP) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11080 Trailer Stop/Turn Relay (TZ0) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11081 Tr - Ya Component Connector End Views (continued) Transfer Case 2/4 Wheel Drive Actuator Position Sensor (NQH) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11082 Transfer Case Encoder Motor (NQF or NQH) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11083 Transfer Case Shift Control Module X1 (NQF or NQH) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11084 Transfer Case Shift Control Module X2 (NQF or NQH) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11085 Transfer Case Shift Control Module X3 (NQF or NQH) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11086 Transfer Case Shift Control Switch (NQF or NQH) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11087 Transfer Case Shift Control Switch (NQG) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11088 Transmission Control Module (TCM) (M30) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11089 Transmission Control Module (TCM) (MW7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11090 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11091 Transmission Power Inverter Module (3 Phase) Cable Cover (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11092 Turbocharger Vane Position Control Solenoid Valve (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11093 Turbocharger Vane Position Sensor (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11094 Turn Signal/Multifunction Switch X1 Turn Signal/Multifunction Switch X2 Turn Signal/Multifunction Switch X3 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11095 Valve Lifter Oil Manifold (VLOM) Assembly (LMG, LC9, LZ1 or L96) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11096 Vehicle Communication Interface Module (VCIM) X1 (UE1) Vehicle Communication Interface Module (VCIM) X2 (UE1) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11097 Vehicle Communication Interface Module (VCIM) X3 (UE1 with UUL or UUK) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11098 Vehicle Inclination Sensor (SPO Alarm) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11099 Vehicle Shock Sensor (SPO Alarm) Vehicle Speed Sensor (VSS) (M30, TZ0, MYC and MW7or M99 with NQG or NQF) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11100 Vehicle Speed Sensor (VSS) (MW7 except NQG or NQF) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11101 Video Display (U42) Water in Fuel Sensor (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11102 Wheel Speed Sensor (WSS) - Left Front (10 Series) Wheel Speed Sensor (WSS) - Left Front (except 10 Series) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11103 Wheel Speed Sensor (WSS) - Left Rear (JL4 or HP2) Wheel Speed Sensor (WSS) - Right Front (10 Series) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11104 Wheel Speed Sensor (WSS) - Right Front (except 10 Series) Wheel Speed Sensor (WSS) - Right Rear (JL4 or HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11105 Window Motor - Driver (A31) Window Motor - Left Rear (Crew Cab with A31 or Extended Cab with ABV) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11106 Window Motor - Passenger (A31) Window Motor - Right Rear (Crew Cab with A31 or Extended Cab with ABV) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11107 Window Switch - Driver X1 (A31 without AN3 or DL3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11108 Window Switch - Driver X2 (A31 without AN3 or DL3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11109 Window Switch - Left Rear (Crew Cab with A31 or Extended Cab with ABV) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11110 Window Switch - Passenger (A31 without AN3 or DL3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11111 Window Switch - Right Rear (Crew Cab with A31 or Extended Cab with ABV) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11112 Windshield Outside Moisture Sensor (CE1) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11113 Windshield Washer Fluid Level Switch Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11114 Windshield Washer Fluid Pump Windshield Wiper Motor Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11115 Wrecker Relay X1 (5X7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11116 Wrecker Relay X2 (5X7) Yaw and Lateral Accelerometer Sensor (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11117 Yaw and Lateral Accelerometer Sensor (JL4 except 10 Series) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11118 Yaw and Lateral Accelerometer Sensor (JL4 with 10 Series) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11119 1-2 Shift - Ac Component Connector End Views 1-2 Shift Solenoid (SS) Valve (M30) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11120 2-3 Shift Solenoid (SS) Valve (M30) A/C Compressor Clutch (C67) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11121 A/C Compressor Clutch (CJ2) A/C Compressor X1 (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11122 A/C Compressor X2 (+) (HP2) A/C Compressor X3 (-) (HP2) A/C Low Pressure Sensor (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11123 A/C Refrigerant Pressure Sensor (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11124 A/C Refrigerant Pressure Sensor (Gas except HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11125 A/C Refrigerant Pressure Sensor (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11126 Accelerator Pedal Position (APP) Sensor Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11127 Accessory DC Power Control Module X1 (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11128 Accessory DC Power Control Module X2 (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11129 Accessory DC Power Control Module X3 (HP2) Accessory DC Power Control Module X4 (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11130 Accessory Power Outlet - Center Console (D07) Accessory Power Outlet - Center Console Compartment (D07) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11131 Accessory Power Outlet - Center Seat (AZ3) Accessory Power Outlet - I/P 1 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11132 Accessory Power Outlet - I/P 2 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11133 Multiple Junction Connector: Diagrams Connector End Views By Number X100 Inline Harness Connector End Views X100 Forward Lamp Harness to Left Front Headlamp Harness Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11134 X102 Inline Harness Connector End Views X102 Brake Clutch Harness to Chassis Harness (JL1) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11135 X103 Inline Harness Connector End Views X103 Instrument Panel Harness to Forward Lamp Harness Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11136 X106 Inline Harness Connector End Views X106 Forward Lamp Harness to Right Front Headlamp Harness Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11137 X107 Inline Harness Connector End Views X107 Engine Chassis Harness to Engine Harness (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11138 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11139 X108 Inline Harness Connector End Views X108 Engine Chassis Harness to Engine Harness (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11140 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11141 X109 Inline Harness Connector End Views X109 Engine Harness (LU3) or Engine Chassis Harness (Diesel) to Instrument Panel Harness (LU3 or Diesel without NQF or NQH) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11142 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11143 X109 Engine Harness (except Diesel) or Engine Chassis Harness (Diesel) to Instrument Panel Harness (HP2, LU3 or Diesel with NQF or NQH) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11144 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11145 X109 Engine Harness to Instrument Panel Harness (Gas except LU3 and without NQF or NQH) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11146 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11147 X109 Engine Harness to Instrument Panel Harness (Gas except LU3 and with NQF or NQH) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11148 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11149 X110 Inline Harness Connector End Views X110 Engine Harness (except Diesel) or Engine Chassis Harness (Diesel) to Front Axle Harness (NQF, NQG or NQH) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11150 X111 Inline Harness Connector End Views X111 Engine Harness to Left Ignition Coil Harness (Gas except LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11151 X112 Inline Harness Connector End Views X112 Engine Harness to Camshaft Position Sensor Jumper Harness (L20, LMG or LC9) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11152 X112 Engine Harness to Camshaft Position Sensor Jumper Harness (LU3) X112 Engine Harness to Camshaft Position Sensor Jumper Harness (LZ1, LY6, L96 or L9H) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11153 X113 Inline Harness Connector End Views X113 Engine Harness to Right Ignition Coil Harness (Gas except LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11154 X113 Engine Jumper Harness to Engine Harness (Diesel) X115 Inline Harness Connector End Views X115 Chassis Harness to Instrument Panel Harness Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11155 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11156 X116 Inline Harness Connector End Views X116 Battery Positive Harness to Brake Clutch Harness (9L4) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11157 X117 Inline Harness Connector End Views X117 Fuel Rail Pressure Sensor Jumper Harness to Engine Harness (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11158 X120 Inline Harness Connector End Views X120 Engine Harness to Forward Lamp Harness (HP2) X121 Inline Harness Connector End Views X121 Battery Negative Harness to Battery Positive Harness (9L4) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11159 X124 Inline Harness Connector End Views X124 Engine Chassis Harness to PTO Jumper Harness (PTO) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11160 X125 Inline Harness Connector End Views X125 Heated Oxygen Sensor (HO2S) Jumper Harness to Engine Harness (LY6 with 31 Series) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11161 X127 Inline Harness Connector End Views X127 Engine Chassis Harness to Generator Jumper Harness (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11162 X128 Inline Harness Connector End Views X128 Fuel Pressure Regulator Harness to Engine Harness (Diesel) X129 Inline Harness Connector End Views X129 Instrument Panel Harness to Chassis Harness (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11163 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11164 X131 Inline Harness Connector End Views X131 Chassis Harness to Engine Harness (LU3) X131 Chassis Harness to Engine Harness (L20, LMG, LC9 or L9H) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11165 X150 Inline Harness Connector End Views X150 Engine Harness to Instrument Panel Harness (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11166 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11167 X122 Inline Harness Connector End Views X122 Auxiliary Battery Harness to Engine Harness (TP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11168 X123 Inline Harness Connector End Views X123 Engine Chassis Harness to Instrument Panel Harness (PTO) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11169 X175 Inline Harness Connector End Views X175 Engine Chassis Harness to Transmission Internal Harness (MW7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11170 X175 Engine Harness to Transmission Internal Harness (M30) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11171 X176 Inline Harness Connector End Views X176 Engine Harness to Transmission Harness (M99) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11172 X200 Inline Harness Connector End Views X200 Instrument Panel Harness to Body Harness Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11173 X201 Inline Harness Connector End Views X201 Steering Column Harness to Instrument Panel Harness Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11174 X202 Inline Harness Connector End Views X202 Instrument Panel Harness to Body Harness Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11175 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11176 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11177 X203 Inline Harness Connector End Views X203 Instrument Panel Harness (Y91) or I/P Extension Harness (except Y91) to Headliner Harness (UE1, UUL or UUK) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11178 X204 Inline Harness Connector End Views X204 Headliner Harness to Instrument Panel Harness (Y91) or I/P Extension Harness (except Y91) (U42) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11179 X205 Inline Harness Connector End Views X205 Brake Clutch Harness to Instrument Panel Harness (except TZ0) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11180 X205 Brake Clutch Harness to Instrument Panel Harness (TZ0) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11181 X206 Inline Harness Connector End Views X206 Right A-Pillar Harness to Instrument Panel Harness (Y91) or I/P Extension Harness (except Y91) (U42) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11182 X207 Inline Harness Connector End Views X207 Instrument Panel Harness to Instrument Panel Harness (6J4) X208 Inline Harness Connector End Views X208 Body Harness to Headliner Harness (YE9) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11183 X209 Inline Harness Connector End Views X209 Rearview Camera Chassis Harness to Rearview Camera I/P Jumper Harness (SPO Rearview Camera) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11184 X210 Inline Harness Connector End Views X210 Rearview Camera I/P Jumper Harness to Rearview Camera I/P Jumper Extension Harness (SPO Rearview Camera with KB6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11185 X212 Inline Harness Connector End Views X212 Instrument Panel Harness to I/P Extension Harness (except Y91, MEX or 8S8) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11186 X214 Inline Harness Connector End Views X214 Brake Clutch Harness to Fuse Block Jumper Harness (9L4) X215 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11187 Inline Harness Connector End Views X215 Body Harness to Instrument Panel Harness (HP2) X219 Inline Harness Connector End Views X219 Brake Clutch Harness to Fuse Block Jumper Harness (9L4) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11188 X224 Inline Harness Connector End Views X224 Brake Clutch Harness to Beacon Harness (5Y0 or 5X7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11189 X225 Inline Harness Connector End Views X225 Brake Clutch Harness to Battery Positive Harness (9L4) X226 Inline Harness Connector End Views X226 Fuse Block Jumper Harness to Brake Clutch Harness (9L4) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11190 X227 Inline Harness Connector End Views X227 LED Indicator Harness to SPO Theft Harness (SPO Alarm) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11191 X228 Inline Harness Connector End Views X228 Beacon Harness to Chassis Harness (5Y0) X240 Inline Harness Connector End Views X240 I/P Extension Harness to Instrument Panel Harness (UVC except Y91) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11192 X241 Inline Harness Connector End Views X241 Instrument Panel Harness (Y91) or I/P Extension Harness (except Y91) to Body Harness (UVC with DRC or DD8) X275 Inline Harness Connector End Views X275 Inflatable Restraint Steering Wheel Module Coil to Body Harness Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11193 X276 Inline Harness Connector End Views X276 Inflatable Restraint Steering Wheel Module Coil to Steering Column Harness (KA9) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11194 X277 Inline Harness Connector End Views X277 Inflatable Restraint Steering Wheel Module Coil to Heated Steering Wheel Harness (KA9) X278 Inline Harness Connector End Views X278 Instrument Panel Harness to Body Harness (MEX or A52) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11195 X279 Inline Harness Connector End Views X279 Instrument Panel Harness to Headliner Harness (MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11196 X300 Inline Harness Connector End Views X300 Chassis Harness to Engine Chassis Harness (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11197 X300 Engine Harness to Chassis Harness (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11198 X300 Chassis Harness to Engine Harness (LY6 or L96) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11199 X301 Inline Harness Connector End Views X301 Instrument Panel Harness (Y91) or I/P Extension Harness (except Y91) to Console Harness (Y91, UQA or D07) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11200 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11201 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11202 X303 Inline Harness Connector End Views X303 Body Harness to Driver Seat Harness (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11203 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11204 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11205 X303 Body Harness to Driver Seat Harness (except AN3 or MEX) X303 Driver Seat Harness to Body Harness (MEX or A52) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11206 X304 Inline Harness Connector End Views X304 Headliner Harness to Overhead Console Harness (except MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11207 X305 Inline Harness Connector End Views X305 Body Harness to Passenger Seat Harness (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11208 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11209 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11210 X305 Body Harness to Passenger Seat Harness (except AN3 or MEX) X306 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11211 Inline Harness Connector End Views X306 Headliner Harness to Right A-Pillar Harness (U42) X309 Inline Harness Connector End Views X309 Body Harness to Console Harness (Y91) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11212 X313 Inline Harness Connector End Views X313 Sunroof Harness (CF5) or Overhead Console Harness (TRW, 5X7 or 5Y0) to Right A-Pillar Harness (CF5, TRW, 5X7 or 5Y0) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11213 X318 Inline Harness Connector End Views X318 Headliner Harness to CHMSL Harness Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11214 X319 Inline Harness Connector End Views X319 Body Harness to Console Harness (HP2, AZ3 or D07 with UQ3) X320 Inline Harness Connector End Views X320 Body Harness to Sliding Rear Window Jumper Harness (A48) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11215 X324 Inline Harness Connector End Views X324 Driver Seat Harness to Driver Seat Jumper Harness (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11216 X325 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11217 Inline Harness Connector End Views X325 Passenger Seat Harness to Passenger Seat Jumper Harness (AN3) X330 Inline Harness Connector End Views X330 Heated Seat Body Harness to Heated Driver Seat Harness (SPO Heated Seats) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11218 X331 Inline Harness Connector End Views X331 Heated Seat Body Harness to Heated Driver Seat Harness (SPO Heated Seats) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11219 X332 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11220 Inline Harness Connector End Views X332 Heated Passenger Seat Harness to Heated Seat Body Harness (SPO Heated Seats) X333 Inline Harness Connector End Views X333 Heated Seat Body Harness to Heated Seat Body Harness (SPO Heated Seats) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11221 X334 Inline Harness Connector End Views X334 Heated Seat Body Harness to Heated Seat Body Harness (SPO Heated Seats) X350 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11222 Inline Harness Connector End Views X350 Body Harness to Drive Motor Generator Battery Control Harness (HP2) X371 Inline Harness Connector End Views X371 SPO Accessory Signal Cable 1A to SPO Accessory Signal Cable 3A (SPO DVD) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11223 X372 Inline Harness Connector End Views X372 SPO Accessory Signal Cable 2B to SPO Accessory Signal Cable 3B (SPO DVD) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11224 X373 Inline Harness Connector End Views X373 SPO Accessory Signal Cable 2A to SPO Accessory Signal Cable 3A (SPO DVD) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11225 X374 Inline Harness Connector End Views X374 SPO Accessory Signal Cable 1B to SPO Accessory Signal Cable 3B (SPO DVD) X414 Inline Harness Connector End Views X414 Chassis Harness to Camper Harness (UY2 or 8S3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11226 X415 Inline Harness Connector End Views X415 Rear Bumper Harness to Left Hip Lamp Harness (RO5) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11227 X451 Inline Harness Connector End Views X451 Body Ground Jumper Harness to Rear Axle Ground Jumper Harness (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11228 X408 Inline Harness Connector End Views X408 Chassis Harness to Rear Bumper Harness (UD7) X416 Inline Harness Connector End Views X416 Rear Bumper Harness to Right Hip Lamp Harness (RO5) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11229 X500 Inline Harness Connector End Views X500 Left Front Door Harness to Body Harness (YE9 or HP2, without AN3 or DL3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11230 X501 Inline Harness Connector End Views X501 Left Front Door Harness to Body Harness (YE9 or HP2, without AN3 or DL3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11231 X502 Inline Harness Connector End Views X502 Left Front Door Harness to Body Harness (ASF with AN3 or DL3, and except YE9) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11232 X600 Inline Harness Connector End Views X600 Right Front Door Harness to Body Harness (YE9 or HP2, without AN3 or DL3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11233 X601 Inline Harness Connector End Views X601 Right Front Door Harness to Body Harness (ASF) X700 - X799 Inline Harness Connector End Views X700 Body Harness to Left Rear Door Harness (Crew Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11234 X700 Left Rear Door Harness to Body Harness (Extended Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11235 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11236 X800 - X899 Inline Harness Connector End Views X800 Body Harness to Right Rear Door Harness (Crew Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11237 X800 Right Rear Door Harness to Body Harness (Extended Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11238 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 11239 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Service and Repair > Relay Replacement (Attached to Wire Harness) Power Distribution Relay: Service and Repair Relay Replacement (Attached to Wire Harness) Relay Replacement (Attached to Wire Harness) Removal Procedure 1. Locate the relay. Refer to the Master Electrical Component List (See: Locations/Component Locations/A - Z Index) to locate the relay in the vehicle. 2. Remove any fasteners which hold the relay in place. 3. Remove any connector position assurance (CPA) devices or secondary locks. Note: Use care when removing a relay in a wiring harness when the relay is secured by fasteners or tape. 4. Separate the relay (1) from the wire harness connector (2). Installation Procedure 1. Connect the relay (1) to the wire harness connector (2). 2. Install any connector position assurance (CPA) devices or secondary locks. 3. Install the relay using any fasteners or tape that originally held the relay in place. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Service and Repair > Relay Replacement (Attached to Wire Harness) > Page 11244 Power Distribution Relay: Service and Repair Relay Replacement (Within an Electrical Center) Relay Replacement (Within an Electrical Center) Special Tools J 43244 Relay Puller Pliers Removal Procedure 1. Remove the electrical center cover. 2. Locate the relay. Refer to Electrical Center Identification Views (See: Fuse/Application and ID) to locate the electrical center where the relay exists. Note: * Always note the orientation of the relay. * If equipped with a notch style relay; observe the location of the notch on the old relay to verify the new relay is installed with the notch in the same location. * Ensure that the electrical center is secure, as not to put added stress on the wires or terminals. 3. Using the J 43244 (1) position the tool on opposing corners of the relay (2). Caution: Use J43244 to pull the relay straight out from the electrical center terminals. The use of pliers or a flat bladed tool could damage the electrical center. 4. Remove the relay (2) from the electrical center. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Service and Repair > Relay Replacement (Attached to Wire Harness) > Page 11245 1. Install the relay (2) in the same position as removed. 2. Install the electrical center cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Service and Repair > Relay Replacement (Attached to Wire Harness) Power Distribution Relay: Service and Repair Relay Replacement (Attached to Wire Harness) Relay Replacement (Attached to Wire Harness) Removal Procedure 1. Locate the relay. Refer to the Master Electrical Component List (See: Locations/Component Locations/A - Z Index) to locate the relay in the vehicle. 2. Remove any fasteners which hold the relay in place. 3. Remove any connector position assurance (CPA) devices or secondary locks. Note: Use care when removing a relay in a wiring harness when the relay is secured by fasteners or tape. 4. Separate the relay (1) from the wire harness connector (2). Installation Procedure 1. Connect the relay (1) to the wire harness connector (2). 2. Install any connector position assurance (CPA) devices or secondary locks. 3. Install the relay using any fasteners or tape that originally held the relay in place. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Service and Repair > Relay Replacement (Attached to Wire Harness) > Page 11251 Power Distribution Relay: Service and Repair Relay Replacement (Within an Electrical Center) Relay Replacement (Within an Electrical Center) Special Tools J 43244 Relay Puller Pliers Removal Procedure 1. Remove the electrical center cover. 2. Locate the relay. Refer to Electrical Center Identification Views (See: Fuse/Application and ID) to locate the electrical center where the relay exists. Note: * Always note the orientation of the relay. * If equipped with a notch style relay; observe the location of the notch on the old relay to verify the new relay is installed with the notch in the same location. * Ensure that the electrical center is secure, as not to put added stress on the wires or terminals. 3. Using the J 43244 (1) position the tool on opposing corners of the relay (2). Caution: Use J43244 to pull the relay straight out from the electrical center terminals. The use of pliers or a flat bladed tool could damage the electrical center. 4. Remove the relay (2) from the electrical center. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Service and Repair > Relay Replacement (Attached to Wire Harness) > Page 11252 1. Install the relay (2) in the same position as removed. 2. Install the electrical center cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood Relay Box: Application and ID Fuse Block - Underhood Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 11257 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 11258 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 11259 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 11260 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 11261 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 11262 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 11263 Fuse Block - Underhood Top View - Diesel Fuse Block - Underhood Top View - Gas Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 11264 Fuse Block - Underhood Bottom View Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 11265 Fuse Block - Underhood X1 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 11266 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 11267 Fuse Block - Underhood X2 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 11268 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 11269 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 11270 Fuse Block - Underhood X3 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 11271 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 11272 Fuse Block - Underhood X4 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 11273 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 11274 Fuse Block - Underhood X5 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 11275 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 11276 Fuse Block - Underhood X6 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 11277 Fuse Block - Underhood X7 (except TP2) Fuse Block - Underhood X7 (TP2) Fuse Block - Underhood X8 (except JL1) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 11278 Fuse Block - Underhood X8 (JL1) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 11279 Relay Box: Application and ID Fuse Block - I/P Electrical Center Identification Views Fuse Block - I/P Label Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 11280 Fuse Block - I/P Top View Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 11281 Fuse Block - I/P Bottom View Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 11282 Fuse Block - I/P X1 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 11283 Fuse Block - I/P X2 (except MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 11284 Fuse Block - I/P X3 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 11285 Fuse Block - I/P X4 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 11286 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 11287 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 11288 Relay Box: Application and ID Fuse Block - Mobile Radio Electrical Center Identification Views Fuse Block - Mobile Radio, Top View (9L4) Fuse Block - Mobile Radio (9L4) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 11289 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 11290 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood Relay Box: Application and ID Fuse Block - Underhood Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 11295 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 11296 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 11297 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 11298 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 11299 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 11300 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 11301 Fuse Block - Underhood Top View - Diesel Fuse Block - Underhood Top View - Gas Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 11302 Fuse Block - Underhood Bottom View Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 11303 Fuse Block - Underhood X1 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 11304 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 11305 Fuse Block - Underhood X2 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 11306 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 11307 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 11308 Fuse Block - Underhood X3 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 11309 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 11310 Fuse Block - Underhood X4 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 11311 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 11312 Fuse Block - Underhood X5 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 11313 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 11314 Fuse Block - Underhood X6 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 11315 Fuse Block - Underhood X7 (except TP2) Fuse Block - Underhood X7 (TP2) Fuse Block - Underhood X8 (except JL1) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 11316 Fuse Block - Underhood X8 (JL1) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 11317 Relay Box: Application and ID Fuse Block - I/P Electrical Center Identification Views Fuse Block - I/P Label Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 11318 Fuse Block - I/P Top View Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 11319 Fuse Block - I/P Bottom View Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 11320 Fuse Block - I/P X1 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 11321 Fuse Block - I/P X2 (except MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 11322 Fuse Block - I/P X3 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 11323 Fuse Block - I/P X4 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 11324 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 11325 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 11326 Relay Box: Application and ID Fuse Block - Mobile Radio Electrical Center Identification Views Fuse Block - Mobile Radio, Top View (9L4) Fuse Block - Mobile Radio (9L4) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 11327 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 11328 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 11-09-41-002 > Mar > 11 > Restraint System - Air Bag Warning Lamp On Repeat DTC's Wiring Harness: Customer Interest Restraint System - Air Bag Warning Lamp On Repeat DTC's TECHNICAL Bulletin No.: 11-09-41-002 Date: March 17, 2011 Subject: Air Bag Warning Lamp Illuminated, Repeat History DTC B0083 0F - B0088 0F (Follow SI and Procedure Outlined Below if necessary) Models: 2010-2011 Cadillac Escalade, Escalade ESV, Escalade EXT, Escalade Hybrid 2010-2011 Chevrolet Avalanche, Silverado, Silverado Hybrid, Suburban, Tahoe, Tahoe Hybrid 2010-2011 GMC Sierra, Sierra Denali, Sierra Hybrid, Yukon, Yukon XL, Yukon XL Denali, Yukon Hybrid, Yukon Denali Hybrid Condition In extremely rare cases, some customers may comment that the air bag warning lamp is illuminated. This condition may be intermittent and when checking the vehicle for DTCs, the SDM may report B0083, B0084, B0085, B0086, B0087 and/or B0088 with symptom code 0F. The code will be stored in history and may be repeated. The code probably will not be current. Cause This condition may be caused by possible electro-magnetic interference (EMI) in the Amarillo, Texas area from external sources such as aviation airspace traffic radar, creating erratic sensor information to the SDM. Correction Perform all diagnostics and repairs documented in SI. Notice If published SI repair information does not resolve the condition, perform the procedure below. Install a steward clamp ferrite bead following the procedure below: 1. Disconnect battery. Refer to SIR Disabling and Enabling in SI. 2. Remove the door trim. Refer to SI door trim removal. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 11-09-41-002 > Mar > 11 > Restraint System - Air Bag Warning Lamp On Repeat DTC's > Page 11337 3. Install the steward clamp ferrite bead on the wire harness (1). 4. Place tape around the steward clamp ferrite bead (1) to avoid vibration or movement. Verify that the door glass does not come in contact with it. 5. Reinstall the door trim. Refer to SI door trim removal. 6. Reconnect the battery. Refer to SIR Disabling and Enabling in SI. Parts Information Parts (Laird HFA100049-0A2) can be purchased from Digi-Key Corporation at www.digikey.com. Material allowance for repair is $1.10 each (in Canada, $1.21). Warranty Information For vehicle repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 10-08-42-001B > Jan > 11 > Lighting - Low Beam Headlamp(s) Inoperative Wiring Harness: Customer Interest Lighting - Low Beam Headlamp(s) Inoperative TECHNICAL Bulletin No.: 10-08-42-001B Date: January 24, 2011 Subject: Low Beam Headlamp Bulb Diagnosis/Replacement (Inspect Bulb and Connector) Models: 2008-2011 Buick Enclave 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2008-2011 Cadillac CTS, CTS-V 2010-2011 Cadillac CTS Sport Wagon, SRX 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2011 Chevrolet Malibu 2009-2011 Chevrolet Traverse 2010-2011 Chevrolet Equinox 2007-2011 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2010-2011 GMC Terrain 2006-2010 Pontiac G6 2007-2010 Saturn AURA, OUTLOOK Attention: This bulletin DOES NOT apply to vehicles equipped with High Intensity Discharge (HID) lamps. Supercede: This bulletin is being revised to update the part number for the recommended splice sleeve. Please discard Corporate Bulletin Number 10-08-42-001A (Section 08 - Body and Accessories). Condition Some customers may comment that the low beam headlamp is inoperative. Correction DO NOT replace the entire headlamp assembly for this condition. Replace the bulb and inspect the connector following the procedure below. 1. Remove the headlamp bulb. Refer to Headlamp Bulb Replacement procedure in SI. 2. Inspect the connector. - If the connector is NOT discolored or damaged, replace the bulb only. For bulb part numbers, see Headlamp Bulb (Low Beam) in Group 02.727 of the appropriate Parts Catalog. - If the connector is discolored at the bulb interface, replace the connector (service pigtail listed below) and bulb. Important Use only Duraseal splice sleeves (salmon, P/N 19168446). Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Refer to Splicing Copper Wire Using Splice Sleeves in SI for splicing procedures. 1. Cut the wires of the connector approximately 45 mm (13/4 in) from the connector and splice in the service pigtail connector. Ensure that the splices are not above the connector when re-installing. 2. Replace the bulb. 3. Verify that the headlamp is fully functional. Parts Information Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 10-08-42-001B > Jan > 11 > Lighting - Low Beam Headlamp(s) Inoperative > Page 11342 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm Wiring Harness: Customer Interest Seats - Driver/Passenger Heated Seats Inop./Slow to Warm TECHNICAL Bulletin No.: 10-08-50-008B Date: January 13, 2011 Subject: Driver or Passenger Heated Seat Inoperative, Slow to Warm, DTC(s) Set (Repair Connector, Re-Route Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Silverado, Suburban, Tahoe 2011 Chevrolet Silverado Heavy Duty 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2011 GMC Sierra Heavy Duty All Equipped with Heated Front Seat (RPO AN3, KA1) or Heated and Cooled Seat (RPO KB6) and/or Luxury Package (RPO PCK) Supercede: This bulletin is being revised to update the RPOs. Please discard Corporate Bulletin Number 10-08-50-008A (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger heated seat system exhibits the following symptoms: - Heated seat turns on and then turns off within 1 to 10 minutes (at any 60 second interval). - The system doesn't get warm enough, or gets warm very slowly. - The heated seat system is completely inoperative. Upon further review, DTCs B2430 0D and/or B2180 0D may be set as a current or history code if the vehicle is equipped with heated seats only (RPO KA1). Also, the LED indicator for the heated seats may come On and then flash after approximately 1 minute, then go out. If the vehicle is equipped with heated and cooled seats (KB6), the switch LED indicator may stay On, but the heated and cooled seat is inoperative. The fan will continue to blow air. Cause Heated Seats (RPO AN3, KA1) The heated seat control circuit terminal and/or ground terminal in harness connector X1 to the memory seat module (MSM) may have lost tension and is loose. The reduced terminal tension increases resistance in the connector, which may result in the symptoms described above. Heated and Cooled Seats (RPO KB6) The thermo-electric device (TED) in the seat cushion/seat back ventilation heating and cooling module may have become inoperative. Correction Heated Seats (RPO AN3, KA1) Follow the steps below to correct the concern with the heated seats. Note This repair requires a unique anti-abrasion electrical tape and harness clip from Kent Automotive. Refer to the Parts Information below. 1. Access and remove the seat bolts/nuts. 2. Adjust the seat rearward about halfway. Adjust the seat recline full forward. 3. Tilt the seat backward to access the bottom of the seat. Prop the seat up with a suitable tool if required. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 11347 4. Disconnect seat harness connectors (1) X1, X2, X3 and X4 from the MSM. 5. Identify connector X1. Refer to Component Connector End Views in SI. 6. Perform a terminal drag test on connector X1, paying special attention to terminals 1, 4, 6, 11 and 14. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Refer to Testing for Intermittent Conditions and Poor Connections in SI. 7. Replace any terminal in question including connector X1 terminals 1, 4, 6, 11 and 14 if necessary. Refer to Repairing Connector Terminals in SI. 8. Identify connector X4. Refer to Component Connector End Views in SI. 9. Perform the terminal drag test described in step 6, paying special attention to terminal 14. 10. Replace any terminal in question including connector X4 terminal 14 if necessary. Refer to Repairing Connector Terminals in SI. 11. Remove the harness clip (1) from the plastic carrier. 12. Cut the electrical tape holding the harness in the plastic carrier using a sharp utility knife in the area shown (1). 13. Free the harness from the carrier back to the area shown (1). 14. Obtain "*Woven Polyester (PET) Electrical Tape" (Special Order P/N RZ97156A00) from Kent Automotive. Refer to Parts Information below. Important Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 11348 DO NOT substitute with vinyl electrical tape or friction tape. Use only the tape specified above. 15. Tape the harness starting at the MSM connectors (1) extending back to the new break-out location (2) in the plastic carrier. 16. Install a plastic tie strap around the harness and the plastic carrier at the break-out point (1). 17. Install the new harness edge clip (1) 10 mm (0.4 in) further from the connectors and the existing harness clip. Ensure the clip is installed in the orientation shown. 18. Install the harness with the new harness clip in the location shown (1). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 11349 19. Reinstall the harness connectors (1) to the MSM. 20. Reinstall the seat to the vehicle. Heated and Cooled Seats (RPO KB6) Follow the steps below to correct the concern with the heated and cooled seats. 1. Inspect the ventilation heating and cooling module for a concern with the TED. Refer to Seat Heating and Cooling, Diagnostic Information and Procedures in SI. Note If the heated and cooled seat function is inoperative, but the heat switch indicators are On, the MSM is functioning properly and the concern is with the TED. 2. If the TED is found to be the concern, replace the seat cushion or seat back ventilation heating and cooling module. Refer to Driver or Passenger Seat Back Ventilation Heating and Cooling Blower Replacement or Driver or Passenger Seat Cushion Ventilation Heating and Cooling Blower Replacement in SI. If the TED is not the concern, follow normal diagnostics and repair in SI. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Use the appropriate Labor Operation based on the repair completed. Heated Seats (RPO AN3, KA1) For vehicles repaired under warranty, use: Heated and Cooled Seats (RPO KB6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 11350 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 11355 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 11356 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 11357 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power Wiring Harness: Customer Interest Electrical - Intermittent MIL/DTC P2138/Reduced Power TECHNICAL Bulletin No.: 07-06-04-019D Date: June 28, 2010 Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced Engine Power (Repair Instrument Panel (IP) to Body Harness Connector) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years and warranty information. Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion System) Condition - Some customers may comment on an intermittent malfunction indicator lamp (MIL) being Illuminated with a message or an indicator that displays Reduced Engine Power. - The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP) Sensor 1-2 Correlation set as Current or in History. Cause This condition may be caused by water intrusion into the instrument panel (IP) to body harness connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value for more than a calibrated period of time, setting P2138. Correction Note Aftermarket equipment can generate DTC P2138 and/or other DTCs. 1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or low reference circuits or to any other ECM/PCM 5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI. 2. Perform the Diagnostic System Check - Vehicle. ‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any 5V reference DTCs are not set, proceed to Step 3. 3. Locate the IP to body harness connector, which may be located in and around the left hand kick panel area or inside the IP. Depending on the vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI. Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped) and windshield/cowl sealing. 4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the leak. Refer to General Information > Water Leaks in SI. ‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair. 5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for Intermittent Conditions and Poor Connections in SI. ‹› If any corrosion and/or debris is observed, repair as necessary. 6. After completing the repair, verify the proper operation of the system. Depending on the vehicle and model year, perform the Diagnostic Repair Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power > Page 11362 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the appropriate labor operation for the source of the water leak Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 10-08-42-001 > May > 10 > Lighting - Low Beam Headlamp(s) Inoperative Wiring Harness: Customer Interest Lighting - Low Beam Headlamp(s) Inoperative TECHNICAL Bulletin No.: 10-08-42-001 Date: May 14, 2010 Subject: Low Beam Headlamp Bulb Diagnosis/Replacement (Inspect Bulb and Connector) Models: 2008-2010 Buick Enclave 2008-2010 Cadillac CTS, CTS-V 2010 Cadillac CTS Sport Wagon, SRX 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Malibu 2009-2010 Chevrolet Traverse 2007-2010 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2006-2010 Pontiac G6 2007-2010 Saturn AURA Attention: This bulletin DOES NOT apply to vehicles equipped with High Intensity Discharge (HID) lamps. Condition Some customers may comment that the low beam headlamp is inoperative. Correction DO NOT replace the entire headlamp assembly for this condition. Replace the bulb and inspect the connector following the procedure below. 1. Remove the lamp assembly, then remove the bulb. Refer to Headlamp Assembly Replacement in SI. 2. Inspect the connector. - If the connector is NOT discolored or damaged, replace the bulb only. For bulb part numbers, see Headlamp Bulb (Low Beam) in Group 02.727 of the appropriate Parts Catalog. - If the connector is discolored at the bulb interface, replace the connector (service pigtail listed below) and bulb. Important Use only Duraseal splice sleeves (salmon, P/N 12089189). Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Refer to Splicing Copper Wire Using Splice Sleeves in SI for splicing procedures. 1. Cut the wires of the connector approximately 45 mm (1-3/4 in) from the connector and splice in the service pigtail connector. Ensure that the splices are not above the connector when re-installing. 2. Replace the bulb. 3. Verify that the headlamp is fully functional. Parts Information Warranty Information For vehicles repaired under warranty, use: Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 10-08-42-001 > May > 10 > Lighting - Low Beam Headlamp(s) Inoperative > Page 11367 If only bulbs are replaced, use labor operation N0440 or N0441. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 08-08-45-002A > May > 10 > Body - L/H/R/H Power Mirror(s) Inoperative Wiring Harness: Customer Interest Body - L/H/R/H Power Mirror(s) Inoperative TECHNICAL Bulletin No.: 08-08-45-002A Date: May 13, 2010 Subject: Left Or Right Power Outside Mirror Inoperative (Inspect Wire Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2010 GMC Sierra, Sierra Denali, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Supercede: This bulletin is being revised to add the 2010 model year and update the Warranty Information. Please discard Corporate Bulletin Number 08-08-45-002 (Section 08 - Body and Accessories). Condition Some customers may comment that the left or right outside power mirror is inoperative. Cause This condition may be caused by two different concerns. 1. The wiring harness may be damaged from a screw that retains the door trim to the door. 2. The wiring harness connector at the mirror glass actuator may not be locked in place. Correction Inspect the wiring harness and connector. 1. Remove the door trim and inspect the wiring harness. Refer to Front Side Door Trim Panel Replacement in SI if necessary. If the harness is damaged , refer to Repairing Damaged Wire Insulation in SI. After making the repair, reposition the harness. 2. Inspect the connector at the mirror actuator. Refer to Outside Rearview Mirror Motor Replacement in SI if necessary. If the connector is loose, remove and reinstall the connector. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 08-08-45-002A > May > 10 > Body - Left/Right Power Outside Mirror Inoperative Wiring Harness: Customer Interest Body - Left/Right Power Outside Mirror Inoperative TECHNICAL Bulletin No.: 08-08-45-002A Date: May 13, 2010 Subject: Left Or Right Power Outside Mirror Inoperative (Inspect Wire Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2010 GMC Sierra, Sierra Denali, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Supercede: This bulletin is being revised to add the 2010 model year and update the Warranty Information. Please discard Corporate Bulletin Number 08-08-45-002 (Section 08 - Body and Accessories). Condition Some customers may comment that the left or right outside power mirror is inoperative. Cause This condition may be caused by two different concerns. 1. The wiring harness may be damaged from a screw that retains the door trim to the door. 2. The wiring harness connector at the mirror glass actuator may not be locked in place. Correction Inspect the wiring harness and connector. 1. Remove the door trim and inspect the wiring harness. Refer to Front Side Door Trim Panel Replacement in SI if necessary. If the harness is damaged , refer to Repairing Damaged Wire Insulation in SI. After making the repair, reposition the harness. 2. Inspect the connector at the mirror actuator. Refer to Outside Rearview Mirror Motor Replacement in SI if necessary. If the connector is loose, remove and reinstall the connector. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 11-09-41-002 > Mar > 11 > Restraint System - Air Bag Warning Lamp On Repeat DTC's Wiring Harness: All Technical Service Bulletins Restraint System - Air Bag Warning Lamp On Repeat DTC's TECHNICAL Bulletin No.: 11-09-41-002 Date: March 17, 2011 Subject: Air Bag Warning Lamp Illuminated, Repeat History DTC B0083 0F - B0088 0F (Follow SI and Procedure Outlined Below if necessary) Models: 2010-2011 Cadillac Escalade, Escalade ESV, Escalade EXT, Escalade Hybrid 2010-2011 Chevrolet Avalanche, Silverado, Silverado Hybrid, Suburban, Tahoe, Tahoe Hybrid 2010-2011 GMC Sierra, Sierra Denali, Sierra Hybrid, Yukon, Yukon XL, Yukon XL Denali, Yukon Hybrid, Yukon Denali Hybrid Condition In extremely rare cases, some customers may comment that the air bag warning lamp is illuminated. This condition may be intermittent and when checking the vehicle for DTCs, the SDM may report B0083, B0084, B0085, B0086, B0087 and/or B0088 with symptom code 0F. The code will be stored in history and may be repeated. The code probably will not be current. Cause This condition may be caused by possible electro-magnetic interference (EMI) in the Amarillo, Texas area from external sources such as aviation airspace traffic radar, creating erratic sensor information to the SDM. Correction Perform all diagnostics and repairs documented in SI. Notice If published SI repair information does not resolve the condition, perform the procedure below. Install a steward clamp ferrite bead following the procedure below: 1. Disconnect battery. Refer to SIR Disabling and Enabling in SI. 2. Remove the door trim. Refer to SI door trim removal. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 11-09-41-002 > Mar > 11 > Restraint System - Air Bag Warning Lamp On Repeat DTC's > Page 11381 3. Install the steward clamp ferrite bead on the wire harness (1). 4. Place tape around the steward clamp ferrite bead (1) to avoid vibration or movement. Verify that the door glass does not come in contact with it. 5. Reinstall the door trim. Refer to SI door trim removal. 6. Reconnect the battery. Refer to SIR Disabling and Enabling in SI. Parts Information Parts (Laird HFA100049-0A2) can be purchased from Digi-Key Corporation at www.digikey.com. Material allowance for repair is $1.10 each (in Canada, $1.21). Warranty Information For vehicle repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-42-001B > Jan > 11 > Lighting - Low Beam Headlamp(s) Inoperative Wiring Harness: All Technical Service Bulletins Lighting - Low Beam Headlamp(s) Inoperative TECHNICAL Bulletin No.: 10-08-42-001B Date: January 24, 2011 Subject: Low Beam Headlamp Bulb Diagnosis/Replacement (Inspect Bulb and Connector) Models: 2008-2011 Buick Enclave 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2008-2011 Cadillac CTS, CTS-V 2010-2011 Cadillac CTS Sport Wagon, SRX 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2011 Chevrolet Malibu 2009-2011 Chevrolet Traverse 2010-2011 Chevrolet Equinox 2007-2011 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2010-2011 GMC Terrain 2006-2010 Pontiac G6 2007-2010 Saturn AURA, OUTLOOK Attention: This bulletin DOES NOT apply to vehicles equipped with High Intensity Discharge (HID) lamps. Supercede: This bulletin is being revised to update the part number for the recommended splice sleeve. Please discard Corporate Bulletin Number 10-08-42-001A (Section 08 - Body and Accessories). Condition Some customers may comment that the low beam headlamp is inoperative. Correction DO NOT replace the entire headlamp assembly for this condition. Replace the bulb and inspect the connector following the procedure below. 1. Remove the headlamp bulb. Refer to Headlamp Bulb Replacement procedure in SI. 2. Inspect the connector. - If the connector is NOT discolored or damaged, replace the bulb only. For bulb part numbers, see Headlamp Bulb (Low Beam) in Group 02.727 of the appropriate Parts Catalog. - If the connector is discolored at the bulb interface, replace the connector (service pigtail listed below) and bulb. Important Use only Duraseal splice sleeves (salmon, P/N 19168446). Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Refer to Splicing Copper Wire Using Splice Sleeves in SI for splicing procedures. 1. Cut the wires of the connector approximately 45 mm (13/4 in) from the connector and splice in the service pigtail connector. Ensure that the splices are not above the connector when re-installing. 2. Replace the bulb. 3. Verify that the headlamp is fully functional. Parts Information Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-42-001B > Jan > 11 > Lighting - Low Beam Headlamp(s) Inoperative > Page 11386 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm Wiring Harness: All Technical Service Bulletins Seats - Driver/Passenger Heated Seats Inop./Slow to Warm TECHNICAL Bulletin No.: 10-08-50-008B Date: January 13, 2011 Subject: Driver or Passenger Heated Seat Inoperative, Slow to Warm, DTC(s) Set (Repair Connector, Re-Route Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Silverado, Suburban, Tahoe 2011 Chevrolet Silverado Heavy Duty 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2011 GMC Sierra Heavy Duty All Equipped with Heated Front Seat (RPO AN3, KA1) or Heated and Cooled Seat (RPO KB6) and/or Luxury Package (RPO PCK) Supercede: This bulletin is being revised to update the RPOs. Please discard Corporate Bulletin Number 10-08-50-008A (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger heated seat system exhibits the following symptoms: - Heated seat turns on and then turns off within 1 to 10 minutes (at any 60 second interval). - The system doesn't get warm enough, or gets warm very slowly. - The heated seat system is completely inoperative. Upon further review, DTCs B2430 0D and/or B2180 0D may be set as a current or history code if the vehicle is equipped with heated seats only (RPO KA1). Also, the LED indicator for the heated seats may come On and then flash after approximately 1 minute, then go out. If the vehicle is equipped with heated and cooled seats (KB6), the switch LED indicator may stay On, but the heated and cooled seat is inoperative. The fan will continue to blow air. Cause Heated Seats (RPO AN3, KA1) The heated seat control circuit terminal and/or ground terminal in harness connector X1 to the memory seat module (MSM) may have lost tension and is loose. The reduced terminal tension increases resistance in the connector, which may result in the symptoms described above. Heated and Cooled Seats (RPO KB6) The thermo-electric device (TED) in the seat cushion/seat back ventilation heating and cooling module may have become inoperative. Correction Heated Seats (RPO AN3, KA1) Follow the steps below to correct the concern with the heated seats. Note This repair requires a unique anti-abrasion electrical tape and harness clip from Kent Automotive. Refer to the Parts Information below. 1. Access and remove the seat bolts/nuts. 2. Adjust the seat rearward about halfway. Adjust the seat recline full forward. 3. Tilt the seat backward to access the bottom of the seat. Prop the seat up with a suitable tool if required. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 11391 4. Disconnect seat harness connectors (1) X1, X2, X3 and X4 from the MSM. 5. Identify connector X1. Refer to Component Connector End Views in SI. 6. Perform a terminal drag test on connector X1, paying special attention to terminals 1, 4, 6, 11 and 14. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Refer to Testing for Intermittent Conditions and Poor Connections in SI. 7. Replace any terminal in question including connector X1 terminals 1, 4, 6, 11 and 14 if necessary. Refer to Repairing Connector Terminals in SI. 8. Identify connector X4. Refer to Component Connector End Views in SI. 9. Perform the terminal drag test described in step 6, paying special attention to terminal 14. 10. Replace any terminal in question including connector X4 terminal 14 if necessary. Refer to Repairing Connector Terminals in SI. 11. Remove the harness clip (1) from the plastic carrier. 12. Cut the electrical tape holding the harness in the plastic carrier using a sharp utility knife in the area shown (1). 13. Free the harness from the carrier back to the area shown (1). 14. Obtain "*Woven Polyester (PET) Electrical Tape" (Special Order P/N RZ97156A00) from Kent Automotive. Refer to Parts Information below. Important Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 11392 DO NOT substitute with vinyl electrical tape or friction tape. Use only the tape specified above. 15. Tape the harness starting at the MSM connectors (1) extending back to the new break-out location (2) in the plastic carrier. 16. Install a plastic tie strap around the harness and the plastic carrier at the break-out point (1). 17. Install the new harness edge clip (1) 10 mm (0.4 in) further from the connectors and the existing harness clip. Ensure the clip is installed in the orientation shown. 18. Install the harness with the new harness clip in the location shown (1). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 11393 19. Reinstall the harness connectors (1) to the MSM. 20. Reinstall the seat to the vehicle. Heated and Cooled Seats (RPO KB6) Follow the steps below to correct the concern with the heated and cooled seats. 1. Inspect the ventilation heating and cooling module for a concern with the TED. Refer to Seat Heating and Cooling, Diagnostic Information and Procedures in SI. Note If the heated and cooled seat function is inoperative, but the heat switch indicators are On, the MSM is functioning properly and the concern is with the TED. 2. If the TED is found to be the concern, replace the seat cushion or seat back ventilation heating and cooling module. Refer to Driver or Passenger Seat Back Ventilation Heating and Cooling Blower Replacement or Driver or Passenger Seat Cushion Ventilation Heating and Cooling Blower Replacement in SI. If the TED is not the concern, follow normal diagnostics and repair in SI. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Use the appropriate Labor Operation based on the repair completed. Heated Seats (RPO AN3, KA1) For vehicles repaired under warranty, use: Heated and Cooled Seats (RPO KB6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 11394 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 11399 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 11400 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 11401 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 11406 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 11407 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 11408 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 11409 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 11410 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 11411 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power Wiring Harness: All Technical Service Bulletins Electrical - Intermittent MIL/DTC P2138/Reduced Power TECHNICAL Bulletin No.: 07-06-04-019D Date: June 28, 2010 Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced Engine Power (Repair Instrument Panel (IP) to Body Harness Connector) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years and warranty information. Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion System) Condition - Some customers may comment on an intermittent malfunction indicator lamp (MIL) being Illuminated with a message or an indicator that displays Reduced Engine Power. - The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP) Sensor 1-2 Correlation set as Current or in History. Cause This condition may be caused by water intrusion into the instrument panel (IP) to body harness connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value for more than a calibrated period of time, setting P2138. Correction Note Aftermarket equipment can generate DTC P2138 and/or other DTCs. 1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or low reference circuits or to any other ECM/PCM 5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI. 2. Perform the Diagnostic System Check - Vehicle. ‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any 5V reference DTCs are not set, proceed to Step 3. 3. Locate the IP to body harness connector, which may be located in and around the left hand kick panel area or inside the IP. Depending on the vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI. Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped) and windshield/cowl sealing. 4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the leak. Refer to General Information > Water Leaks in SI. ‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair. 5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for Intermittent Conditions and Poor Connections in SI. ‹› If any corrosion and/or debris is observed, repair as necessary. 6. After completing the repair, verify the proper operation of the system. Depending on the vehicle and model year, perform the Diagnostic Repair Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power > Page 11416 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the appropriate labor operation for the source of the water leak Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-42-001 > May > 10 > Lighting - Low Beam Headlamp(s) Inoperative Wiring Harness: All Technical Service Bulletins Lighting - Low Beam Headlamp(s) Inoperative TECHNICAL Bulletin No.: 10-08-42-001 Date: May 14, 2010 Subject: Low Beam Headlamp Bulb Diagnosis/Replacement (Inspect Bulb and Connector) Models: 2008-2010 Buick Enclave 2008-2010 Cadillac CTS, CTS-V 2010 Cadillac CTS Sport Wagon, SRX 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Malibu 2009-2010 Chevrolet Traverse 2007-2010 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2006-2010 Pontiac G6 2007-2010 Saturn AURA Attention: This bulletin DOES NOT apply to vehicles equipped with High Intensity Discharge (HID) lamps. Condition Some customers may comment that the low beam headlamp is inoperative. Correction DO NOT replace the entire headlamp assembly for this condition. Replace the bulb and inspect the connector following the procedure below. 1. Remove the lamp assembly, then remove the bulb. Refer to Headlamp Assembly Replacement in SI. 2. Inspect the connector. - If the connector is NOT discolored or damaged, replace the bulb only. For bulb part numbers, see Headlamp Bulb (Low Beam) in Group 02.727 of the appropriate Parts Catalog. - If the connector is discolored at the bulb interface, replace the connector (service pigtail listed below) and bulb. Important Use only Duraseal splice sleeves (salmon, P/N 12089189). Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Refer to Splicing Copper Wire Using Splice Sleeves in SI for splicing procedures. 1. Cut the wires of the connector approximately 45 mm (1-3/4 in) from the connector and splice in the service pigtail connector. Ensure that the splices are not above the connector when re-installing. 2. Replace the bulb. 3. Verify that the headlamp is fully functional. Parts Information Warranty Information For vehicles repaired under warranty, use: Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-42-001 > May > 10 > Lighting - Low Beam Headlamp(s) Inoperative > Page 11421 If only bulbs are replaced, use labor operation N0440 or N0441. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 08-08-45-002A > May > 10 > Body - L/H/R/H Power Mirror(s) Inoperative Wiring Harness: All Technical Service Bulletins Body - L/H/R/H Power Mirror(s) Inoperative TECHNICAL Bulletin No.: 08-08-45-002A Date: May 13, 2010 Subject: Left Or Right Power Outside Mirror Inoperative (Inspect Wire Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2010 GMC Sierra, Sierra Denali, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Supercede: This bulletin is being revised to add the 2010 model year and update the Warranty Information. Please discard Corporate Bulletin Number 08-08-45-002 (Section 08 - Body and Accessories). Condition Some customers may comment that the left or right outside power mirror is inoperative. Cause This condition may be caused by two different concerns. 1. The wiring harness may be damaged from a screw that retains the door trim to the door. 2. The wiring harness connector at the mirror glass actuator may not be locked in place. Correction Inspect the wiring harness and connector. 1. Remove the door trim and inspect the wiring harness. Refer to Front Side Door Trim Panel Replacement in SI if necessary. If the harness is damaged , refer to Repairing Damaged Wire Insulation in SI. After making the repair, reposition the harness. 2. Inspect the connector at the mirror actuator. Refer to Outside Rearview Mirror Motor Replacement in SI if necessary. If the connector is loose, remove and reinstall the connector. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 08-08-45-002A > May > 10 > Body - Left/Right Power Outside Mirror Inoperative Wiring Harness: All Technical Service Bulletins Body - Left/Right Power Outside Mirror Inoperative TECHNICAL Bulletin No.: 08-08-45-002A Date: May 13, 2010 Subject: Left Or Right Power Outside Mirror Inoperative (Inspect Wire Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2010 GMC Sierra, Sierra Denali, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Supercede: This bulletin is being revised to add the 2010 model year and update the Warranty Information. Please discard Corporate Bulletin Number 08-08-45-002 (Section 08 - Body and Accessories). Condition Some customers may comment that the left or right outside power mirror is inoperative. Cause This condition may be caused by two different concerns. 1. The wiring harness may be damaged from a screw that retains the door trim to the door. 2. The wiring harness connector at the mirror glass actuator may not be locked in place. Correction Inspect the wiring harness and connector. 1. Remove the door trim and inspect the wiring harness. Refer to Front Side Door Trim Panel Replacement in SI if necessary. If the harness is damaged , refer to Repairing Damaged Wire Insulation in SI. After making the repair, reposition the harness. 2. Inspect the connector at the mirror actuator. Refer to Outside Rearview Mirror Motor Replacement in SI if necessary. If the connector is loose, remove and reinstall the connector. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 11435 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 11436 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 11437 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 11438 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 11439 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 11440 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions Auxiliary Power Outlet: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Schematic Symbols Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11446 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11447 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11448 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11449 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11450 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11451 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11452 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11453 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11454 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11455 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11456 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11457 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11458 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11459 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11460 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11461 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11462 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11463 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11464 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11465 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11466 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11467 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11468 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11469 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11470 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11471 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11472 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11473 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11474 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11475 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11476 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11477 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11478 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11479 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11480 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11481 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11482 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11483 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11484 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11485 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11486 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11487 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11488 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11489 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11490 Auxiliary Power Outlet: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed with Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11491 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11492 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Connector Test Adapters) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11493 Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Test Lamp) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Fused Jumper Wires) * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage Drop) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Frequency) * Testing Ground and Low Reference Circuits (See: Testing and Inspection/Component Tests and General Diagnostics/Testing Ground and Low Reference Circuits) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fuses) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Circuit Breakers) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fusible Links) Troubleshooting with a Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Testing for a Short to Voltage Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11494 Testing for a Short to Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure tests for a short to voltage in a circuit. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the Digital Multimeter (DMM) to the V (DC) position. 4. Connect the positive lead of the DMM to one end of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. Turn ON the ignition and operate all accessories. 7. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Special Tools J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure). Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents). Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11495 The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the frequency of a signal. Note: Connecting the Digital Multimeter (DMM) to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Set to Hz on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11496 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the Digital Multimeter (DMM). 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the difference in voltage potential between 2 points. 1. Set the Digital Multimeter (DMM) to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11497 Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Backprobe Note: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11498 (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for Continuity Testing for Continuity Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures verify good continuity in a circuit. With a Digital Multimeter (DMM) 1. Set the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Select the MIN MAX function on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11499 Testing for Electrical Intermittents Testing for Electrical Intermittents Special Tools J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. Note: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions). 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11500 visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing for Terminal Fretting Some intermittent conditions can be caused by wire terminal fretting corrosion. Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can pile up enough at the electrical contact spots that the electrical resistance across the connection increases. Movement between the contacting surfaces as small as 10 to 100 microns can cause fretting. To put this in perspective, a sheet of paper is about 100 microns thick, so fretting motion is small and hard to see. Vibration and thermal expansion/contraction are the main sources that create fretting motion. Since vehicles vibrate and can experience large temperature swings, they are a good source for fretting motion. Tin, copper, nickel, and iron surfaces are all susceptible to fretting corrosion. Fretting corrosion can be difficult to see but it looks like small, dark smudges on the terminals contact surface. To correct a fretting condition disconnect the suspect connector and add Nyogel lubricant 760G (dielectric grease) to both sides of the connector terminals. Then reconnect the connector and wipe away any excess lubricant. This will correct the additional terminal contact resistance due to the terminal fretting corrosion. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11501 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Power Distribution Schematics). * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Ground Distribution Schematics). Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Checking Aftermarket Accessories). * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11502 Note: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures test for a short to ground in a circuit. With a Digital Multimeter (DMM) 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohms position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Danger: High voltage circuits should only be tested using a digital multimeter (DMM) and test leads with at least a CAT III rating, such as the J 39200-A Digital Multimeter. Failure to follow the procedures exactly as written may result in serious injury or death. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Digital Multimeter (DMM) Basic Requirements Service information is validated using digital multimeters that meet or exceed the following requirements. Using a multimeter that does not meet these basic requirements may give inaccurate readings which could lead to an incorrect diagnosis. Display and Settings 1. Four digits displayed 2. Voltage, amperage, resistance, frequency, diode test settings, and min-max function 3. Display positive and negative values Voltage 1. Have at least 10 M ohm input impedance Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11503 2. Test a DC voltage range of 0.1-1000 V. 3. Test an AC voltage range of 0.1-1000 V. Amperage 1. Test a DC amperage range of 0.1µA-10 A. 2. Test an AC amperage range of 0.1µA-10 A. Resistance Test a resistance range of 0.1 ohm-40 Mohm and displays infinite for a value greater than 40 M ohm (O.L. (Over-load)) Frequency Test for a frequency range of 0.5 HZ-199 K HZ Diode Test 1. Apply at least 1 mA when performing the diode bias test 2. Display the break over voltage drop (0-3 V) of a forward biased diode 3. Display infinite (O.L. (Over-load)) when a diode is reverse biased Min-Max Readings 1. Can update at a 1 ms sample rate 2. Saves and displays minimum and maximum values Note: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Probe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors). * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the EL-38125-580 GM Approved Terminal Release Tool Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the EL-38125-580 GM Approved Terminal Release Tool Kit , ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the EL-38125-580 GM Approved Terminal Release Tool Kit label on the inside of the EL-38125-580 GM Approved Terminal Release Tool Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11504 Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/EPC Connectors AFL/EPC Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11505 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 3. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11506 View showing depressing of the lever lock release tab. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11507 6. Release the rear lower half of the wiredress cover. 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11508 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11509 Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Bosch Connectors (ECM) Bosch Connectors (ECM) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11510 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. 2. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11511 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-bladed tool to release the locking tabs and remove the dress cover. 4. The terminal positive assurance (TPA) is located in the front of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11512 5. Use a small flat-blade tool to remove TPA from the connector. 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11513 Note: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11514 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11515 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Terminal Replacement Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11516 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11517 5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Position Assurance Locks) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Terminal Position Assurance Locks) * AFL/EPC Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/AFL/EPC Connectors) * Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (BSK))Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (0.64))Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (2.8 JPT))Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (ECM)) * Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Weather Pack))Delphi Connectors (Push To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Push to Seat))Delphi Connectors Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11518 (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Pull to Seat))Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro-Pack 100W))Delphi Connectors (Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro .64))Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (12-Way)) * FCI Connectors (Lever Lock) (See: General Electrical Diagnostic Procedures/Connector Repairs/FCI Connectors (Lever Lock)) * JST Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/JST Connectors) * Kostal Connectors (Glow Plug Control Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Glow Plug Control Module))Kostal Connectors (Transmission) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Transmission)) * Molex Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Molex Connectors) * Sumitomo Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Sumitomo Connectors) * Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (CM 42-Way))Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Sensor))Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (0.25 Cap))Tyco/AMP Connectors (43-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (43-Way))Tyco/AMP Connectors (Door Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Door Module))Tyco/AMP Connectors (102-Way Inline) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (102-Way Inline))Tyco/AMP Connectors (Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Seat))Tyco/AMP Connectors (SIR) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (SIR)) * Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (2-Way))Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (16-Way)) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11519 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11520 * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11521 * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11522 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11523 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11524 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Push to Seat) Delphi Connectors (Push To Seat) Special Tools J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11525 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs). 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Terminated Lead Repair 1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice sleeves depending on the gauge size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Delphi Connectors (Pull to Seat) Delphi Connectors (Pull To Seat) Special Tools Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11526 J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Note: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11527 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. View of a typical Micro 64 connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11528 Depress the lock and pull the lever over and past the lock. View of the connector when released from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11529 View of another type of Micro 64 connector. Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11530 View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11531 Note: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11532 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11533 Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Note: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11534 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11535 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11536 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11537 1. Cut the wire as close to the terminal as possible. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11538 Terminal Replacement Procedure After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Special Tools J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Note: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals). 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12-Way) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11539 Delphi Connectors (12-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11540 4. Release the lower wire dress cover locking tab. 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11541 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11542 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors (Lever Lock) FCI Connectors (Lever Lock) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11543 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. The release tab is located on the top of the wiredress cover. 3. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11544 6. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11545 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11546 1. While depressing the lock, remove the connector from the component. 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11547 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. 4. View of the TPA when removed from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11548 5. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Glow Plug Control Module) Kostal Connectors (Glow Plug Control Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11549 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11550 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11551 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. Note: The front TPA cannot be removed from the connector. Only move it to the preset position. 6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm). 7. Use a small flat-blade tool to completely remove the rear TPA from the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11552 8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Transmission) Kostal Connectors (Transmission) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11553 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11554 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Terminal Replacement Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11555 After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11556 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11557 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11558 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11559 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11560 3. To assemble the connector, reverse the connector disassembly procedure. Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11561 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11562 7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11563 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11564 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11565 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11566 Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11567 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11568 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11569 6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (102-Way Inline) Tyco/AMP Connectors (102-Way Inline) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11570 View of a typical connector in the assembled position. 1. Pull the locking lever to the 90 degree position from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11571 2. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal. 3. Slide the male connector body out away from the guide plates. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11572 Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 4. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. 5. Using terminal release tool J 38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11573 6. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 7. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11574 8. The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool J-38125-11A or equivalent to release the locking tab and slide the connector off the female body. 9. Move the locking lever 180 degrees from the connected position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11575 10. With the locking lever in the 180 degree position the guide plates can be removed from the connector body. Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 11. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11576 12. Using terminal release tool J 38125-216, lift the terminal plate past the terminals and out of the connector body cavity. 13. Terminal plate will bind slightly on each corner. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11577 14. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 15. Using terminal release tool J 38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11578 16. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 17. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11579 18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever. 19. Slide the male connector body back inward toward the guide plates. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11580 20. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly. 21. Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Seat) Tyco/AMP Connectors (Seat) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11581 Removal Procedure 1. Grasp the locking slide lever and pull outward from the end of the connector. 2. As the slide lever is pulled out the mating connector is lifted from the seated position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11582 Note: TPA is keyed and can only be inserted in one direction. 3. Using terminal release tool J 38125-11A or equivalent, push the TPA tabs into the connector body. 4. Pull the TPA from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11583 5. Using terminal release tool J 38125-11A or equivalent, release the connector wire dress cover locking tab. 6. With the lock tab released, lift the connector wire dress cover from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11584 7. Using terminal release tool J 38125-212, press the prongs into the holes each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 8. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11585 9. Using terminal release tool J 38125-556, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (SIR) Tyco/AMP Connectors (SIR) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11586 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11587 3. Using terminal tool J-38125-11A or equivalent, release the wire dress cover locking tabs. 4. Pivot connector wire dress cover while removing from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11588 5. Using terminal tool J-38125-11A or equivalent, remove the TPA by lifting straight off the connector body. 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals Repairing Connector Terminals Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11589 Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gauge size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11590 2. Disconnect the connector from the component. 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11591 4. Relieve the tension on the nose piece retainers by inserting J 38125-12A into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. 5. Once the nose piece retainers are relaxed, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11592 6. On the opposite side of the nose piece, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11593 8. Insert the J 38125-553 tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11594 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. If the TPA is removed, be sure to reinstall it before reconnecting the connector. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11595 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Special Tools Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11596 J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Note: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11597 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11598 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11599 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11600 1. While depressing the lock, pull the two connector halves apart. Note: The TPA is fragile and may break if not done carefully. 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. 3. View of the male half of the connector with female terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11601 4. View of the female half of the connector with male terminals. 5. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. View of the female half of the connector with male terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11602 7. View of the male half of the connector with female terminals. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11603 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are a one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine if the element in the fuse is broken (2). If not broken (1), also check for continuity using a Digital Multimeter (DMM) or a continuity tester. If the element is broken or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a Digital Multimeter (DMM) at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gauge size. Repairing a Fusible Link Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11604 Flat Wire Repairs The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Special Tools J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool * J 38125-5 Ultra Torch Special Tool The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Note: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation). GMLAN Connector Terminal Repair Note: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) for the appropriate connector repair procedure. GMLAN Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11605 Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11606 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Special Tools J-38125 Terminal Repair Kit Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11607 repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs High Temperature Wiring Repairs Special Tools J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gauge size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11608 splice. Note: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11609 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11610 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the wire insulation has been chafed, or broken, enough to show the conductive portion of the wire, and the wire is not damaged, determine the length of insulation that needs to be repaired. If the repair is less than 280 mm (11 in), cut the wire within the damaged area. Then slide the appropriate heat shrink tubing (listed below) over the wire, and repair the wire by splicing the wires together. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Once the wire is spliced together slide heat shrink tubing over the damaged area and apply heat to seal the repaired wire. If the wire is damaged, or the damaged area is larger than 280 mm (11 in), then replace the damaged wire by splicing in a new section of wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11611 SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Special Tools J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11612 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11613 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11614 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Special Tools J-38125 Terminal Repair Kit Note: Use only DuraSeal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use DuraSeal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use DuraSeal splice sleeves where there are special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11615 * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11616 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11617 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the instructions for Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Staggering the splices by 65 mm (2.5 in) is recommended. Note: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product AL-36FR to replace the damaged mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Flat Wire Repairs) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/GMLAN Wiring Repairs) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Heated Oxygen Sensor Wiring Repairs) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves) * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Twisted or Shielded Cable) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Inline Harness Diodes) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/SIR/SRS Wiring Repairs) US English/Metric Conversion US English/Metric Conversion Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11618 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11619 Testing Ground and Low Reference Circuits Testing Ground and Low Reference Circuits Because a test lamp can light with up to 200 ohm in a ground or low reference circuit they are not recommended to be used for this type of test. A low impedance test lamp can light and indicate the circuit is good when there is as much as 20-30 ohm present, while a high impedance test lamp can light with up to 200 ohm present in the circuit. This is why the Digital Multi-Meter (DMM) is used when validating a ground or low reference circuit continuity. When using the DMM there are many vehicle conditions that can affect the ground and low reference continuity testing. If these conditions are not met, a ground or low reference circuit test can fail on a good circuit. This may cause longer diagnosis time and incorrect component replacement. Any current flow through a ground or low reference circuit, while being tested, will skew the DMM continuity reading, or display a reading higher than when there is no current flowing. Performing a ground or low reference circuit continuity test, in reference to the vehicles battery negative terminal, will have the highest risk of failing a good ground or low reference circuit test than any other ground reference point. The best ground test points would be a control module housing (if the control modules housing is metal and grounded), door jamb striker (if attached to metal), under dash metal frame work, engine block, or body ground studs (other than where the negative battery cable is attached). A typical DMM ground or low reference circuit continuity reading can be as high as 100 ohm with the ignition ON, and drop to 15-25 ohm after the ignition is turned OFF. The reading will drop below 10 ohm after 30-40 seconds, then below 5 ohm after 60 seconds. Once the vehicle completely goes to sleep (generally 3-10 minutes) the reading will drop below 0.3 ohm. The following list of conditions may need to be met to ensure a valid continuity reading on a ground or low reference circuit: * Ignition OFF * Key out of the ignition switch (when not equipped with keyless entry and remote start) * Retained Accessory Power (RAP) OFF (open and close the driver door after ignition OFF) * Battery charger set at a 2 A or less charge rate * Scan tool not communicating with any vehicle control module (in some cases it may need to be disconnected from the DLC) * All entry doors closed * Headlamps OFF (auto headlamps disabled) * Any delay lighting OFF * HVAC after blow OFF * Any accessory that can work when the ignition is OFF * Wait up to 60 seconds (after all other listed conditions are met) Activating the DOOR LOCK function with a key fob can greatly reduce the time to achieve a valid ground or low reference continuity test result. Terminal Removal Terminal Removal Special Tools * EL-38125-580 - Terminal Release Tool Kit * EL-35616 - Connector Test Adapter Kit For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repair procedures. 1. Find the appropriate connector end view within the connector end view section. The connector end view has the following information: Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11620 * Diagnostic probe tool * Terminal release tool * Terminal/terminated lead part numbers Note: Not using the proper test kit probe may cause damage to the terminal(s) that are probed. 2. Determine if a terminal is damaged. * Locate the diagnostic probe tool from the connector end view. The connector end view describes the color and part number to help the technician find and use the correct tool. * Connect the probe tool to the Digital Multimeter. * Insert the probe tool into the cavity and follow the procedures from the Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter). 3. Disconnect the connector body to perform the repair. 4. Use the following procedure to remove the terminal from the connector body. Note: Several procedures for specific connector bodies are called out in the Wiring Repairs section. * The terminal position assurance (TPA) and connector position assurance (CPA) should be removed before releasing the terminal for the connector body. * Look at the connector end view to locate the cavity of the damaged terminal and find the proper terminal release tool from the terminal release tool kit. Note: Using the incorrect terminal release tool can damage the connector body. * Insert the terminal release tool into the cavity. Note: Some terminals have a lever that must be disengaged before the terminal can be released. 5. Gently pull the wire out of the back of the connector. 6. Repair the terminal by following the Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) procedure. 7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminated Lead Repair Terminated Lead Repair Special Tools * J-38125-8 - Splice Sleeve Crimp Tool Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11621 * J-38125-5 - Ultra Torch For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) procedures. Terminated leads are terminals that are crimped onto wires. The terminated lead can be used throughout the vehicle since it is designed for temperatures up to 150°C. The length of the wire is 450 mm. The DuraSeal splice sleeve has the following 2 critical features: * A special heat shrink tubing that environmentally seals the splice. The shrink tubing contains a sealing adhesive inside the shrink tubing. * A cross hatched (knurled) core crimp that provides the necessary contact integrity for sensitive low energy circuits. 1. Use the connector end view to identify the correct terminated lead. 2. The terminated lead package should include a DuraSeal splice sleeve. If not, use the chart to identify the correct part. 3. Open the harness by removing any tape: Use a sewing seam ripper, or a comparable tool, to cut open the harness, to avoid wire insulation damage. 4. Depending on how many terminals need repairs, cut the terminal and wire back at least 40 mm. Try to keep the harness wire length the same. If more than one terminated lead is required, stagger the lengths by 40 mm. This helps reduce the bundle size of the wire harness. 5. Use the EL-38125-10 - tool in order to position the DuraSeal splice sleeve in the proper color nest of the splice sleeve crimp tool. The crimp tool has four nests, one for each color. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11622 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the J-38125-5 - ultra torch , apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11623 Auxiliary Power Outlet: Connector Views Component Connector End Views Accessory Power Outlet - Center Console (D07) Accessory Power Outlet - Center Console Compartment (D07) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11624 Accessory Power Outlet - Center Seat (AZ3) Accessory Power Outlet - I/P 1 Accessory Power Outlet - I/P 2 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11625 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 11626 Auxiliary Power Outlet: Electrical Diagrams Cigar Lighter/Power Outlet Schematics Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 11627 Auxiliary Power Outlet: Description and Operation Power Outlets Description and Operation 12 Volt Power Outlet Receptacle Description and Operation The accessory power receptacles are supplied battery voltage at all times. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Testing and Inspection > Symptoms - Power Outlets Auxiliary Power Outlet: Testing and Inspection Symptoms - Power Outlets Symptoms - Power Outlets Visual/Physical Inspection * Inspect for aftermarket devices which can affect the operation of the power outlets. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Checking Aftermarket Accessories) * Inspect the accessible system components or the visible system components for obvious damage or for obvious conditions which can cause the symptom. Intermittent Electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) Symptom List Refer to Power Outlet Receptacle Malfunction (See: Power Outlet Receptacle Inoperative (120 VAC)) in order to diagnose the system. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Testing and Inspection > Symptoms - Power Outlets > Page 11630 Auxiliary Power Outlet: Testing and Inspection Power Outlet Receptacle Inoperative (120 VAC) Power Outlet Receptacle Malfunction Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions )provides an overview of each diagnostic category. Diagnostic Fault Information Circuit/System Description The accessory power receptacles are supplied B+ all the time. Reference Information Schematic Reference Cigar Lighter/Power Outlet Schematics (See: Diagrams/Electrical Diagrams) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views) Description and Operation Power Outlets Description and Operation (See: Description and Operation) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) Circuit/System Testing 1. Ignition OFF, disconnect the harness connector at the appropriate X80 accessory power receptacle. 2. Test for less than 5 ohm between the ground circuit terminal C and ground. ‹› If greater than the specified range, test the ground circuit for an open/high resistance. 3. Verify that a test lamp illuminate between the B+ circuit terminal A and ground. ‹› If the test lamp does not illuminate, test the B+ circuit for a short to ground or an open/high resistance. 4. If all circuits test normal, test or replace the X80 accessory power receptacle. Repair Instructions Perform the Diagnostic Repair Verification (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Testing and Inspection > Symptoms - Power Outlets > Page 11631 Cigar Lighter Receptacle or 12-Volt Accessory Power Receptacle Replacement (See: Service and Repair) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Testing and Inspection > Page 11632 Auxiliary Power Outlet: Service and Repair Cigar Lighter Receptacle or 12-Volt Accessory Power Receptacle Replacement Tools Required J 42059 Cigar Lighter Socket Remover Removal Procedure 1. Remove the auxiliary power outlet fuse from the fuse block. 2. Remove the receptacle: 1. Look into the receptacle. There are two 3 mm (0.11 in) tab windows 12 mm (0.47 in) from the front of the receptacle. The J 42059 pushes the plastic latches from these tab windows and the receptacle can be pulled straight out. 2. Place one side of the "T" portion of the J 42059 into the tab window. The J 42059 will not fit straight into the receptacle. Angle the J 42059 slightly for insertion into the receptacle. 3. Insert the other side of the "T" into the opposite tab window. You must move the J 42059 handle toward horizontal to engage the other tab window. 4. Use the J 42059 to pull the receptacle straight out. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Testing and Inspection > Page 11633 3. If J 42059 tool fails to release the lighter socket from the retainer, perform the following alternate method: 1. Insert a small grinding tool with a cutoff wheel into the socket. 2. Remove the plastic latches in the 3 mm (0.11 in) square windows. 3. Use the J 42059 as directed above to remove the socket. Installation Procedure 1. Route the connector through the retainer. Align the accessory power receptacle retainer to the slot in the opening. 2. Install the retainer by pressing into place fully seated. 3. Connect the electrical connector to the receptacle. 4. Align the tabs on the receptacle to the slots in the retainer. Install the accessory power receptacle by pressing into place until fully seated. 5. Install the accessory power receptacle fuse. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Testing and Inspection > Page 11634 Auxiliary Power Outlet: Tools and Equipment Special Tools Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 07-08-46-002D > Jul > 09 > Audio System - Noise When Using OnStar(R) Electronic Noise Suppressor: Customer Interest Audio System - Noise When Using OnStar(R) TECHNICAL Bulletin No.: 07-08-46-002D Date: July 29, 2009 Subject: Audio Whine Noise from Radio Speakers When Using OnStar(R) (Install Noise Suppression Filter) Models: 2007-2010 GM Passenger Cars and Trucks (Including Saturn) 2007-2010 HUMMER H2, H3 2007-2009 Saab 9-7X Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update the Warranty Information. Please discard Corporate Bulletin Number 07-08-46-002C (Section 08 - Body and Accessories). Condition Some customers may comment on an audio whine coming from the radio speakers when using the OnStar(R) system. The amplitude and frequency of the whine will change with an increase or decrease in engine speed. Cause This condition may be caused by electrical noise on the OnStar(R) Vehicle Communication Interface Module (VCIM) battery feed wire being passed to the microphone output pins at the radio. Correction Technicians are to install a noise suppression filter, P/N 1224205, into the OnStar(R) battery voltage circuit, a few centimeters (inches) from the VCIM. The filter package has three attached wires - a single yellow wire at one end with a yellow wire and a black wire at the other. Install the single yellow wire side into the battery voltage circuit towards the VCIM. Install the remaining single yellow wire into the battery voltage circuit toward the fuse and the black wire to ground. Important The noise suppression filter is polarity sensitive. The filter is designed to be most effective when the end with the capacitor ground is connected towards the source of the electrical noise. Install the filter in this polarity first. If the noise level is still not satisfactory, try disconnecting the capacitor ground. In some cases, if the first installation does not correct the noise, try reversing the filter polarity (removing the filter, turning it end for end and then reinstalling it) and grounding the capacitor lead. Parts Information Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table above. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 07-08-46-002D > Jul > 09 > Audio System - Noise When Using OnStar(R) > Page 11643 Warranty Information (Saab U.S. Models) Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 07-08-46-002D > Jul > 09 > Audio System - Noise When Using OnStar(R) Electronic Noise Suppressor: All Technical Service Bulletins Audio System - Noise When Using OnStar(R) TECHNICAL Bulletin No.: 07-08-46-002D Date: July 29, 2009 Subject: Audio Whine Noise from Radio Speakers When Using OnStar(R) (Install Noise Suppression Filter) Models: 2007-2010 GM Passenger Cars and Trucks (Including Saturn) 2007-2010 HUMMER H2, H3 2007-2009 Saab 9-7X Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update the Warranty Information. Please discard Corporate Bulletin Number 07-08-46-002C (Section 08 - Body and Accessories). Condition Some customers may comment on an audio whine coming from the radio speakers when using the OnStar(R) system. The amplitude and frequency of the whine will change with an increase or decrease in engine speed. Cause This condition may be caused by electrical noise on the OnStar(R) Vehicle Communication Interface Module (VCIM) battery feed wire being passed to the microphone output pins at the radio. Correction Technicians are to install a noise suppression filter, P/N 1224205, into the OnStar(R) battery voltage circuit, a few centimeters (inches) from the VCIM. The filter package has three attached wires - a single yellow wire at one end with a yellow wire and a black wire at the other. Install the single yellow wire side into the battery voltage circuit towards the VCIM. Install the remaining single yellow wire into the battery voltage circuit toward the fuse and the black wire to ground. Important The noise suppression filter is polarity sensitive. The filter is designed to be most effective when the end with the capacitor ground is connected towards the source of the electrical noise. Install the filter in this polarity first. If the noise level is still not satisfactory, try disconnecting the capacitor ground. In some cases, if the first installation does not correct the noise, try reversing the filter polarity (removing the filter, turning it end for end and then reinstalling it) and grounding the capacitor lead. Parts Information Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table above. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 07-08-46-002D > Jul > 09 > Audio System - Noise When Using OnStar(R) > Page 11649 Warranty Information (Saab U.S. Models) Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Center Instrument Panel Fuse Block - Owners Manual Fuse: Locations Center Instrument Panel Fuse Block - Owners Manual CENTER INSTRUMENT PANEL FUSE BLOCK The center instrument panel fuse block is located underneath the instrument panel, to the left of the steering column. TOP VIEW HARNESS CONNECTOR - USAGE BODY 2 ............................................................................................................................................... ................................... Body Harness Connector 2 BODY 1 ............................................................... ................................................................................................................... Body Harness Connector 1 BODY 3 ............................................................................................................................................ ...................................... Body Harness Connector 3 HEADLINER 3 .................................................. .............................................................................................................. Headliner Harness Connector 3 HEADLINER 2 ................................................................................................................ ................................................ Headliner Harness Connector 2 HEADLINER 1 ................................. ............................................................................................................................... Headliner Harness Connector 1 SEO/UPFITTER .......................................................................................................................... Special Equipment Option Upfitter Harness Connector CIRCUIT BREAKER - USAGE CB1 ......................................................................................................................................................... Passenger Side Power Window Circuit Breaker CB2 ......................................................................... .......................................................................................................... Passenger Seat Circuit Breaker CB3 ...................................................................................................................................................... .................................. Driver Seat Circuit Breaker CB4 ....................................................................... .......................................................................................................................... Rear Sliding Window Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Center Instrument Panel Fuse Block - Owners Manual > Page 11654 Fuse: Locations Instrument Panel Fuse Block - Owners Manual INSTRUMENT PANEL FUSE BLOCK The instrument panel fuse block access door is located on the driver side edge of the instrument panel. Pull off the cover to access the fuse block. The vehicle may not use all of the fuses shown. FUSES ................................................................................................................................................. ..................................................................... USAGE Fuse 1 .................................................................................................................................................. .............................................................. Rear Seats Fuse 2 ................................................................ .................................................................................................................. Rear Accessory Power Outlet Fuse 3 ....................................................................................................................................... ................................... Steering Wheel Controls Backlight Fuse 4 ...................................................... .......................................................................................................................................... Driver Door Module Fuse 5 ..................................................................................................................................... ............................... Dome Lamps, Driver Side Turn Signal Fuse 6 .................................................... ...................................................................................................................... Driver Side Turn Signal, Stoplamp Fuse 7 ................................................................................................................................. .............................................. Instrument Panel Back Lighting Fuse 8 ................................................ .................................................................................................................... Passenger Side Turn Signal, Stoplamp Fuse 9 ..................................................................................................................... ............................................. Passenger Door Module, Driver Unlock Fuse 10 .................................. ................................................................................................................................. Power Door Lock 2 (Unlock Feature) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Center Instrument Panel Fuse Block - Owners Manual > Page 11655 Fuse 11 ................................................................................................................................................ ....................... Power Door Lock 2 (Lock Feature) Fuse 12 ......................................................................................................................................................... Stoplamps, Center-High Mounted Stoplamp Fuse 13 ......................................................................... .................................................................................................................. Rear Climate Controls Fuse 14 ................................................................................................................................................ ......................................................... Power Mirror Fuse 15 ................................................................ ............................................................................................................... Body Control Module (BCM) Fuse 16 ................................................................................................................................................ ....................................... Accessory Power Outlets Fuse 17 .............................................................. ......................................................................................................................................... Interior Lamps Fuse 18 .................................................................................................................................... ............................... Power Door Lock 1 (Unlock Feature) Fuse 19 .................................................... .................................................................................................................................... Rear Seat Entertainment Fuse 20 ..................................................................................................................................................... Ultrasonic Rear Parking Assist, Power Liftgate Fuse 21 ..................................................................... .................................................................................................. Power Door Lock 1 (Lock Feature) Fuse 22 ................................................................................................................................................ ........................... Driver Information Center (DIC) Fuse 23 ................................................................. ............................................................................................................................................ Rear Wiper Fuse 24 ..................................................................................................................................... ..................................................................... Cooled Seats Fuse 25 .............................................................................................................................................. Driver Seat Module, Remote Keyless Entry System Fuse 26 ........................................................................................................................................................... Driver Power Door Lock (Unlock Feature) CIRCUIT BREAKER ............................................................................................................................ ................................................................ USAGE LT DR .......................................................................................................................................................... Driver Side Power Window Circuit Breaker HARNESS CONNECTOR ................................................................................................................... ................................................................. USAGE LT DR .................................................................................................................................................. .......................... Driver Door Harness Connection BODY .................................................................. ................................................................................................................................ Harness Connector BODY ................................................................................................................................. ................................................................. Harness Connector Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood Fuse: Application and ID Fuse Block - Underhood Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11658 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11659 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11660 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11661 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11662 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11663 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11664 Fuse Block - Underhood Top View - Diesel Fuse Block - Underhood Top View - Gas Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11665 Fuse Block - Underhood Bottom View Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11666 Fuse Block - Underhood X1 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11667 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11668 Fuse Block - Underhood X2 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11669 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11670 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11671 Fuse Block - Underhood X3 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11672 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11673 Fuse Block - Underhood X4 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11674 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11675 Fuse Block - Underhood X5 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11676 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11677 Fuse Block - Underhood X6 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11678 Fuse Block - Underhood X7 (except TP2) Fuse Block - Underhood X7 (TP2) Fuse Block - Underhood X8 (except JL1) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11679 Fuse Block - Underhood X8 (JL1) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11680 Fuse: Application and ID Fuse Block - I/P Electrical Center Identification Views Fuse Block - I/P Label Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11681 Fuse Block - I/P Top View Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11682 Fuse Block - I/P Bottom View Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11683 Fuse Block - I/P X1 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11684 Fuse Block - I/P X2 (except MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11685 Fuse Block - I/P X3 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11686 Fuse Block - I/P X4 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11687 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11688 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11689 Fuse: Application and ID Fuse Block - Mobile Radio Electrical Center Identification Views Fuse Block - Mobile Radio, Top View (9L4) Fuse Block - Mobile Radio (9L4) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11690 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11691 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11692 Fuse: Application and ID Fuse Holder Electrical Center Identification Views Fuse Block - Auxiliary, Fuse Holder (HP2) Fuse Block - Auxiliary, Fuse Holder (HP2) Fuse Holder X1 (Gas except 9L4) Fuse Holder X1 (Diesel or Gas with 9L4) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11693 Fuse Holder X2 (Gas with TP2) Fuse Holder X2 (Diesel or Gas except LU3) Fuse Holder X2 (LU3) Fuse Holder X2 (Gas except LU3) Fuse Holder X2 (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11694 Fuse Holder X3 (9L4) Fuse Holder X3 (Diesel) Fuse Holder X4 (TP2) Fuse Holder X4 (Diesel) Fuse Holder X4 (Diesel with K76 or YF2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11695 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11696 Fuse: Application and ID Junction Block Electrical Center Identification Views Junction Block - Left I/P, Label Junction Block - Left I/P, Top View Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11697 Junction Block - Left I/P, Bottom View Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11698 Junction Block - Left I/P X1 (except MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11699 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11700 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11701 Junction Block - Left I/P X2 (except MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11702 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11703 Junction Block - Left I/P X3 (except MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11704 Junction Block - Left I/P X4 (except MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11705 Junction Block - Left I/P X5 (SPO Alarm or SPO Heated Seats) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11706 Junction Block - Left I/P X7 (JF4) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11707 Junction Block - Left I/P X8 (except MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11708 Junction Block - Left I/P X9 (except MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11709 Junction Block - Left I/P X10 (except MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11710 Junction Block - Left I/P X11 (except MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11711 Junction Block - Left I/P X12 (except MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11712 Junction Block - Left I/P X13 (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11713 Junction Block - Left I/P X14 (5X7, 5Y0, 9L4, SPO DVD or SPO Heated Seats) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11714 Junction Block - Right I/P, Top View Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11715 Junction Block - Right I/P (Wire Entry) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11716 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11717 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11718 Junction Block - Right I/P X2 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11719 Junction Block - Right I/P X3 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11720 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11721 Junction Block - Right I/P X4 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11722 Junction Block - Right I/P X5 Junction Block - Right I/P X6 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11723 Junction Block - Rear Lamps Junction Block - Rear Lamps X1 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11724 Junction Block - Rear Lamps X2 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11725 Junction Block - Rear Lamps X3 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuse Block - Underhood > Page 11726 Junction Block - Rear Lamps X4 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations Fuse Block: Component Locations Fuse Block - I/P Electrical Center Identification Views Fuse Block - I/P Label Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 11731 Fuse Block - I/P Top View Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 11732 Fuse Block - I/P Bottom View Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 11733 Fuse Block - I/P X1 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 11734 Fuse Block - I/P X2 (except MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 11735 Fuse Block - I/P X3 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 11736 Fuse Block - I/P X4 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 11737 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 11738 Fuse Block - Underhood Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 11739 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 11740 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 11741 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 11742 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 11743 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 11744 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 11745 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 11746 Fuse Block - Underhood Top View - Diesel Fuse Block - Underhood Top View - Gas Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 11747 Fuse Block - Underhood Bottom View Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 11748 Fuse Block - Underhood X1 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 11749 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 11750 Fuse Block - Underhood X2 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 11751 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 11752 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 11753 Fuse Block - Underhood X3 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 11754 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 11755 Fuse Block - Underhood X4 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 11756 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 11757 Fuse Block - Underhood X5 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 11758 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 11759 Fuse Block - Underhood X6 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 11760 Fuse Block - Underhood X7 (except TP2) Fuse Block - Underhood X7 (TP2) Fuse Block - Underhood X8 (except JL1) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 11761 Fuse Block - Underhood X8 (JL1) Fuse Block - Mobile Radio Electrical Center Identification Views Fuse Block - Mobile Radio, Top View (9L4) Fuse Block - Mobile Radio (9L4) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 11762 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 11763 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 11764 Fuse Block: Connector Locations Harness Routing Views Chassis Harness Routing (Except LY6/LMM/HP2) 1 - X300 2 - X408 (UD7) 3 - G401 4 - J423 (except LU3) 5 - J331 6 - Fuse Block - Underhood X3 7 - X115 8 - X102 (JL1) 9 - J338 (except LU3/LMG) 10 - J300 11 - G300 Chassis Harness Routing (LY6/LMM except 31 Series) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 11765 1 - X300 2 - X408 (UD7) 3 - Trailer Connector (UY7) 4 - J411 (JL1) 5 - G401 6 - J331 7 - Fuse Block - Underhood X3 8 - X115 9 - X102 (JL1) 10 - J300 11 - G300 Chassis Harness - Front Engine Compartment (31 Series) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 11766 1 - X102 (JL1) 2 - Fuel Pump Relay - Secondary (LY6 without NQZ) 3 - Fuse Block - Underhood 4 X126 Driver Door Harness Routing Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 11767 1 - Door Frame 2 - Fuse Block - I/P X4 3 - J502 (YE9 without AN3) 4 - X500 (YE9 without AN3/DL3) 5 - X502 (ASF without YE9 or with AN3) Engine Harness Routing - Left Side (4.3L) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 11768 1 - Throttle Body 2 - G107 3 - Transmission 4 - X300 5 - X109 6 - X110 (NQG/NQH) 7 - Fuse Block - Underhood X2 Engine Harness Routing - Left Front Side (4.8L/5.3L/6.0L/6.2L except LFA/HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 11769 1 - Air Intake Duct 2 - X111 3 - Fuse Block - Underhood X2 4 - X109 5 - X110 (NQF/NQG/NQH) 6 Engine Control Module (ECM) X2 7 - Engine Control Module (ECM) X1 8 - G102 9 - J105 Engine Chassis Harness Routing - Top Front (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 11770 1 - Battery - Right 2 - Fuse Holder 3 - X127 4 - X108 5 - X107 6 - X123 (PTO) 7 - Fuse Block Underhood 8 - X109 9 - Battery - Left 10 - Engine Control Module (ECM) 11 - Transmission Control Module (TCM) I/P Harness Routing - Engine Compartment (Except HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 11771 1 - G110 (XA7) 2 - J113 (NQH) 3 - Fuse Block - Underhood X5 4 - Fuse Block - Underhood X4 5 Left Front Fender 6 - X103 7 - X109 8 - X115 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Schematic Symbols Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11774 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11775 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11776 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11777 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11778 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11779 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11780 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11781 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11782 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11783 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11784 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11785 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11786 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11787 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11788 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11789 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11790 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11791 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11792 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11793 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11794 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11795 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11796 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11797 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11798 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11799 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11800 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11801 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11802 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11803 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11804 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11805 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11806 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11807 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11808 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11809 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11810 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11811 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11812 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11813 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11814 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11815 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11816 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11817 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11818 Fuse Block: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed with Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11819 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11820 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Connector Test Adapters) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11821 Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Test Lamp) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Fused Jumper Wires) * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage Drop) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Frequency) * Testing Ground and Low Reference Circuits (See: Testing and Inspection/Component Tests and General Diagnostics/Testing Ground and Low Reference Circuits) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fuses) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Circuit Breakers) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fusible Links) Troubleshooting with a Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Testing for a Short to Voltage Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11822 Testing for a Short to Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure tests for a short to voltage in a circuit. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the Digital Multimeter (DMM) to the V (DC) position. 4. Connect the positive lead of the DMM to one end of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. Turn ON the ignition and operate all accessories. 7. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Special Tools J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure). Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents). Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11823 The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the frequency of a signal. Note: Connecting the Digital Multimeter (DMM) to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Set to Hz on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11824 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the Digital Multimeter (DMM). 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the difference in voltage potential between 2 points. 1. Set the Digital Multimeter (DMM) to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11825 Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Backprobe Note: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11826 (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for Continuity Testing for Continuity Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures verify good continuity in a circuit. With a Digital Multimeter (DMM) 1. Set the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Select the MIN MAX function on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11827 Testing for Electrical Intermittents Testing for Electrical Intermittents Special Tools J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. Note: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions). 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11828 visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing for Terminal Fretting Some intermittent conditions can be caused by wire terminal fretting corrosion. Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can pile up enough at the electrical contact spots that the electrical resistance across the connection increases. Movement between the contacting surfaces as small as 10 to 100 microns can cause fretting. To put this in perspective, a sheet of paper is about 100 microns thick, so fretting motion is small and hard to see. Vibration and thermal expansion/contraction are the main sources that create fretting motion. Since vehicles vibrate and can experience large temperature swings, they are a good source for fretting motion. Tin, copper, nickel, and iron surfaces are all susceptible to fretting corrosion. Fretting corrosion can be difficult to see but it looks like small, dark smudges on the terminals contact surface. To correct a fretting condition disconnect the suspect connector and add Nyogel lubricant 760G (dielectric grease) to both sides of the connector terminals. Then reconnect the connector and wipe away any excess lubricant. This will correct the additional terminal contact resistance due to the terminal fretting corrosion. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11829 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Power Distribution Schematics). * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Ground Distribution Schematics). Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Checking Aftermarket Accessories). * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11830 Note: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures test for a short to ground in a circuit. With a Digital Multimeter (DMM) 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohms position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Danger: High voltage circuits should only be tested using a digital multimeter (DMM) and test leads with at least a CAT III rating, such as the J 39200-A Digital Multimeter. Failure to follow the procedures exactly as written may result in serious injury or death. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Digital Multimeter (DMM) Basic Requirements Service information is validated using digital multimeters that meet or exceed the following requirements. Using a multimeter that does not meet these basic requirements may give inaccurate readings which could lead to an incorrect diagnosis. Display and Settings 1. Four digits displayed 2. Voltage, amperage, resistance, frequency, diode test settings, and min-max function 3. Display positive and negative values Voltage 1. Have at least 10 M ohm input impedance Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11831 2. Test a DC voltage range of 0.1-1000 V. 3. Test an AC voltage range of 0.1-1000 V. Amperage 1. Test a DC amperage range of 0.1µA-10 A. 2. Test an AC amperage range of 0.1µA-10 A. Resistance Test a resistance range of 0.1 ohm-40 Mohm and displays infinite for a value greater than 40 M ohm (O.L. (Over-load)) Frequency Test for a frequency range of 0.5 HZ-199 K HZ Diode Test 1. Apply at least 1 mA when performing the diode bias test 2. Display the break over voltage drop (0-3 V) of a forward biased diode 3. Display infinite (O.L. (Over-load)) when a diode is reverse biased Min-Max Readings 1. Can update at a 1 ms sample rate 2. Saves and displays minimum and maximum values Note: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Probe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors). * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the EL-38125-580 GM Approved Terminal Release Tool Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the EL-38125-580 GM Approved Terminal Release Tool Kit , ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the EL-38125-580 GM Approved Terminal Release Tool Kit label on the inside of the EL-38125-580 GM Approved Terminal Release Tool Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11832 Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/EPC Connectors AFL/EPC Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11833 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 3. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11834 View showing depressing of the lever lock release tab. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11835 6. Release the rear lower half of the wiredress cover. 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11836 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11837 Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Bosch Connectors (ECM) Bosch Connectors (ECM) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11838 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. 2. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11839 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-bladed tool to release the locking tabs and remove the dress cover. 4. The terminal positive assurance (TPA) is located in the front of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11840 5. Use a small flat-blade tool to remove TPA from the connector. 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11841 Note: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11842 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11843 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Terminal Replacement Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11844 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11845 5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Position Assurance Locks) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Terminal Position Assurance Locks) * AFL/EPC Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/AFL/EPC Connectors) * Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (BSK))Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (0.64))Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (2.8 JPT))Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (ECM)) * Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Weather Pack))Delphi Connectors (Push To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Push to Seat))Delphi Connectors Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11846 (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Pull to Seat))Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro-Pack 100W))Delphi Connectors (Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro .64))Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (12-Way)) * FCI Connectors (Lever Lock) (See: General Electrical Diagnostic Procedures/Connector Repairs/FCI Connectors (Lever Lock)) * JST Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/JST Connectors) * Kostal Connectors (Glow Plug Control Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Glow Plug Control Module))Kostal Connectors (Transmission) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Transmission)) * Molex Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Molex Connectors) * Sumitomo Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Sumitomo Connectors) * Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (CM 42-Way))Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Sensor))Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (0.25 Cap))Tyco/AMP Connectors (43-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (43-Way))Tyco/AMP Connectors (Door Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Door Module))Tyco/AMP Connectors (102-Way Inline) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (102-Way Inline))Tyco/AMP Connectors (Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Seat))Tyco/AMP Connectors (SIR) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (SIR)) * Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (2-Way))Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (16-Way)) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11847 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11848 * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11849 * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11850 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11851 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11852 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Push to Seat) Delphi Connectors (Push To Seat) Special Tools J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11853 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs). 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Terminated Lead Repair 1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice sleeves depending on the gauge size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Delphi Connectors (Pull to Seat) Delphi Connectors (Pull To Seat) Special Tools Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11854 J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Note: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11855 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. View of a typical Micro 64 connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11856 Depress the lock and pull the lever over and past the lock. View of the connector when released from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11857 View of another type of Micro 64 connector. Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11858 View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11859 Note: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11860 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11861 Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Note: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11862 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11863 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11864 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11865 1. Cut the wire as close to the terminal as possible. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11866 Terminal Replacement Procedure After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Special Tools J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Note: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals). 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12-Way) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11867 Delphi Connectors (12-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11868 4. Release the lower wire dress cover locking tab. 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11869 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11870 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors (Lever Lock) FCI Connectors (Lever Lock) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11871 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. The release tab is located on the top of the wiredress cover. 3. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11872 6. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11873 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11874 1. While depressing the lock, remove the connector from the component. 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11875 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. 4. View of the TPA when removed from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11876 5. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Glow Plug Control Module) Kostal Connectors (Glow Plug Control Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11877 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11878 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11879 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. Note: The front TPA cannot be removed from the connector. Only move it to the preset position. 6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm). 7. Use a small flat-blade tool to completely remove the rear TPA from the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11880 8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Transmission) Kostal Connectors (Transmission) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11881 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11882 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Terminal Replacement Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11883 After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11884 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11885 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11886 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11887 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11888 3. To assemble the connector, reverse the connector disassembly procedure. Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11889 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11890 7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11891 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11892 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11893 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11894 Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11895 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11896 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11897 6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (102-Way Inline) Tyco/AMP Connectors (102-Way Inline) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11898 View of a typical connector in the assembled position. 1. Pull the locking lever to the 90 degree position from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11899 2. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal. 3. Slide the male connector body out away from the guide plates. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11900 Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 4. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. 5. Using terminal release tool J 38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11901 6. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 7. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11902 8. The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool J-38125-11A or equivalent to release the locking tab and slide the connector off the female body. 9. Move the locking lever 180 degrees from the connected position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11903 10. With the locking lever in the 180 degree position the guide plates can be removed from the connector body. Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 11. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11904 12. Using terminal release tool J 38125-216, lift the terminal plate past the terminals and out of the connector body cavity. 13. Terminal plate will bind slightly on each corner. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11905 14. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 15. Using terminal release tool J 38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11906 16. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 17. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11907 18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever. 19. Slide the male connector body back inward toward the guide plates. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11908 20. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly. 21. Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Seat) Tyco/AMP Connectors (Seat) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11909 Removal Procedure 1. Grasp the locking slide lever and pull outward from the end of the connector. 2. As the slide lever is pulled out the mating connector is lifted from the seated position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11910 Note: TPA is keyed and can only be inserted in one direction. 3. Using terminal release tool J 38125-11A or equivalent, push the TPA tabs into the connector body. 4. Pull the TPA from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11911 5. Using terminal release tool J 38125-11A or equivalent, release the connector wire dress cover locking tab. 6. With the lock tab released, lift the connector wire dress cover from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11912 7. Using terminal release tool J 38125-212, press the prongs into the holes each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 8. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11913 9. Using terminal release tool J 38125-556, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (SIR) Tyco/AMP Connectors (SIR) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11914 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11915 3. Using terminal tool J-38125-11A or equivalent, release the wire dress cover locking tabs. 4. Pivot connector wire dress cover while removing from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11916 5. Using terminal tool J-38125-11A or equivalent, remove the TPA by lifting straight off the connector body. 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals Repairing Connector Terminals Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11917 Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gauge size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11918 2. Disconnect the connector from the component. 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11919 4. Relieve the tension on the nose piece retainers by inserting J 38125-12A into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. 5. Once the nose piece retainers are relaxed, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11920 6. On the opposite side of the nose piece, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11921 8. Insert the J 38125-553 tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11922 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. If the TPA is removed, be sure to reinstall it before reconnecting the connector. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11923 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Special Tools Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11924 J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Note: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11925 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11926 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11927 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11928 1. While depressing the lock, pull the two connector halves apart. Note: The TPA is fragile and may break if not done carefully. 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. 3. View of the male half of the connector with female terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11929 4. View of the female half of the connector with male terminals. 5. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. View of the female half of the connector with male terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11930 7. View of the male half of the connector with female terminals. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11931 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are a one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine if the element in the fuse is broken (2). If not broken (1), also check for continuity using a Digital Multimeter (DMM) or a continuity tester. If the element is broken or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a Digital Multimeter (DMM) at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gauge size. Repairing a Fusible Link Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11932 Flat Wire Repairs The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Special Tools J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool * J 38125-5 Ultra Torch Special Tool The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Note: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation). GMLAN Connector Terminal Repair Note: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) for the appropriate connector repair procedure. GMLAN Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11933 Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11934 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Special Tools J-38125 Terminal Repair Kit Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11935 repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs High Temperature Wiring Repairs Special Tools J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gauge size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11936 splice. Note: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11937 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11938 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the wire insulation has been chafed, or broken, enough to show the conductive portion of the wire, and the wire is not damaged, determine the length of insulation that needs to be repaired. If the repair is less than 280 mm (11 in), cut the wire within the damaged area. Then slide the appropriate heat shrink tubing (listed below) over the wire, and repair the wire by splicing the wires together. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Once the wire is spliced together slide heat shrink tubing over the damaged area and apply heat to seal the repaired wire. If the wire is damaged, or the damaged area is larger than 280 mm (11 in), then replace the damaged wire by splicing in a new section of wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11939 SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Special Tools J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11940 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11941 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11942 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Special Tools J-38125 Terminal Repair Kit Note: Use only DuraSeal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use DuraSeal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use DuraSeal splice sleeves where there are special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11943 * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11944 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11945 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the instructions for Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Staggering the splices by 65 mm (2.5 in) is recommended. Note: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product AL-36FR to replace the damaged mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Flat Wire Repairs) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/GMLAN Wiring Repairs) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Heated Oxygen Sensor Wiring Repairs) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves) * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Twisted or Shielded Cable) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Inline Harness Diodes) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/SIR/SRS Wiring Repairs) US English/Metric Conversion US English/Metric Conversion Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11946 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11947 Testing Ground and Low Reference Circuits Testing Ground and Low Reference Circuits Because a test lamp can light with up to 200 ohm in a ground or low reference circuit they are not recommended to be used for this type of test. A low impedance test lamp can light and indicate the circuit is good when there is as much as 20-30 ohm present, while a high impedance test lamp can light with up to 200 ohm present in the circuit. This is why the Digital Multi-Meter (DMM) is used when validating a ground or low reference circuit continuity. When using the DMM there are many vehicle conditions that can affect the ground and low reference continuity testing. If these conditions are not met, a ground or low reference circuit test can fail on a good circuit. This may cause longer diagnosis time and incorrect component replacement. Any current flow through a ground or low reference circuit, while being tested, will skew the DMM continuity reading, or display a reading higher than when there is no current flowing. Performing a ground or low reference circuit continuity test, in reference to the vehicles battery negative terminal, will have the highest risk of failing a good ground or low reference circuit test than any other ground reference point. The best ground test points would be a control module housing (if the control modules housing is metal and grounded), door jamb striker (if attached to metal), under dash metal frame work, engine block, or body ground studs (other than where the negative battery cable is attached). A typical DMM ground or low reference circuit continuity reading can be as high as 100 ohm with the ignition ON, and drop to 15-25 ohm after the ignition is turned OFF. The reading will drop below 10 ohm after 30-40 seconds, then below 5 ohm after 60 seconds. Once the vehicle completely goes to sleep (generally 3-10 minutes) the reading will drop below 0.3 ohm. The following list of conditions may need to be met to ensure a valid continuity reading on a ground or low reference circuit: * Ignition OFF * Key out of the ignition switch (when not equipped with keyless entry and remote start) * Retained Accessory Power (RAP) OFF (open and close the driver door after ignition OFF) * Battery charger set at a 2 A or less charge rate * Scan tool not communicating with any vehicle control module (in some cases it may need to be disconnected from the DLC) * All entry doors closed * Headlamps OFF (auto headlamps disabled) * Any delay lighting OFF * HVAC after blow OFF * Any accessory that can work when the ignition is OFF * Wait up to 60 seconds (after all other listed conditions are met) Activating the DOOR LOCK function with a key fob can greatly reduce the time to achieve a valid ground or low reference continuity test result. Terminal Removal Terminal Removal Special Tools * EL-38125-580 - Terminal Release Tool Kit * EL-35616 - Connector Test Adapter Kit For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repair procedures. 1. Find the appropriate connector end view within the connector end view section. The connector end view has the following information: Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11948 * Diagnostic probe tool * Terminal release tool * Terminal/terminated lead part numbers Note: Not using the proper test kit probe may cause damage to the terminal(s) that are probed. 2. Determine if a terminal is damaged. * Locate the diagnostic probe tool from the connector end view. The connector end view describes the color and part number to help the technician find and use the correct tool. * Connect the probe tool to the Digital Multimeter. * Insert the probe tool into the cavity and follow the procedures from the Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter). 3. Disconnect the connector body to perform the repair. 4. Use the following procedure to remove the terminal from the connector body. Note: Several procedures for specific connector bodies are called out in the Wiring Repairs section. * The terminal position assurance (TPA) and connector position assurance (CPA) should be removed before releasing the terminal for the connector body. * Look at the connector end view to locate the cavity of the damaged terminal and find the proper terminal release tool from the terminal release tool kit. Note: Using the incorrect terminal release tool can damage the connector body. * Insert the terminal release tool into the cavity. Note: Some terminals have a lever that must be disengaged before the terminal can be released. 5. Gently pull the wire out of the back of the connector. 6. Repair the terminal by following the Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) procedure. 7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminated Lead Repair Terminated Lead Repair Special Tools * J-38125-8 - Splice Sleeve Crimp Tool Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11949 * J-38125-5 - Ultra Torch For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) procedures. Terminated leads are terminals that are crimped onto wires. The terminated lead can be used throughout the vehicle since it is designed for temperatures up to 150°C. The length of the wire is 450 mm. The DuraSeal splice sleeve has the following 2 critical features: * A special heat shrink tubing that environmentally seals the splice. The shrink tubing contains a sealing adhesive inside the shrink tubing. * A cross hatched (knurled) core crimp that provides the necessary contact integrity for sensitive low energy circuits. 1. Use the connector end view to identify the correct terminated lead. 2. The terminated lead package should include a DuraSeal splice sleeve. If not, use the chart to identify the correct part. 3. Open the harness by removing any tape: Use a sewing seam ripper, or a comparable tool, to cut open the harness, to avoid wire insulation damage. 4. Depending on how many terminals need repairs, cut the terminal and wire back at least 40 mm. Try to keep the harness wire length the same. If more than one terminated lead is required, stagger the lengths by 40 mm. This helps reduce the bundle size of the wire harness. 5. Use the EL-38125-10 - tool in order to position the DuraSeal splice sleeve in the proper color nest of the splice sleeve crimp tool. The crimp tool has four nests, one for each color. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11950 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the J-38125-5 - ultra torch , apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11951 Fuse Block: Connector Views Electrical Center Identification Views Junction Block - Left I/P, Label Junction Block - Left I/P, Top View Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11952 Junction Block - Left I/P, Bottom View Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11953 Junction Block - Left I/P X1 (except MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11954 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11955 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11956 Junction Block - Left I/P X2 (except MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11957 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11958 Junction Block - Left I/P X3 (except MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11959 Junction Block - Left I/P X4 (except MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11960 Junction Block - Left I/P X5 (SPO Alarm or SPO Heated Seats) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11961 Junction Block - Left I/P X7 (JF4) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11962 Junction Block - Left I/P X8 (except MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11963 Junction Block - Left I/P X9 (except MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11964 Junction Block - Left I/P X10 (except MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11965 Junction Block - Left I/P X11 (except MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11966 Junction Block - Left I/P X12 (except MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11967 Junction Block - Left I/P X13 (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11968 Junction Block - Left I/P X14 (5X7, 5Y0, 9L4, SPO DVD or SPO Heated Seats) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11969 Junction Block - Right I/P, Top View Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11970 Junction Block - Right I/P (Wire Entry) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11971 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11972 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11973 Junction Block - Right I/P X2 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11974 Junction Block - Right I/P X3 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11975 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11976 Junction Block - Right I/P X4 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11977 Junction Block - Right I/P X5 Junction Block - Right I/P X6 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11978 Junction Block - Rear Lamps Junction Block - Rear Lamps X1 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11979 Junction Block - Rear Lamps X2 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11980 Junction Block - Rear Lamps X3 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 11981 Junction Block - Rear Lamps X4 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Procedures Fuse Block: Procedures Ground Repair Electrical Grounds Proper electrical system function relies on secure, positive, corrosion-free ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacements. In general, electrical ground connections are accomplished using one, or a combination of, three attachment methods: * Welded M6 stud and nut * Welded M6 nut and bolt * Welded M8 nut and bolt Caution: Use GM approved replacement fasteners with conductive finish for electrical ground repair. Determine which attachment method is used, and carry out the appropriate repair. M6 Weld Stud Replacement 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note: Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Carefully remove paint and primer from the area surrounding the rivet stud flange until bare metal is visible. Caution: Use GM approved replacement fasteners with conductive finish for electrical ground repair. 5. Select a replacement conductive M6 rivet stud. Refer to GM parts catalog for the correct part number and application. 6. Using a rivet stud installer, install the replacement conductive M6 rivet stud. 7. Ensure the new rivet stud is securely fastened, with no detectable movement. Note: The rivet stud and surrounding panel area must be properly refinished prior to the installation of the ground terminal and nut to maintain positive electrical grounding. 8. Completely wrap the threads of the rivet stud with painters tape or equivalent. 9. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair (). 10. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 11. Remove the painters tape or equivalent from the rivet stud threads. 12. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 13. Carefully remove any corrosion from the electrical ground wire terminal. Refer to Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections). 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the new conductive M6 rivet stud threads. 15. Install the ground terminal to the new rivet stud. 16. Select a new, conductive M6 nut. Refer to GM parts catalog for the correct part number and application. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 17. Install the M6 nut and tighten to 8 Nm (71 lb in). 18. Check for proper system operation. M6 Weld Nut Caution: Use GM approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a new, conductive self-threading M7 bolt may be used to secure the ground terminal. Refer to GM parts catalog for the correct part number and application. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the new, conductive, self-threading M7 bolt Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Procedures > Page 11984 threads. 5. Carefully remove any corrosion from the electrical ground terminal. Refer to Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections). 6. Install the electrical ground terminal to the new, conductive M7 bolt. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 7. Install the M7 bolt and tighten to 9 Nm (80 lb in). 8. Check for proper system operation. M6 Weld Nut (Alternative Repair) Caution: Use GM approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a conductive M6 bolt and a conductive M6 nut may be used to secure the electrical ground terminal. Refer to GM parts catalog for the correct part number and application. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 ) clearance behind the panel surface and 20 mm (0.79 ) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note: Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Carefully remove paint and primer from the area surrounding the new ground site until bare metal is visible. 6. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the new, conductive M6 bolt threads. 7. Carefully remove any corrosion from the electrical ground terminal. Refer to Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections). 8. Install the electrical ground terminal and new, conductive M6 bolt to the ground location. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 9. Install the conductive M6 nut and tighten to 8 Nm (71 lb in). Note: The repair area must be properly refinished to maintain positive electrical grounding. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair (). 11. Check for proper system operation. M8 Weld Nut Caution: Use GM approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a conductive M8 bolt and a conductive M8 nut may be used to secure the ground terminal. Refer to GM parts catalog for the correct part numbers and application. 2. Select a location adjacent to M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note: Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Carefully remove paint and primer from the area surrounding the new ground site until bare metal is visible. 6. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the new, conductive M8 bolt threads. 7. Carefully remove any corrosion from the electrical ground terminal. Refer to Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections). 8. Install the electrical ground terminal and new, conductive M8 bolt to the ground location. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 9. Install the conductive M8 nut and tighten to 22 Nm (16 lb ft). Note: The repair area must be properly refinished to maintain positive electrical grounding. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Procedures > Page 11985 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair (). 11. Check for proper system operation. M8 Weld Nut (Alternative Repair) Caution: Use GM approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a conductive M6 rivet stud and a conductive M6 nut may be used to secure the ground terminal. Refer to GM parts catalog for the correct part numbers and application. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new, conductive M6 rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note: Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Carefully remove paint and primer from the area surrounding the rivet stud flange until bare metal is visible. 6. Using a rivet stud installer, install the replacement conductive M6 rivet stud. 7. Ensure the new rivet stud is securely fastened, with no detectable movement. Note: The rivet stud and surrounding panel area must be properly refinished prior to the installation of the ground terminal and nut to maintain positive electrical grounding. 8. Completely wrap the threads of the rivet stud with painters tape or equivalent. 9. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair (). 10. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 11. Remove the painters tape or equivalent from the rivet stud threads. 12. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 13. Carefully remove any corrosion from the electrical ground wire terminal. Refer to Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections). 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the new conductive M6 rivet stud threads. 15. Install the ground terminal to the new, conductive M6 rivet stud. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 16. Install the conductive M6 nut and tighten to 8 Nm (71 lb in). 17. Check for proper system operation. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Procedures > Page 11986 Fuse Block: Removal and Replacement 175 Amp Mega Fuse Replacement (Diesel) 175 Amp Mega Fuse Replacement (Diesel) Removal Procedure 1. Disconnect the auxiliary battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 2. Remove the mega fuse cover (3). 3. Remove the starter solenoid cable nut (1) from the fuse stud. 4. Remove the starter solenoid cable terminal (2) from the fuse stud. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Procedures > Page 11987 5. Remove the auxiliary battery positive cable nut (1) from the mega fuse holder. 6. Remove the generator battery jumper cable to fuse nut (3). 7. Remove the generator battery jumper cable terminal (2) from the fuse stud. 8. Remove the auxiliary battery positive cable from the fuse studs. 9. Remove the upper mega fuse nut (1), if necessary. 10. Remove the appropriate mega fuse (2). Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Procedures > Page 11988 1. Install the appropriate mega fuse (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the upper mega fuse nut (1), if necessary. Tighten the nut to 15 Nm (11 lb ft). 3. Install the auxiliary battery positive cable to the fuse studs. 4. Install the generator battery jumper cable terminal (2) to the fuse stud. 5. Install the generator battery jumper cable to fuse nut (3). Tighten the nut to 9 Nm (80 lb in). 6. Install the auxiliary battery positive cable nut (1) to the mega fuse holder. Tighten the nut to 15 Nm (11 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Procedures > Page 11989 7. Install the starter solenoid cable terminal (2) to the fuse stud. 8. Install the starter solenoid cable nut (1) to the fuse stud. Tighten the nut to 15 Nm (11 lb ft). 9. Install the mega fuse cover (3). 10. Connect the auxiliary battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 175 Amp Mega Fuse Replacement (Single Battery) 175 Amp Mega Fuse Replacement (Single Battery) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Procedures > Page 11990 175 Amp Mega Fuse Replacement (Auxiliary Battery) 175 Amp Mega Fuse Replacement (Auxiliary Battery) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Procedures > Page 11991 200 Amp Mega Fuse and Auxiliary Electrical Center 12VDC Junction Block Replacement 200 Amp Mega Fuse and Auxiliary Electrical Center 12VDC Junction Block Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Procedures > Page 11992 Instrument Panel Electrical Center or Junction Block Replacement - Left Side Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Procedures > Page 11993 Instrument Panel Electrical Center or Junction Block Replacement - Left Side Body Wiring Harness Junction Block Replacement Body Wiring Harness Junction Block Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Procedures > Page 11994 Underhood Electrical Center or Junction Block Replacement Underhood Electrical Center or Junction Block Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Procedures > Page 11995 Underhood Electrical Center or Junction Block Bracket Replacement Underhood Electrical Center or Junction Block Bracket Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Procedures > Page 11996 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair Grounding Point: Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 12001 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 12002 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 12003 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 12004 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 12005 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 12006 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Customer Interest for Multiple Junction Connector: > 10-08-50-008B > Jan > 11 > Seats Driver/Passenger Heated Seats Inop./Slow to Warm Multiple Junction Connector: Customer Interest Seats - Driver/Passenger Heated Seats Inop./Slow to Warm TECHNICAL Bulletin No.: 10-08-50-008B Date: January 13, 2011 Subject: Driver or Passenger Heated Seat Inoperative, Slow to Warm, DTC(s) Set (Repair Connector, Re-Route Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Silverado, Suburban, Tahoe 2011 Chevrolet Silverado Heavy Duty 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2011 GMC Sierra Heavy Duty All Equipped with Heated Front Seat (RPO AN3, KA1) or Heated and Cooled Seat (RPO KB6) and/or Luxury Package (RPO PCK) Supercede: This bulletin is being revised to update the RPOs. Please discard Corporate Bulletin Number 10-08-50-008A (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger heated seat system exhibits the following symptoms: - Heated seat turns on and then turns off within 1 to 10 minutes (at any 60 second interval). - The system doesn't get warm enough, or gets warm very slowly. - The heated seat system is completely inoperative. Upon further review, DTCs B2430 0D and/or B2180 0D may be set as a current or history code if the vehicle is equipped with heated seats only (RPO KA1). Also, the LED indicator for the heated seats may come On and then flash after approximately 1 minute, then go out. If the vehicle is equipped with heated and cooled seats (KB6), the switch LED indicator may stay On, but the heated and cooled seat is inoperative. The fan will continue to blow air. Cause Heated Seats (RPO AN3, KA1) The heated seat control circuit terminal and/or ground terminal in harness connector X1 to the memory seat module (MSM) may have lost tension and is loose. The reduced terminal tension increases resistance in the connector, which may result in the symptoms described above. Heated and Cooled Seats (RPO KB6) The thermo-electric device (TED) in the seat cushion/seat back ventilation heating and cooling module may have become inoperative. Correction Heated Seats (RPO AN3, KA1) Follow the steps below to correct the concern with the heated seats. Note This repair requires a unique anti-abrasion electrical tape and harness clip from Kent Automotive. Refer to the Parts Information below. 1. Access and remove the seat bolts/nuts. 2. Adjust the seat rearward about halfway. Adjust the seat recline full forward. 3. Tilt the seat backward to access the bottom of the seat. Prop the seat up with a suitable tool if required. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Customer Interest for Multiple Junction Connector: > 10-08-50-008B > Jan > 11 > Seats Driver/Passenger Heated Seats Inop./Slow to Warm > Page 12015 4. Disconnect seat harness connectors (1) X1, X2, X3 and X4 from the MSM. 5. Identify connector X1. Refer to Component Connector End Views in SI. 6. Perform a terminal drag test on connector X1, paying special attention to terminals 1, 4, 6, 11 and 14. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Refer to Testing for Intermittent Conditions and Poor Connections in SI. 7. Replace any terminal in question including connector X1 terminals 1, 4, 6, 11 and 14 if necessary. Refer to Repairing Connector Terminals in SI. 8. Identify connector X4. Refer to Component Connector End Views in SI. 9. Perform the terminal drag test described in step 6, paying special attention to terminal 14. 10. Replace any terminal in question including connector X4 terminal 14 if necessary. Refer to Repairing Connector Terminals in SI. 11. Remove the harness clip (1) from the plastic carrier. 12. Cut the electrical tape holding the harness in the plastic carrier using a sharp utility knife in the area shown (1). 13. Free the harness from the carrier back to the area shown (1). 14. Obtain "*Woven Polyester (PET) Electrical Tape" (Special Order P/N RZ97156A00) from Kent Automotive. Refer to Parts Information below. Important Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Customer Interest for Multiple Junction Connector: > 10-08-50-008B > Jan > 11 > Seats Driver/Passenger Heated Seats Inop./Slow to Warm > Page 12016 DO NOT substitute with vinyl electrical tape or friction tape. Use only the tape specified above. 15. Tape the harness starting at the MSM connectors (1) extending back to the new break-out location (2) in the plastic carrier. 16. Install a plastic tie strap around the harness and the plastic carrier at the break-out point (1). 17. Install the new harness edge clip (1) 10 mm (0.4 in) further from the connectors and the existing harness clip. Ensure the clip is installed in the orientation shown. 18. Install the harness with the new harness clip in the location shown (1). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Customer Interest for Multiple Junction Connector: > 10-08-50-008B > Jan > 11 > Seats Driver/Passenger Heated Seats Inop./Slow to Warm > Page 12017 19. Reinstall the harness connectors (1) to the MSM. 20. Reinstall the seat to the vehicle. Heated and Cooled Seats (RPO KB6) Follow the steps below to correct the concern with the heated and cooled seats. 1. Inspect the ventilation heating and cooling module for a concern with the TED. Refer to Seat Heating and Cooling, Diagnostic Information and Procedures in SI. Note If the heated and cooled seat function is inoperative, but the heat switch indicators are On, the MSM is functioning properly and the concern is with the TED. 2. If the TED is found to be the concern, replace the seat cushion or seat back ventilation heating and cooling module. Refer to Driver or Passenger Seat Back Ventilation Heating and Cooling Blower Replacement or Driver or Passenger Seat Cushion Ventilation Heating and Cooling Blower Replacement in SI. If the TED is not the concern, follow normal diagnostics and repair in SI. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Use the appropriate Labor Operation based on the repair completed. Heated Seats (RPO AN3, KA1) For vehicles repaired under warranty, use: Heated and Cooled Seats (RPO KB6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Customer Interest for Multiple Junction Connector: > 10-08-50-008B > Jan > 11 > Seats Driver/Passenger Heated Seats Inop./Slow to Warm > Page 12018 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Customer Interest for Multiple Junction Connector: > 07-06-04-019D > Jun > 10 > Electrical Intermittent MIL/DTC P2138/Reduced Power Multiple Junction Connector: Customer Interest Electrical - Intermittent MIL/DTC P2138/Reduced Power TECHNICAL Bulletin No.: 07-06-04-019D Date: June 28, 2010 Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced Engine Power (Repair Instrument Panel (IP) to Body Harness Connector) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years and warranty information. Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion System) Condition - Some customers may comment on an intermittent malfunction indicator lamp (MIL) being Illuminated with a message or an indicator that displays Reduced Engine Power. - The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP) Sensor 1-2 Correlation set as Current or in History. Cause This condition may be caused by water intrusion into the instrument panel (IP) to body harness connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value for more than a calibrated period of time, setting P2138. Correction Note Aftermarket equipment can generate DTC P2138 and/or other DTCs. 1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or low reference circuits or to any other ECM/PCM 5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI. 2. Perform the Diagnostic System Check - Vehicle. ‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any 5V reference DTCs are not set, proceed to Step 3. 3. Locate the IP to body harness connector, which may be located in and around the left hand kick panel area or inside the IP. Depending on the vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI. Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped) and windshield/cowl sealing. 4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the leak. Refer to General Information > Water Leaks in SI. ‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair. 5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for Intermittent Conditions and Poor Connections in SI. ‹› If any corrosion and/or debris is observed, repair as necessary. 6. After completing the repair, verify the proper operation of the system. Depending on the vehicle and model year, perform the Diagnostic Repair Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Customer Interest for Multiple Junction Connector: > 07-06-04-019D > Jun > 10 > Electrical Intermittent MIL/DTC P2138/Reduced Power > Page 12023 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the appropriate labor operation for the source of the water leak Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm Multiple Junction Connector: All Technical Service Bulletins Seats - Driver/Passenger Heated Seats Inop./Slow to Warm TECHNICAL Bulletin No.: 10-08-50-008B Date: January 13, 2011 Subject: Driver or Passenger Heated Seat Inoperative, Slow to Warm, DTC(s) Set (Repair Connector, Re-Route Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Silverado, Suburban, Tahoe 2011 Chevrolet Silverado Heavy Duty 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2011 GMC Sierra Heavy Duty All Equipped with Heated Front Seat (RPO AN3, KA1) or Heated and Cooled Seat (RPO KB6) and/or Luxury Package (RPO PCK) Supercede: This bulletin is being revised to update the RPOs. Please discard Corporate Bulletin Number 10-08-50-008A (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger heated seat system exhibits the following symptoms: - Heated seat turns on and then turns off within 1 to 10 minutes (at any 60 second interval). - The system doesn't get warm enough, or gets warm very slowly. - The heated seat system is completely inoperative. Upon further review, DTCs B2430 0D and/or B2180 0D may be set as a current or history code if the vehicle is equipped with heated seats only (RPO KA1). Also, the LED indicator for the heated seats may come On and then flash after approximately 1 minute, then go out. If the vehicle is equipped with heated and cooled seats (KB6), the switch LED indicator may stay On, but the heated and cooled seat is inoperative. The fan will continue to blow air. Cause Heated Seats (RPO AN3, KA1) The heated seat control circuit terminal and/or ground terminal in harness connector X1 to the memory seat module (MSM) may have lost tension and is loose. The reduced terminal tension increases resistance in the connector, which may result in the symptoms described above. Heated and Cooled Seats (RPO KB6) The thermo-electric device (TED) in the seat cushion/seat back ventilation heating and cooling module may have become inoperative. Correction Heated Seats (RPO AN3, KA1) Follow the steps below to correct the concern with the heated seats. Note This repair requires a unique anti-abrasion electrical tape and harness clip from Kent Automotive. Refer to the Parts Information below. 1. Access and remove the seat bolts/nuts. 2. Adjust the seat rearward about halfway. Adjust the seat recline full forward. 3. Tilt the seat backward to access the bottom of the seat. Prop the seat up with a suitable tool if required. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 12029 4. Disconnect seat harness connectors (1) X1, X2, X3 and X4 from the MSM. 5. Identify connector X1. Refer to Component Connector End Views in SI. 6. Perform a terminal drag test on connector X1, paying special attention to terminals 1, 4, 6, 11 and 14. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Refer to Testing for Intermittent Conditions and Poor Connections in SI. 7. Replace any terminal in question including connector X1 terminals 1, 4, 6, 11 and 14 if necessary. Refer to Repairing Connector Terminals in SI. 8. Identify connector X4. Refer to Component Connector End Views in SI. 9. Perform the terminal drag test described in step 6, paying special attention to terminal 14. 10. Replace any terminal in question including connector X4 terminal 14 if necessary. Refer to Repairing Connector Terminals in SI. 11. Remove the harness clip (1) from the plastic carrier. 12. Cut the electrical tape holding the harness in the plastic carrier using a sharp utility knife in the area shown (1). 13. Free the harness from the carrier back to the area shown (1). 14. Obtain "*Woven Polyester (PET) Electrical Tape" (Special Order P/N RZ97156A00) from Kent Automotive. Refer to Parts Information below. Important Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 12030 DO NOT substitute with vinyl electrical tape or friction tape. Use only the tape specified above. 15. Tape the harness starting at the MSM connectors (1) extending back to the new break-out location (2) in the plastic carrier. 16. Install a plastic tie strap around the harness and the plastic carrier at the break-out point (1). 17. Install the new harness edge clip (1) 10 mm (0.4 in) further from the connectors and the existing harness clip. Ensure the clip is installed in the orientation shown. 18. Install the harness with the new harness clip in the location shown (1). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 12031 19. Reinstall the harness connectors (1) to the MSM. 20. Reinstall the seat to the vehicle. Heated and Cooled Seats (RPO KB6) Follow the steps below to correct the concern with the heated and cooled seats. 1. Inspect the ventilation heating and cooling module for a concern with the TED. Refer to Seat Heating and Cooling, Diagnostic Information and Procedures in SI. Note If the heated and cooled seat function is inoperative, but the heat switch indicators are On, the MSM is functioning properly and the concern is with the TED. 2. If the TED is found to be the concern, replace the seat cushion or seat back ventilation heating and cooling module. Refer to Driver or Passenger Seat Back Ventilation Heating and Cooling Blower Replacement or Driver or Passenger Seat Cushion Ventilation Heating and Cooling Blower Replacement in SI. If the TED is not the concern, follow normal diagnostics and repair in SI. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Use the appropriate Labor Operation based on the repair completed. Heated Seats (RPO AN3, KA1) For vehicles repaired under warranty, use: Heated and Cooled Seats (RPO KB6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 12032 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power Multiple Junction Connector: All Technical Service Bulletins Electrical - Intermittent MIL/DTC P2138/Reduced Power TECHNICAL Bulletin No.: 07-06-04-019D Date: June 28, 2010 Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced Engine Power (Repair Instrument Panel (IP) to Body Harness Connector) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years and warranty information. Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion System) Condition - Some customers may comment on an intermittent malfunction indicator lamp (MIL) being Illuminated with a message or an indicator that displays Reduced Engine Power. - The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP) Sensor 1-2 Correlation set as Current or in History. Cause This condition may be caused by water intrusion into the instrument panel (IP) to body harness connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value for more than a calibrated period of time, setting P2138. Correction Note Aftermarket equipment can generate DTC P2138 and/or other DTCs. 1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or low reference circuits or to any other ECM/PCM 5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI. 2. Perform the Diagnostic System Check - Vehicle. ‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any 5V reference DTCs are not set, proceed to Step 3. 3. Locate the IP to body harness connector, which may be located in and around the left hand kick panel area or inside the IP. Depending on the vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI. Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped) and windshield/cowl sealing. 4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the leak. Refer to General Information > Water Leaks in SI. ‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair. 5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for Intermittent Conditions and Poor Connections in SI. ‹› If any corrosion and/or debris is observed, repair as necessary. 6. After completing the repair, verify the proper operation of the system. Depending on the vehicle and model year, perform the Diagnostic Repair Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power > Page 12037 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the appropriate labor operation for the source of the water leak Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Page 12038 Multiple Junction Connector: Locations Harness Routing Views Rear Bumper Harness Routing 1 - Rear Bumper 2 - J403 (UD7) 3 - J404 (UD7) 4 - Junction Block - Rear Lamps Connector 5 X408 (UD7) Brake Clutch Harness Routing Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Page 12039 1 - Driver Door Frame 2 - X205 3 - X102 (JL1) 4 - Accelerator Pedal Position (APP) Sensor Connector 5 - Junction Block - Left I/P (except MEX) Chassis Harness (31 Series) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Page 12040 1 - Trailer Brake Control Relay (JL1) 2 - J422 (JL1) 3 - Trailer Connector 4 - J331 (Diesel without NQZ/LY6) 5 - X300 (LY6) 6 - X300 (Diesel) 7 - J411 (JL1) 8 - Junction Block - Rear Lamps 9 G401 10 - J338 (JL1) 11 - G300 12 - J300 (LY6 without NQZ) Passenger Door Harness Routing Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Page 12041 1 - J604 (YE9 without AN3/DL3) 2 - Junction Block - Right I/P X3 3 - Door Frame 4 - X601 (ASF) 5 - X600 (YE9 without AN3/DL3) 6 - J603 (YE9 without AN3/DL3) I/P Harness Routing - Passenger Compartment (Except HP2) - 1 of 2 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Page 12042 1 - X201 2 - X205 3 - Junction Block - Right I/P 4 - X200 5 - X202 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name Multiple Junction Connector: Diagrams Connector End Views By Name Ai - Ba Component Connector End Views (continued) Air Temperature Actuator - Left (CJ2) Air Temperature Actuator - Right (CJ2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12045 Air Temperature Actuator (C67 or C42) Air Temperature Sensor - Inside (CJ2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12046 Air Temperature Sensor - Lower Left (CJ2) Air Temperature Sensor - Lower Right (CJ2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12047 Air Temperature Sensor - Upper Left (CJ2) Air Temperature Sensor - Upper Right (CJ2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12048 Ambient Air Temperature Sensor (CJ2 or C67) Ambient Light Sensor (C67, C42 or MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12049 Ambient Light/Sunload Sensor (CJ2) Audio Amplifier X1 (UQA with Y91) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12050 Audio Amplifier X1 (UQA without Y91) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12051 Audio Amplifier X2 (UQA) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12052 Audio Amplifier X3 (UQA) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12053 Audio/Video Adapter (U42) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12054 Automatic Transmission Auxiliary Fluid Pump Control Module X1 (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12055 Automatic Transmission Auxiliary Fluid Pump Control Module X2 (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12056 Automatic Transmission Fluid Temperature (TFT) Sensor (M30) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12057 Automatic Transmission Input Shaft Speed (ISS) Sensor (M30) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12058 Automatic Transmission Internal Mode Switch (MW7) Automatic Transmission Shift Lever (M30, MYC, MYD, M99 or MW7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12059 Automatic Transmission Shift Lock Control Solenoid Automatic Transmission Turbine Speed Sensor (MW7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12060 Auxiliary Battery Relay X1 (TP2) Auxiliary Battery Relay X2 (TP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12061 Auxiliary Battery Relay X3 (TP2) Auxiliary Battery Run Relay (TP2) Auxiliary Body Control Module (XBCM) X1 (EXP) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12062 Auxiliary Body Control Module (XBCM) X2 (EXP) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12063 Backup Alarm (8S3) Backup Lamp - Left Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12064 Backup Lamp - Right Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12065 Backup Lamp Switch (TZ0) Barometric Pressure (BARO) Sensor (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12066 Battery - Left (-) (Auxiliary Battery Negative Cable) (6A6) Battery - Left (-) (Auxiliary Battery Negative Cable) (TP2) Battery - Left (-) (Battery Negative Cable) (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12067 Battery - Left (+) (Auxiliary Battery Positive Cable) (TP2) Battery - Left (+) (Starter Cable) (6A6 or Diesel) Battery - Right (-) (Battery Negative Cable) (Gas) Battery - Right (-) (Starter Cable) (Diesel) Ba - Da Component Connector End Views (continued) Battery - Right (+) (Diesel or 9L4) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12068 Battery - Right (+) (Gas without 9L4) Battery (+) (Battery Positive Cable) (HP2) Battery (+) (Battery Positive Cable) (HP2) Battery Current Sensor (10 Series without MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12069 Battery Module 1 (HP2) Battery Module 21 (HP2) Battery Module 22 (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12070 Battery Module 40 (HP2) Blower Motor Blower Motor Control Module X1 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12071 Blower Motor Control Module X2 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12072 Body Control Module (BCM) X1 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12073 Body Control Module (BCM) X2 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12074 Body Control Module (BCM) X3 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12075 Body Control Module (BCM) X4 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12076 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12077 Body Control Module (BCM) X5 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12078 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12079 Body Control Module (BCM) X6 Body Control Module (BCM) X7 (except MEX or A52) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12080 Brake Booster Vacuum Sensor (JL4 with 10 Series) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12081 Brake Fluid Level Switch Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12082 Brake Master Cylinder Piston Position Sensor (HP2) Brake Master Cylinder Pressure Sensor (JL1) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12083 Camshaft Position (CMP) Actuator Solenoid Valve (LZ1, LY6, L96 or L9H) Camshaft Position (CMP) Sensor (LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12084 Camshaft Position (CMP) Sensor (Gas except LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12085 Camshaft Position (CMP) Sensor (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12086 Cellular Telephone Microphone (UE1, UUL or UUK) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12087 Center High Mounted Stop Lamp (CHMSL) X1 Center High Mounted Stop Lamp (CHMSL) X2 Center High Mounted Stop Lamp (CHMSL) X3 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12088 Center High Mounted Stop Lamp (CHMSL) X4 Central Sequential Fuel Injection (Central SFI) X1-X6 (LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12089 Central Sequential Fuel Injection (Central SFI) X7 (LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12090 Chime Module (UL5) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12091 Clutch Pedal Position (CPP) Switch (TZ0) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12092 Control Solenoid Valve Assembly X1 (MYC, MYD or M99) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12093 Control Solenoid Valve Assembly X2 (MYC, MYD or M99) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12094 Control Solenoid Valve Assembly X3 (MYC, MYD or M99) Crankshaft Position (CKP) Sensor (LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12095 Crankshaft Position (CKP) Sensor (Gas except LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12096 Crankshaft Position (CKP) Sensor (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12097 Data Link Connector (DLC) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12098 Da - Dr Component Connector End Views (continued) Data Link Resistor Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12099 Data Link Resistor 2 (HP2) Digital Radio Receiver (U2K) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12100 Digital Video Disc (DVD) Control Module X1 (SPO DVD) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12101 Digital Video Disc (DVD) Control Module X2 (SPO DVD) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12102 Digital Video Disc (DVD) Control Module X3 (SPO DVD) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12103 Digital Video Disc (DVD) Control Module X4 (SPO DVD) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12104 Digital Video Disc (DVD) Control Module X5 (SPO DVD) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12105 Digital Video Disc (DVD) Control Module X6 (SPO DVD) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12106 Digital Video Disc (DVD) Display - Driver Seat Headrest X1 (SPO DVD) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12107 Digital Video Disc (DVD) Display - Driver Seat Headrest X2 (SPO DVD) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12108 Digital Video Disc (DVD) Display - Passenger Seat Headrest X1 (SPO DVD) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12109 Digital Video Disc (DVD) Display - Passenger Seat Headrest X2 (SPO DVD) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12110 Dome/Reading Lamps - Front Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12111 Dome/Reading Lamps - Rear (Crew Cab or Extended Cab) Door Latch - Driver (AU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12112 Door Latch - Driver (except AU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12113 Door Latch - Left Rear (Crew Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12114 Door Latch - Passenger Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12115 Door Latch - Right Rear (Crew Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12116 Door Lock Switch - Driver (AU3 without AN3 or DL3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12117 Door Lock Switch - Passenger (AU3 without AN3 or DL3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12118 Door Lock/Window Switch - Driver X1 (AN3 or DL3) Door Lock/Window Switch - Driver X2 (AN3 or DL3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12119 Door Lock/Window Switch - Driver X3 (AN3 or DL3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12120 Door Lock/Window Switch - Driver X4 (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12121 Door Lock/Window Switch - Driver X7 (AN3 or DL3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12122 Door Lock/Window Switch - Passenger X1 (AN3 or DL3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12123 Door Lock/Window Switch - Passenger X2 (AN3 or DL3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12124 Door Lock/Window Switch - Passenger X3 (AN3 or DL3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12125 Door Lock/Window Switch - Passenger X4 (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12126 Door Lock/Window Switch - Passenger X7 (AN3 or DL3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12127 Drive Motor Battery Cable Terminal Extension Cover (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12128 Drive Motor Battery Current Sensor (HP2) Drive Motor Battery High Voltage Manual Disconnect Lever X2 (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12129 Drive Motor Battery High Voltage Manual Disconnect Lever X3 (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12130 Drive Motor Battery Negative High Voltage Contactor Relay X1 (HP2) Drive Motor Battery Negative High Voltage Contactor Relay X2 (HP2) Drive Motor Battery Negative High Voltage Contactor Relay X3 (HP2) Drive Motor Battery Positive High Voltage Contactor Relay X1 (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12131 Drive Motor Battery Positive High Voltage Contactor Relay X2 (HP2) Drive Motor Battery Positive High Voltage Contactor Relay X3 (HP2) Drive Motor Generator Battery (-) (Drive Motor Battery Positive and Negative Cable Assembly) (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12132 Drive Motor Generator Battery (+) (Drive Motor Battery Positive and Negative Cable Assembly) (HP2) Drive Motor Generator Battery Control Module X1 (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12133 Drive Motor Generator Battery Control Module X2 (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12134 Drive Motor Generator Battery Control Module X3 (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12135 Drive Motor Generator Battery Control Module X4 (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12136 Drive Motor Generator Battery Control Module X5 (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12137 Dr - En Component Connector End Views (continued) Drive Motor Generator Battery X1 (HP2) Drive Motor Generator Battery X2 (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12138 Drive Motor Generator Power Inverter Module Cover (HP2) Drive Motor Generator Power Inverter Module X1 (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12139 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12140 Drive Motor Generator Power Inverter Module X2 (HP2) Drive Motor Generator Power Inverter Module X3 (HP2) Drive Motor Generator Power Inverter Module X4 (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12141 Drive Motor Generator Power Inverter Module X5 (HP2) Drive Motor Generator Power Inverter Module X6 (HP2) Drive Motor Generator Power Inverter Module X7 (HP2) Drive Motor Generator Power Inverter Module X8 (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12142 Drive Motor Generator Power Inverter Module X9 (HP2) Drive Motor Generator Power Inverter Module X10 (HP2) Drive Motor Generator Power Inverter Module X11 (HP2) Drive Motor Generator Power Inverter Module X12 (HP2) Drive Motor Power Inverter Current Limit Relay X1 (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12143 Drive Motor Power Inverter Current Limit Relay X2 (HP2) Driver Information Center (DIC) Switch (except MEX or 8S8) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12144 Electronic Adjustable Pedal (EAP) Assembly (JF4) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12145 Electronic Brake Control Module (EBCM) (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12146 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12147 Electronic Brake Control Module (EBCM) (JF3 or JF7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12148 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12149 Electronic Brake Control Module (EBCM) (JH6 or JH7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12150 Electronic Brake Control Module (EBCM) (JL4 except 10 Series) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12151 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12152 Electronic Brake Control Module (EBCM) (JL4 with 10 Series) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12153 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12154 Electronic Compass Module (YE9) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12155 Electronic Power Steering Motor Control Module X1 (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12156 Electronic Power Steering Motor Control Module X3 (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12157 Electronic Power Steering Motor Control Module X4 (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12158 Emergency Vehicle Roof Lamp Relay (5Y0) Engine Control Module (ECM) X1 (LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12159 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12160 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12161 Engine Control Module (ECM) X1 (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12162 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12163 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12164 Engine Control Module (ECM) X1 (LY2, LMG, LC9, LY5, LH6, L76 or L9H) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12165 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12166 Engine Control Module (ECM) X1 (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12167 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12168 Engine Control Module (ECM) X1 (LY6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12169 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12170 Engine Control Module (ECM) X2 (LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12171 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12172 En - Fu Component Connector End Views (continued) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12173 Engine Control Module (ECM) X2 (LY2, LY6 or L9H with Y91) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12174 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12175 Engine Control Module (ECM) X2 (LMG, LC9, LY5, LH6, L76 or L9H without Y91) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12176 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12177 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12178 Engine Control Module (ECM) X2 (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12179 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12180 Engine Control Module (ECM) X2 (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12181 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12182 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12183 Engine Control Module (ECM) X3 (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12184 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12185 Engine Coolant Level Switch (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12186 Engine Coolant Temperature (ECT) Sensor (Diesel) Engine Coolant Temperature (ECT) Sensor (Gas) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12187 Engine Cooling Fan - Left (Gas except LY6) Engine Cooling Fan - Right (Gas except LY6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12188 Engine Cooling Fan Resistor - Left (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12189 Engine Cooling Fan Resistor - Right (HP2) Engine Oil Level (EOL) Switch (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12190 Engine Oil Pressure (EOP) Sensor (Diesel) Engine Oil Pressure (EOP) Sensor (Gas except LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12191 Engine Oil Pressure (EOP) Sensor (LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12192 Evaporative Emission (EVAP) Canister Purge Solenoid Valve (Gas) Evaporative Emission (EVAP) Canister Vent Solenoid Valve (Gas) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12193 Evaporator Temperature Sensor (except HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12194 Exhaust Gas Recirculation (EGR) Temperature Sensor 1 (Diesel) Exhaust Gas Recirculation (EGR) Temperature Sensor 2 (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12195 Exhaust Gas Recirculation (EGR) Valve (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12196 Exhaust Pressure Differential Sensor (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12197 Exhaust Temperature Sensor 1 (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12198 Exhaust Temperature Sensor 2 (Diesel) Fog Lamp - Left Front (T96) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12199 Fog Lamp - Right Front (T96) Front Drive Axle Actuator (NQF, NQG or NQH) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12200 Fuel Heater (Diesel) Fuel Injector 1 (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12201 Fuel Injector 1 (Gas except LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12202 Fuel Injector 1 (LU3) Fuel Injector 2 (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12203 Fuel Injector 2 (Gas except LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12204 Fuel Injector 2 (LU3) Fuel Injector 3 (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12205 Fuel Injector 3 (Gas except LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12206 Fuel Injector 3 (LU3) Fuel Injector 4 (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12207 Fuel Injector 4 (Gas except LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12208 Fuel Injector 4 (LU3) Fuel Injector 5 (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12209 Fu - He Component Connector End Views (continued) Fuel Injector 5 (Gas except LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12210 Fuel Injector 5 (LU3) Fuel Injector 6 (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12211 Fuel Injector 6 (Gas except LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12212 Fuel Injector 6 (LU3) Fuel Injector 7 (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12213 Fuel Injector 7 (Gas except LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12214 Fuel Injector 8 (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12215 Fuel Injector 8 (Gas except LU3) Fuel Level Sensor - Primary (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12216 Fuel Level Sensor - Secondary (Diesel with 31 Series without NQZ) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12217 Fuel Pressure Regulator (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12218 Fuel Pressure Sensor (Gas except LU3 or LY6) Fuel Pump/Trailer Brake Control Module (Gas with JL1 and except LU3, LY6 or LY6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12219 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12220 Fuel Pump (Diesel with 31 Series without NQZ) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12221 Fuel Pump and Sender Assembly - Front (Gas except MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12222 Fuel Pump and Sender Assembly - Front (MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12223 Fuel Pump and Sender Assembly - Rear (LY6 except MEX and without NQZ) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12224 Fuel Pump and Sender Assembly - Rear (LY6 with MEX and without NQZ) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12225 Fuel Pump Flow Control Module (Gas except JL1 and except LU3, LY6 or LY6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12226 Fuel Pump Relay - Secondary (LY6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12227 Fuel Rail Pressure (FRP) Sensor (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12228 Fuel Tank Pressure (FTP) Sensor (Gas) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12229 Fuel Temperature Sensor (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12230 Garage Door Opener (GDO) (UG1) Generator - Auxiliary X1 (Diesel with K76 or YF2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12231 Generator - Auxiliary X2 (Diesel with K76 or YF2) Generator Battery Vent Fan (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12232 Generator Battery Vent Fan Relay (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12233 Generator Control Module Coolant Pump - Left (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12234 Generator Control Module Coolant Pump - Right (HP2) Generator Control Module Temperature Sensor (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12235 Generator X1 (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12236 Generator X1 (Gas) Generator X2 (Diesel) Generator X2 (LU3) Generator X2 (Gas except LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12237 Glow Plug Control Module (GPCM) X1 (Diesel) Glow Plug Control Module (GPCM) X2 (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12238 Headlamp - Left High Beam Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12239 Headlamp - Left Low Beam Headlamp - Right High Beam Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12240 Headlamp - Right Low Beam Headlamp and Panel Dimmer Switch Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12241 Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 (LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12242 He - In Component Connector End Views (continued) Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 (Gas except LU3 and except ZW9) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12243 Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 (LY6 or L96 with ZW9) Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 2 (LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12244 Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 2 (Gas except LU3) Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 (LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12245 Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 (Gas except LU3 and except ZW9) Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 (LY6 or L96 with ZW9) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12246 Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 2 (LU3) Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 2 (Gas except LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12247 Heated Seat Control Module X1 (SPO Heated Seats) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12248 Heated Seat Control Module X2 (SPO Heated Seats) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12249 Heated Seat Control Module X3 (SPO Heated Seats) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12250 Heated Seat Control Module X4 (SPO Heated Seats) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12251 Heated Seat Element - Driver Back (AN3 without KB6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12252 Heated Seat Element - Driver Back (SPO Heated Seats) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12253 Heated Seat Element - Driver Cushion (AN3 without KB6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12254 Heated Seat Element - Driver Cushion (SPO Heated Seats) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12255 Heated Seat Element - Passenger Back (AN3 without KB6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12256 Heated Seat Element - Passenger Back (SPO Heated Seats) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12257 Heated Seat Element - Passenger Cushion (AN3 without KB6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12258 Heated Seat Element - Passenger Cushion (SPO Heated Seats) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12259 Heated Seat Switch - Driver (SPO Heated Seats) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12260 Heated Seat Switch - Passenger (SPO Heated Seats) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12261 Heated Steering Wheel (KA9) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12262 Heater Coolant Pump (HP2) High Voltage Circuit Impact Detection Sensor (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12263 Hood Ajar Switch (AP3, AP8 or PTO) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12264 Horn - Left Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12265 Horn - Right (Z71, YE9 or HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12266 HVAC Control Module X1 (CJ2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12267 HVAC Control Module X2 (C67, C42 or MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12268 HVAC Control Module X2 (CJ2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12269 HVAC Control Module X3 (C67, C42, CJ2 or MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12270 Ignition Coil 1 (Gas except LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12271 Ignition Coil 2 (Gas except LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12272 Ignition Coil 3 (Gas except LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12273 Ignition Coil 4 (Gas except LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12274 Ignition Coil 5 (Gas except LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12275 Ignition Coil 6 (Gas except LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12276 Ignition Coil 7 (Gas except LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12277 Ignition Coil 8 (Gas except LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12278 Ignition Control Module (ICM) (LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12279 Ignition Switch Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12280 Inflatable Restraint Front End Sensor - Left (10 Series) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12281 Inflatable Restraint Front End Sensor - Right (10 Series) Inflatable Restraint Front End Sensor (except 10 Series) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12282 Inflatable Restraint I/P Module (10 Series except MEX) Inflatable Restraint I/P Module (20/30/31 Series or MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12283 Inflatable Restraint I/P Module Disable Switch (C99 or MEX) Inflatable Restraint I/P Module Indicator (AL0 or C99 except MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12284 Inflatable Restraint Passenger Presence System (PPS) Module (AL0) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12285 Inflatable Restraint Roof Rail Module - Driver (Crew Cab with ASF) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12286 Inflatable Restraint Roof Rail Module - Driver (Extended Cab with ASF) In - Ob Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12287 Component Connector End Views (continued) Inflatable Restraint Roof Rail Module - Driver (Regular Cab with ASF) Inflatable Restraint Roof Rail Module - Passenger (Crew Cab with ASF) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12288 Inflatable Restraint Roof Rail Module - Passenger (Extended Cab with ASF) Inflatable Restraint Roof Rail Module - Passenger (Regular Cab with ASF) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12289 Inflatable Restraint Seat Position Sensor - Driver (10 Series except MEX) Inflatable Restraint Seat Position Sensor - Passenger (10 Series except Crew Cab or MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12290 Inflatable Restraint Sensing and Diagnostic Module (SDM) X1 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12291 Inflatable Restraint Sensing and Diagnostic Module (SDM) X2 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12292 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12293 Inflatable Restraint Side Impact Module - Left (10 Series except HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12294 Inflatable Restraint Side Impact Module - Left (HP2) Inflatable Restraint Side Impact Module - Right (10 Series except HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12295 Inflatable Restraint Side Impact Module - Right (HP2) Inflatable Restraint Side Impact Sensor (SIS) - Left Front (ASF) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12296 Inflatable Restraint Side Impact Sensor (SIS) - Left Rear (Extended or Crew Cab with ASF) Inflatable Restraint Side Impact Sensor (SIS) - Right Front (ASF) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12297 Inflatable Restraint Side Impact Sensor (SIS) - Right Rear (Extended or Crew Cab with ASF) Inflatable Restraint Steering Wheel Module Coil X1 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12298 Inflatable Restraint Steering Wheel Module Coil X2 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12299 Inflatable Restraint Steering Wheel Module X1 (10 Series) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12300 Inflatable Restraint Steering Wheel Module X2 (10 Series) Inflatable Restraint Steering Wheel Module (except 10 Series) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12301 Infrared Transmitter (U42) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12302 Inside Rearview Mirror (ISRVM) (except MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12303 Instrument Panel Cluster (IPC) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12304 Intake Air Heater (IAH) X1 (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12305 Intake Air Heater X2 (Diesel) Intake Air Temperature (IAT) Sensor 2 (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12306 Intake Air Valve (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12307 Knock Sensor (KS) 1 (Gas) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12308 Knock Sensor (KS) 2 (Gas) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12309 License Lamp - Left License Lamp - Right Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12310 Manifold Absolute Pressure (MAP) Sensor (LU3) Manifold Absolute Pressure (MAP) Sensor (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12311 Manifold Absolute Pressure (MAP) Sensor (Gas except LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12312 Marker Lamp - Tailgate (RO5) Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12313 Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (Gas) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12314 Memory Seat Module (MSM) X1 (AN3) Memory Seat Module (MSM) X2 (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12315 Memory Seat Module (MSM) X3 (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12316 Memory Seat Module (MSM) X4 (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12317 Memory Seat Module (MSM) X5 (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12318 Memory Seat Module (MSM) X6 (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12319 Memory Seat Module (MSM) X7 (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12320 Mode Actuator (C67, C42 or CJ2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12321 Modulated Main Pressure Control (PC) Solenoid Valve (MW7) Multifunction Switch - I/P (except MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12322 Noise Compensation Microphone (UQA with Y91) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12323 Object Alarm Sensor - Left Rear Corner (UD7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12324 Ob - Se Component Connector End Views (continued) Object Alarm Sensor - Left Rear Middle (UD7) Object Alarm Sensor - Right Rear Corner (UD7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12325 Object Alarm Sensor - Right Rear Middle (UD7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12326 Output Speed Sensor (OSS) (M99) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12327 Outside Rearview Mirror - Driver (DL3, DL8 or DPN) Outside Rearview Mirror - Passenger (DL3, DL8 or DPN) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12328 Outside Rearview Mirror Switch (DL8 or DPN) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12329 Park Brake Switch Park/Neutral Position (PNP) Switch (M30) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12330 Park/Turn Signal Lamp - Lower Left Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12331 Park/Turn Signal Lamp - Lower Right Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12332 Park/Turn Signal Lamp - Upper Left Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12333 Park/Turn Signal Lamp - Upper Right Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12334 Power Steering Assist Motor X1 (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12335 Power Steering Assist Motor X2 (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12336 Power Take Off (PTO) Module (PTO) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12337 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12338 Power Take Off (PTO) Relay (PTO) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12339 Power Take-Off (PTO) Switch (PTO) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12340 Pressure Control (PC) Solenoid Valve (M30) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12341 Pressure Control (PC) Solenoid Valve 1 (MW7) Pressure Control (PC) Solenoid Valve 2 (MW7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12342 Pressure Switch Manifold (PSM) (MW7) Radio X1 (except Y91) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12343 Radio X1 (Y91 or 8S8) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12344 Radio X2 (except Y91 or 8S8) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12345 Radio X2 (Y91 or 8S8) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12346 Radio X3 (U42) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12347 Radio X4 (UUL or UUK) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12348 Rear Fender Clearance Lamp - Left Front (RO5) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12349 Rear Fender Clearance Lamp - Left Rear (RO5) Rear Fender Clearance Lamp - Right Front (RO5) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12350 Rear Fender Clearance Lamp - Right Rear (RO5) Rear Object Sensor Control Module X1 (UD7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12351 Rear Object Sensor Control Module X2 (UD7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12352 Rear Seat Audio (RSA) Control X1 (UK6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12353 Rear Seat Audio (RSA) Control X2 (UK6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12354 Rear Window Defogger Grid X1 (C49) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12355 Rear Window Defogger Grid X2 (C49) Rearview Camera (SPO Rearview Camera) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12356 Rearview Camera Image Display Module X1 (UVC) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12357 Rearview Camera Image Display Module X2 (UVC) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12358 Recirculation Actuator (C67 or CJ2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12359 Remote Control Door Lock Receiver (RCDLR) (AP3 or AP8) Roof Beacon Relay (TRW) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12360 Roof Beacon Switch (5X7, 5Y0 or TRW) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12361 Roof Clearance Lamp - Left Front Outer (U01) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12362 Roof Clearance Lamp - Front Middle (U01) Roof Clearance Lamp - Right Front Outer (U01) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12363 Seat Adjuster Motor Assembly - Driver (AG1 without AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12364 Seat Adjuster Motor Assembly - Driver X1 (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12365 Se - Sp Component Connector End Views (continued) Seat Adjuster Motor Assembly - Driver X2 (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12366 Seat Adjuster Motor Assembly - Passenger (AG2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12367 Seat Adjuster Switch - Driver (AG1 without AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12368 Seat Adjuster Switch - Driver (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12369 Seat Adjuster Switch - Passenger (AG2 without AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12370 Seat Adjuster Switch - Passenger (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12371 Seat Back Ventilation Heating and Cooling Module - Driver (KB6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12372 Seat Back Ventilation Heating and Cooling Module - Passenger (KB6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12373 Seat Belt Buckle - Driver Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12374 Seat Belt Buckle - Passenger X1 (10 Series without MEX) Seat Belt Buckle - Passenger X2 (AL0) Seat Belt Pretensioner - Driver Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12375 Seat Belt Pretensioner - Passenger Seat Climate Control Module X1 (KB6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12376 Seat Climate Control Module X2 (KB6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12377 Seat Climate Control Module X3 (KB6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12378 Seat Cushion Ventilation Heating and Cooling Module - Driver (KB6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12379 Seat Cushion Ventilation Heating and Cooling Module - Passenger (KB6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12380 Seat Front Vertical Motor - Driver (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12381 Seat Front Vertical Motor - Passenger (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12382 Seat Horizontal Motor - Driver (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12383 Seat Horizontal Motor - Passenger (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12384 Seat Lumbar Horizontal Motor - Driver (AN3) Seat Lumbar Horizontal Motor - Passenger (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12385 Seat Lumbar Horizontal Motor Position Sensor - Driver (AN3) Seat Lumbar Switch - Driver (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12386 Seat Lumbar Switch - Passenger (AN3) Seat Lumbar Vertical Motor - Driver (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12387 Seat Lumbar Vertical Motor - Passenger (AN3) Seat Lumbar Vertical Motor Position Sensor - Driver (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12388 Seat Rear Vertical Motor - Driver (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12389 Seat Rear Vertical Motor - Passenger (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12390 Seat Recline Motor - Driver (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12391 Seat Recline Motor - Passenger (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12392 Seat Recline Position Sensor - Driver (AN3) Security Indicator Lamp (SPO Alarm) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12393 Serial Data Gateway (SDG) Module X1 (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12394 Serial Data Gateway (SDG) Module X2 (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12395 Shift Solenoid (SS) Valve 1 (MW7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12396 Shift Solenoid (SS) Valve 2 (MW7) Shift Solenoid (SS) Valve 3 (MW7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12397 Side Marker Lamp - Left Front (Z88) Side Marker Lamp - Left Rear (Z88) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12398 Side Marker Lamp - Right Front (Z88) Side Marker Lamp - Right Rear (Z88) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12399 Sliding Rear Window Close Relay (A48) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12400 Sliding Rear Window Motor (A48) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12401 Sliding Rear Window Open Relay (A48) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12402 Sliding Rear Window Switch (A48) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12403 Speaker - Center I/P (UQA with Y91) Speaker - Left Front (UQ3) Speaker - Left Front (UQ5) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12404 Speaker - Left Front (UQA) Sp - Tr Component Connector End Views (continued) Speaker - Left Front Tweeter (except MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12405 Speaker - Left Rear (Extended Cab or Crew Cab with UQ3 or UQ5) Speaker - Left Rear (Extended Cab or Crew Cab with UQA) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12406 Speaker - Left Rear (Regular Cab) Speaker - Right Front (UQ3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12407 Speaker - Right Front (UQ5) Speaker - Right Front (UQA) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12408 Speaker - Right Front Tweeter (except MEX) Speaker - Right Rear (Extended Cab or Crew Cab with UQ3 or UQ5) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12409 Speaker - Right Rear (Extended Cab or Crew Cab with UQA) Speaker - Right Rear (Regular Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12410 Speaker - Subwoofer (UQA) Starter Motor X1 (5X7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12411 Starter Motor X1 (LU3 without 9L4) Starter Motor X1 (6A6) Starter Motor X1 (9L4 or Gas except LU3) Starter Motor X1 (Diesel) Starter Motor X2 (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12412 Starter Motor X2 (Gas) Steering Angle Sensor (JL4) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12413 Steering Wheel Control Switch - Left (K34 or KA9) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12414 Steering Wheel Control Switch - Right (UK3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12415 Stop Lamp Switch Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12416 Sunroof Control Module (CF5) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12417 Sunroof Switch (CF5) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12418 Sunshade - Left (DH6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12419 Sunshade - Right (DH6) Tail/Stop and Turn Signal Lamp - Lower Left Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12420 Tail/Stop and Turn Signal Lamp - Lower Right Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12421 Tail/Stop and Turn Signal Lamp - Upper Left Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12422 Tail/Stop and Turn Signal Lamp - Upper Right Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12423 Theft Deterrent Module (TDM) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12424 Throttle Body (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12425 Throttle Body (Gas except HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12426 Torque Converter Clutch (TCC) Pressure Control (PC) Solenoid Valve (MW7) Torque Converter Clutch (TCC) Pulse Width Modulated (PWM) Solenoid Valve (M30) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12427 Torque Converter Clutch (TCC) Solenoid Valve (M30) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12428 Wiring Diagram Trailer Brake Control Module (JL1 except 31 Series) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12429 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12430 Trailer Brake Control Module (JL1 with 31 Series) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12431 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12432 Trailer Brake Control Relay (JL1) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12433 Trailer Brake Control Switch (JL1) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12434 Trailer Connector (except MEX or EXP) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12435 Trailer Stop/Turn Relay (TZ0) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12436 Tr - Ya Component Connector End Views (continued) Transfer Case 2/4 Wheel Drive Actuator Position Sensor (NQH) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12437 Transfer Case Encoder Motor (NQF or NQH) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12438 Transfer Case Shift Control Module X1 (NQF or NQH) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12439 Transfer Case Shift Control Module X2 (NQF or NQH) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12440 Transfer Case Shift Control Module X3 (NQF or NQH) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12441 Transfer Case Shift Control Switch (NQF or NQH) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12442 Transfer Case Shift Control Switch (NQG) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12443 Transmission Control Module (TCM) (M30) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12444 Transmission Control Module (TCM) (MW7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12445 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12446 Transmission Power Inverter Module (3 Phase) Cable Cover (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12447 Turbocharger Vane Position Control Solenoid Valve (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12448 Turbocharger Vane Position Sensor (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12449 Turn Signal/Multifunction Switch X1 Turn Signal/Multifunction Switch X2 Turn Signal/Multifunction Switch X3 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12450 Valve Lifter Oil Manifold (VLOM) Assembly (LMG, LC9, LZ1 or L96) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12451 Vehicle Communication Interface Module (VCIM) X1 (UE1) Vehicle Communication Interface Module (VCIM) X2 (UE1) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12452 Vehicle Communication Interface Module (VCIM) X3 (UE1 with UUL or UUK) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12453 Vehicle Inclination Sensor (SPO Alarm) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12454 Vehicle Shock Sensor (SPO Alarm) Vehicle Speed Sensor (VSS) (M30, TZ0, MYC and MW7or M99 with NQG or NQF) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12455 Vehicle Speed Sensor (VSS) (MW7 except NQG or NQF) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12456 Video Display (U42) Water in Fuel Sensor (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12457 Wheel Speed Sensor (WSS) - Left Front (10 Series) Wheel Speed Sensor (WSS) - Left Front (except 10 Series) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12458 Wheel Speed Sensor (WSS) - Left Rear (JL4 or HP2) Wheel Speed Sensor (WSS) - Right Front (10 Series) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12459 Wheel Speed Sensor (WSS) - Right Front (except 10 Series) Wheel Speed Sensor (WSS) - Right Rear (JL4 or HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12460 Window Motor - Driver (A31) Window Motor - Left Rear (Crew Cab with A31 or Extended Cab with ABV) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12461 Window Motor - Passenger (A31) Window Motor - Right Rear (Crew Cab with A31 or Extended Cab with ABV) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12462 Window Switch - Driver X1 (A31 without AN3 or DL3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12463 Window Switch - Driver X2 (A31 without AN3 or DL3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12464 Window Switch - Left Rear (Crew Cab with A31 or Extended Cab with ABV) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12465 Window Switch - Passenger (A31 without AN3 or DL3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12466 Window Switch - Right Rear (Crew Cab with A31 or Extended Cab with ABV) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12467 Windshield Outside Moisture Sensor (CE1) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12468 Windshield Washer Fluid Level Switch Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12469 Windshield Washer Fluid Pump Windshield Wiper Motor Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12470 Wrecker Relay X1 (5X7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12471 Wrecker Relay X2 (5X7) Yaw and Lateral Accelerometer Sensor (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12472 Yaw and Lateral Accelerometer Sensor (JL4 except 10 Series) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12473 Yaw and Lateral Accelerometer Sensor (JL4 with 10 Series) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12474 1-2 Shift - Ac Component Connector End Views 1-2 Shift Solenoid (SS) Valve (M30) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12475 2-3 Shift Solenoid (SS) Valve (M30) A/C Compressor Clutch (C67) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12476 A/C Compressor Clutch (CJ2) A/C Compressor X1 (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12477 A/C Compressor X2 (+) (HP2) A/C Compressor X3 (-) (HP2) A/C Low Pressure Sensor (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12478 A/C Refrigerant Pressure Sensor (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12479 A/C Refrigerant Pressure Sensor (Gas except HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12480 A/C Refrigerant Pressure Sensor (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12481 Accelerator Pedal Position (APP) Sensor Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12482 Accessory DC Power Control Module X1 (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12483 Accessory DC Power Control Module X2 (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12484 Accessory DC Power Control Module X3 (HP2) Accessory DC Power Control Module X4 (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12485 Accessory Power Outlet - Center Console (D07) Accessory Power Outlet - Center Console Compartment (D07) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12486 Accessory Power Outlet - Center Seat (AZ3) Accessory Power Outlet - I/P 1 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12487 Accessory Power Outlet - I/P 2 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12488 Multiple Junction Connector: Diagrams Connector End Views By Number X100 Inline Harness Connector End Views X100 Forward Lamp Harness to Left Front Headlamp Harness Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12489 X102 Inline Harness Connector End Views X102 Brake Clutch Harness to Chassis Harness (JL1) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12490 X103 Inline Harness Connector End Views X103 Instrument Panel Harness to Forward Lamp Harness Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12491 X106 Inline Harness Connector End Views X106 Forward Lamp Harness to Right Front Headlamp Harness Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12492 X107 Inline Harness Connector End Views X107 Engine Chassis Harness to Engine Harness (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12493 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12494 X108 Inline Harness Connector End Views X108 Engine Chassis Harness to Engine Harness (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12495 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12496 X109 Inline Harness Connector End Views X109 Engine Harness (LU3) or Engine Chassis Harness (Diesel) to Instrument Panel Harness (LU3 or Diesel without NQF or NQH) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12497 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12498 X109 Engine Harness (except Diesel) or Engine Chassis Harness (Diesel) to Instrument Panel Harness (HP2, LU3 or Diesel with NQF or NQH) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12499 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12500 X109 Engine Harness to Instrument Panel Harness (Gas except LU3 and without NQF or NQH) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12501 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12502 X109 Engine Harness to Instrument Panel Harness (Gas except LU3 and with NQF or NQH) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12503 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12504 X110 Inline Harness Connector End Views X110 Engine Harness (except Diesel) or Engine Chassis Harness (Diesel) to Front Axle Harness (NQF, NQG or NQH) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12505 X111 Inline Harness Connector End Views X111 Engine Harness to Left Ignition Coil Harness (Gas except LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12506 X112 Inline Harness Connector End Views X112 Engine Harness to Camshaft Position Sensor Jumper Harness (L20, LMG or LC9) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12507 X112 Engine Harness to Camshaft Position Sensor Jumper Harness (LU3) X112 Engine Harness to Camshaft Position Sensor Jumper Harness (LZ1, LY6, L96 or L9H) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12508 X113 Inline Harness Connector End Views X113 Engine Harness to Right Ignition Coil Harness (Gas except LU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12509 X113 Engine Jumper Harness to Engine Harness (Diesel) X115 Inline Harness Connector End Views X115 Chassis Harness to Instrument Panel Harness Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12510 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12511 X116 Inline Harness Connector End Views X116 Battery Positive Harness to Brake Clutch Harness (9L4) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12512 X117 Inline Harness Connector End Views X117 Fuel Rail Pressure Sensor Jumper Harness to Engine Harness (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12513 X120 Inline Harness Connector End Views X120 Engine Harness to Forward Lamp Harness (HP2) X121 Inline Harness Connector End Views X121 Battery Negative Harness to Battery Positive Harness (9L4) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12514 X124 Inline Harness Connector End Views X124 Engine Chassis Harness to PTO Jumper Harness (PTO) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12515 X125 Inline Harness Connector End Views X125 Heated Oxygen Sensor (HO2S) Jumper Harness to Engine Harness (LY6 with 31 Series) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12516 X127 Inline Harness Connector End Views X127 Engine Chassis Harness to Generator Jumper Harness (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12517 X128 Inline Harness Connector End Views X128 Fuel Pressure Regulator Harness to Engine Harness (Diesel) X129 Inline Harness Connector End Views X129 Instrument Panel Harness to Chassis Harness (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12518 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12519 X131 Inline Harness Connector End Views X131 Chassis Harness to Engine Harness (LU3) X131 Chassis Harness to Engine Harness (L20, LMG, LC9 or L9H) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12520 X150 Inline Harness Connector End Views X150 Engine Harness to Instrument Panel Harness (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12521 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12522 X122 Inline Harness Connector End Views X122 Auxiliary Battery Harness to Engine Harness (TP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12523 X123 Inline Harness Connector End Views X123 Engine Chassis Harness to Instrument Panel Harness (PTO) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12524 X175 Inline Harness Connector End Views X175 Engine Chassis Harness to Transmission Internal Harness (MW7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12525 X175 Engine Harness to Transmission Internal Harness (M30) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12526 X176 Inline Harness Connector End Views X176 Engine Harness to Transmission Harness (M99) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12527 X200 Inline Harness Connector End Views X200 Instrument Panel Harness to Body Harness Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12528 X201 Inline Harness Connector End Views X201 Steering Column Harness to Instrument Panel Harness Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12529 X202 Inline Harness Connector End Views X202 Instrument Panel Harness to Body Harness Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12530 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12531 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12532 X203 Inline Harness Connector End Views X203 Instrument Panel Harness (Y91) or I/P Extension Harness (except Y91) to Headliner Harness (UE1, UUL or UUK) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12533 X204 Inline Harness Connector End Views X204 Headliner Harness to Instrument Panel Harness (Y91) or I/P Extension Harness (except Y91) (U42) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12534 X205 Inline Harness Connector End Views X205 Brake Clutch Harness to Instrument Panel Harness (except TZ0) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12535 X205 Brake Clutch Harness to Instrument Panel Harness (TZ0) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12536 X206 Inline Harness Connector End Views X206 Right A-Pillar Harness to Instrument Panel Harness (Y91) or I/P Extension Harness (except Y91) (U42) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12537 X207 Inline Harness Connector End Views X207 Instrument Panel Harness to Instrument Panel Harness (6J4) X208 Inline Harness Connector End Views X208 Body Harness to Headliner Harness (YE9) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12538 X209 Inline Harness Connector End Views X209 Rearview Camera Chassis Harness to Rearview Camera I/P Jumper Harness (SPO Rearview Camera) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12539 X210 Inline Harness Connector End Views X210 Rearview Camera I/P Jumper Harness to Rearview Camera I/P Jumper Extension Harness (SPO Rearview Camera with KB6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12540 X212 Inline Harness Connector End Views X212 Instrument Panel Harness to I/P Extension Harness (except Y91, MEX or 8S8) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12541 X214 Inline Harness Connector End Views X214 Brake Clutch Harness to Fuse Block Jumper Harness (9L4) X215 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12542 Inline Harness Connector End Views X215 Body Harness to Instrument Panel Harness (HP2) X219 Inline Harness Connector End Views X219 Brake Clutch Harness to Fuse Block Jumper Harness (9L4) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12543 X224 Inline Harness Connector End Views X224 Brake Clutch Harness to Beacon Harness (5Y0 or 5X7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12544 X225 Inline Harness Connector End Views X225 Brake Clutch Harness to Battery Positive Harness (9L4) X226 Inline Harness Connector End Views X226 Fuse Block Jumper Harness to Brake Clutch Harness (9L4) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12545 X227 Inline Harness Connector End Views X227 LED Indicator Harness to SPO Theft Harness (SPO Alarm) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12546 X228 Inline Harness Connector End Views X228 Beacon Harness to Chassis Harness (5Y0) X240 Inline Harness Connector End Views X240 I/P Extension Harness to Instrument Panel Harness (UVC except Y91) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12547 X241 Inline Harness Connector End Views X241 Instrument Panel Harness (Y91) or I/P Extension Harness (except Y91) to Body Harness (UVC with DRC or DD8) X275 Inline Harness Connector End Views X275 Inflatable Restraint Steering Wheel Module Coil to Body Harness Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12548 X276 Inline Harness Connector End Views X276 Inflatable Restraint Steering Wheel Module Coil to Steering Column Harness (KA9) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12549 X277 Inline Harness Connector End Views X277 Inflatable Restraint Steering Wheel Module Coil to Heated Steering Wheel Harness (KA9) X278 Inline Harness Connector End Views X278 Instrument Panel Harness to Body Harness (MEX or A52) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12550 X279 Inline Harness Connector End Views X279 Instrument Panel Harness to Headliner Harness (MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12551 X300 Inline Harness Connector End Views X300 Chassis Harness to Engine Chassis Harness (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12552 X300 Engine Harness to Chassis Harness (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12553 X300 Chassis Harness to Engine Harness (LY6 or L96) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12554 X301 Inline Harness Connector End Views X301 Instrument Panel Harness (Y91) or I/P Extension Harness (except Y91) to Console Harness (Y91, UQA or D07) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12555 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12556 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12557 X303 Inline Harness Connector End Views X303 Body Harness to Driver Seat Harness (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12558 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12559 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12560 X303 Body Harness to Driver Seat Harness (except AN3 or MEX) X303 Driver Seat Harness to Body Harness (MEX or A52) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12561 X304 Inline Harness Connector End Views X304 Headliner Harness to Overhead Console Harness (except MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12562 X305 Inline Harness Connector End Views X305 Body Harness to Passenger Seat Harness (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12563 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12564 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12565 X305 Body Harness to Passenger Seat Harness (except AN3 or MEX) X306 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12566 Inline Harness Connector End Views X306 Headliner Harness to Right A-Pillar Harness (U42) X309 Inline Harness Connector End Views X309 Body Harness to Console Harness (Y91) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12567 X313 Inline Harness Connector End Views X313 Sunroof Harness (CF5) or Overhead Console Harness (TRW, 5X7 or 5Y0) to Right A-Pillar Harness (CF5, TRW, 5X7 or 5Y0) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12568 X318 Inline Harness Connector End Views X318 Headliner Harness to CHMSL Harness Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12569 X319 Inline Harness Connector End Views X319 Body Harness to Console Harness (HP2, AZ3 or D07 with UQ3) X320 Inline Harness Connector End Views X320 Body Harness to Sliding Rear Window Jumper Harness (A48) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12570 X324 Inline Harness Connector End Views X324 Driver Seat Harness to Driver Seat Jumper Harness (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12571 X325 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12572 Inline Harness Connector End Views X325 Passenger Seat Harness to Passenger Seat Jumper Harness (AN3) X330 Inline Harness Connector End Views X330 Heated Seat Body Harness to Heated Driver Seat Harness (SPO Heated Seats) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12573 X331 Inline Harness Connector End Views X331 Heated Seat Body Harness to Heated Driver Seat Harness (SPO Heated Seats) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12574 X332 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12575 Inline Harness Connector End Views X332 Heated Passenger Seat Harness to Heated Seat Body Harness (SPO Heated Seats) X333 Inline Harness Connector End Views X333 Heated Seat Body Harness to Heated Seat Body Harness (SPO Heated Seats) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12576 X334 Inline Harness Connector End Views X334 Heated Seat Body Harness to Heated Seat Body Harness (SPO Heated Seats) X350 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12577 Inline Harness Connector End Views X350 Body Harness to Drive Motor Generator Battery Control Harness (HP2) X371 Inline Harness Connector End Views X371 SPO Accessory Signal Cable 1A to SPO Accessory Signal Cable 3A (SPO DVD) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12578 X372 Inline Harness Connector End Views X372 SPO Accessory Signal Cable 2B to SPO Accessory Signal Cable 3B (SPO DVD) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12579 X373 Inline Harness Connector End Views X373 SPO Accessory Signal Cable 2A to SPO Accessory Signal Cable 3A (SPO DVD) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12580 X374 Inline Harness Connector End Views X374 SPO Accessory Signal Cable 1B to SPO Accessory Signal Cable 3B (SPO DVD) X414 Inline Harness Connector End Views X414 Chassis Harness to Camper Harness (UY2 or 8S3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12581 X415 Inline Harness Connector End Views X415 Rear Bumper Harness to Left Hip Lamp Harness (RO5) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12582 X451 Inline Harness Connector End Views X451 Body Ground Jumper Harness to Rear Axle Ground Jumper Harness (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12583 X408 Inline Harness Connector End Views X408 Chassis Harness to Rear Bumper Harness (UD7) X416 Inline Harness Connector End Views X416 Rear Bumper Harness to Right Hip Lamp Harness (RO5) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12584 X500 Inline Harness Connector End Views X500 Left Front Door Harness to Body Harness (YE9 or HP2, without AN3 or DL3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12585 X501 Inline Harness Connector End Views X501 Left Front Door Harness to Body Harness (YE9 or HP2, without AN3 or DL3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12586 X502 Inline Harness Connector End Views X502 Left Front Door Harness to Body Harness (ASF with AN3 or DL3, and except YE9) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12587 X600 Inline Harness Connector End Views X600 Right Front Door Harness to Body Harness (YE9 or HP2, without AN3 or DL3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12588 X601 Inline Harness Connector End Views X601 Right Front Door Harness to Body Harness (ASF) X700 - X799 Inline Harness Connector End Views X700 Body Harness to Left Rear Door Harness (Crew Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12589 X700 Left Rear Door Harness to Body Harness (Extended Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12590 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12591 X800 - X899 Inline Harness Connector End Views X800 Body Harness to Right Rear Door Harness (Crew Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12592 X800 Right Rear Door Harness to Body Harness (Extended Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12593 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > Connector End Views By Name > Page 12594 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Service and Repair > Relay Replacement (Attached to Wire Harness) Power Distribution Relay: Service and Repair Relay Replacement (Attached to Wire Harness) Relay Replacement (Attached to Wire Harness) Removal Procedure 1. Locate the relay. Refer to the Master Electrical Component List (See: Locations/Component Locations/A - Z Index) to locate the relay in the vehicle. 2. Remove any fasteners which hold the relay in place. 3. Remove any connector position assurance (CPA) devices or secondary locks. Note: Use care when removing a relay in a wiring harness when the relay is secured by fasteners or tape. 4. Separate the relay (1) from the wire harness connector (2). Installation Procedure 1. Connect the relay (1) to the wire harness connector (2). 2. Install any connector position assurance (CPA) devices or secondary locks. 3. Install the relay using any fasteners or tape that originally held the relay in place. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Service and Repair > Relay Replacement (Attached to Wire Harness) > Page 12599 Power Distribution Relay: Service and Repair Relay Replacement (Within an Electrical Center) Relay Replacement (Within an Electrical Center) Special Tools J 43244 Relay Puller Pliers Removal Procedure 1. Remove the electrical center cover. 2. Locate the relay. Refer to Electrical Center Identification Views (See: Fuse/Application and ID) to locate the electrical center where the relay exists. Note: * Always note the orientation of the relay. * If equipped with a notch style relay; observe the location of the notch on the old relay to verify the new relay is installed with the notch in the same location. * Ensure that the electrical center is secure, as not to put added stress on the wires or terminals. 3. Using the J 43244 (1) position the tool on opposing corners of the relay (2). Caution: Use J43244 to pull the relay straight out from the electrical center terminals. The use of pliers or a flat bladed tool could damage the electrical center. 4. Remove the relay (2) from the electrical center. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Service and Repair > Relay Replacement (Attached to Wire Harness) > Page 12600 1. Install the relay (2) in the same position as removed. 2. Install the electrical center cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Service and Repair > Relay Replacement (Attached to Wire Harness) Power Distribution Relay: Service and Repair Relay Replacement (Attached to Wire Harness) Relay Replacement (Attached to Wire Harness) Removal Procedure 1. Locate the relay. Refer to the Master Electrical Component List (See: Locations/Component Locations/A - Z Index) to locate the relay in the vehicle. 2. Remove any fasteners which hold the relay in place. 3. Remove any connector position assurance (CPA) devices or secondary locks. Note: Use care when removing a relay in a wiring harness when the relay is secured by fasteners or tape. 4. Separate the relay (1) from the wire harness connector (2). Installation Procedure 1. Connect the relay (1) to the wire harness connector (2). 2. Install any connector position assurance (CPA) devices or secondary locks. 3. Install the relay using any fasteners or tape that originally held the relay in place. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Service and Repair > Relay Replacement (Attached to Wire Harness) > Page 12606 Power Distribution Relay: Service and Repair Relay Replacement (Within an Electrical Center) Relay Replacement (Within an Electrical Center) Special Tools J 43244 Relay Puller Pliers Removal Procedure 1. Remove the electrical center cover. 2. Locate the relay. Refer to Electrical Center Identification Views (See: Fuse/Application and ID) to locate the electrical center where the relay exists. Note: * Always note the orientation of the relay. * If equipped with a notch style relay; observe the location of the notch on the old relay to verify the new relay is installed with the notch in the same location. * Ensure that the electrical center is secure, as not to put added stress on the wires or terminals. 3. Using the J 43244 (1) position the tool on opposing corners of the relay (2). Caution: Use J43244 to pull the relay straight out from the electrical center terminals. The use of pliers or a flat bladed tool could damage the electrical center. 4. Remove the relay (2) from the electrical center. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Service and Repair > Relay Replacement (Attached to Wire Harness) > Page 12607 1. Install the relay (2) in the same position as removed. 2. Install the electrical center cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood Relay Box: Application and ID Fuse Block - Underhood Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12612 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12613 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12614 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12615 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12616 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12617 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12618 Fuse Block - Underhood Top View - Diesel Fuse Block - Underhood Top View - Gas Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12619 Fuse Block - Underhood Bottom View Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12620 Fuse Block - Underhood X1 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12621 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12622 Fuse Block - Underhood X2 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12623 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12624 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12625 Fuse Block - Underhood X3 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12626 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12627 Fuse Block - Underhood X4 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12628 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12629 Fuse Block - Underhood X5 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12630 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12631 Fuse Block - Underhood X6 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12632 Fuse Block - Underhood X7 (except TP2) Fuse Block - Underhood X7 (TP2) Fuse Block - Underhood X8 (except JL1) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12633 Fuse Block - Underhood X8 (JL1) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12634 Relay Box: Application and ID Fuse Block - I/P Electrical Center Identification Views Fuse Block - I/P Label Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12635 Fuse Block - I/P Top View Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12636 Fuse Block - I/P Bottom View Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12637 Fuse Block - I/P X1 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12638 Fuse Block - I/P X2 (except MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12639 Fuse Block - I/P X3 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12640 Fuse Block - I/P X4 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12641 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12642 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12643 Relay Box: Application and ID Fuse Block - Mobile Radio Electrical Center Identification Views Fuse Block - Mobile Radio, Top View (9L4) Fuse Block - Mobile Radio (9L4) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12644 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12645 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood Relay Box: Application and ID Fuse Block - Underhood Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12650 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12651 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12652 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12653 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12654 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12655 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12656 Fuse Block - Underhood Top View - Diesel Fuse Block - Underhood Top View - Gas Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12657 Fuse Block - Underhood Bottom View Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12658 Fuse Block - Underhood X1 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12659 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12660 Fuse Block - Underhood X2 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12661 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12662 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12663 Fuse Block - Underhood X3 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12664 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12665 Fuse Block - Underhood X4 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12666 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12667 Fuse Block - Underhood X5 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12668 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12669 Fuse Block - Underhood X6 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12670 Fuse Block - Underhood X7 (except TP2) Fuse Block - Underhood X7 (TP2) Fuse Block - Underhood X8 (except JL1) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12671 Fuse Block - Underhood X8 (JL1) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12672 Relay Box: Application and ID Fuse Block - I/P Electrical Center Identification Views Fuse Block - I/P Label Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12673 Fuse Block - I/P Top View Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12674 Fuse Block - I/P Bottom View Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12675 Fuse Block - I/P X1 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12676 Fuse Block - I/P X2 (except MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12677 Fuse Block - I/P X3 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12678 Fuse Block - I/P X4 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12679 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12680 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12681 Relay Box: Application and ID Fuse Block - Mobile Radio Electrical Center Identification Views Fuse Block - Mobile Radio, Top View (9L4) Fuse Block - Mobile Radio (9L4) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12682 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuse Block - Underhood > Page 12683 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 11-09-41-002 > Mar > 11 > Restraint System - Air Bag Warning Lamp On Repeat DTC's Wiring Harness: Customer Interest Restraint System - Air Bag Warning Lamp On Repeat DTC's TECHNICAL Bulletin No.: 11-09-41-002 Date: March 17, 2011 Subject: Air Bag Warning Lamp Illuminated, Repeat History DTC B0083 0F - B0088 0F (Follow SI and Procedure Outlined Below if necessary) Models: 2010-2011 Cadillac Escalade, Escalade ESV, Escalade EXT, Escalade Hybrid 2010-2011 Chevrolet Avalanche, Silverado, Silverado Hybrid, Suburban, Tahoe, Tahoe Hybrid 2010-2011 GMC Sierra, Sierra Denali, Sierra Hybrid, Yukon, Yukon XL, Yukon XL Denali, Yukon Hybrid, Yukon Denali Hybrid Condition In extremely rare cases, some customers may comment that the air bag warning lamp is illuminated. This condition may be intermittent and when checking the vehicle for DTCs, the SDM may report B0083, B0084, B0085, B0086, B0087 and/or B0088 with symptom code 0F. The code will be stored in history and may be repeated. The code probably will not be current. Cause This condition may be caused by possible electro-magnetic interference (EMI) in the Amarillo, Texas area from external sources such as aviation airspace traffic radar, creating erratic sensor information to the SDM. Correction Perform all diagnostics and repairs documented in SI. Notice If published SI repair information does not resolve the condition, perform the procedure below. Install a steward clamp ferrite bead following the procedure below: 1. Disconnect battery. Refer to SIR Disabling and Enabling in SI. 2. Remove the door trim. Refer to SI door trim removal. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 11-09-41-002 > Mar > 11 > Restraint System - Air Bag Warning Lamp On Repeat DTC's > Page 12692 3. Install the steward clamp ferrite bead on the wire harness (1). 4. Place tape around the steward clamp ferrite bead (1) to avoid vibration or movement. Verify that the door glass does not come in contact with it. 5. Reinstall the door trim. Refer to SI door trim removal. 6. Reconnect the battery. Refer to SIR Disabling and Enabling in SI. Parts Information Parts (Laird HFA100049-0A2) can be purchased from Digi-Key Corporation at www.digikey.com. Material allowance for repair is $1.10 each (in Canada, $1.21). Warranty Information For vehicle repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 10-08-42-001B > Jan > 11 > Lighting - Low Beam Headlamp(s) Inoperative Wiring Harness: Customer Interest Lighting - Low Beam Headlamp(s) Inoperative TECHNICAL Bulletin No.: 10-08-42-001B Date: January 24, 2011 Subject: Low Beam Headlamp Bulb Diagnosis/Replacement (Inspect Bulb and Connector) Models: 2008-2011 Buick Enclave 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2008-2011 Cadillac CTS, CTS-V 2010-2011 Cadillac CTS Sport Wagon, SRX 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2011 Chevrolet Malibu 2009-2011 Chevrolet Traverse 2010-2011 Chevrolet Equinox 2007-2011 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2010-2011 GMC Terrain 2006-2010 Pontiac G6 2007-2010 Saturn AURA, OUTLOOK Attention: This bulletin DOES NOT apply to vehicles equipped with High Intensity Discharge (HID) lamps. Supercede: This bulletin is being revised to update the part number for the recommended splice sleeve. Please discard Corporate Bulletin Number 10-08-42-001A (Section 08 - Body and Accessories). Condition Some customers may comment that the low beam headlamp is inoperative. Correction DO NOT replace the entire headlamp assembly for this condition. Replace the bulb and inspect the connector following the procedure below. 1. Remove the headlamp bulb. Refer to Headlamp Bulb Replacement procedure in SI. 2. Inspect the connector. - If the connector is NOT discolored or damaged, replace the bulb only. For bulb part numbers, see Headlamp Bulb (Low Beam) in Group 02.727 of the appropriate Parts Catalog. - If the connector is discolored at the bulb interface, replace the connector (service pigtail listed below) and bulb. Important Use only Duraseal splice sleeves (salmon, P/N 19168446). Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Refer to Splicing Copper Wire Using Splice Sleeves in SI for splicing procedures. 1. Cut the wires of the connector approximately 45 mm (13/4 in) from the connector and splice in the service pigtail connector. Ensure that the splices are not above the connector when re-installing. 2. Replace the bulb. 3. Verify that the headlamp is fully functional. Parts Information Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 10-08-42-001B > Jan > 11 > Lighting - Low Beam Headlamp(s) Inoperative > Page 12697 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm Wiring Harness: Customer Interest Seats - Driver/Passenger Heated Seats Inop./Slow to Warm TECHNICAL Bulletin No.: 10-08-50-008B Date: January 13, 2011 Subject: Driver or Passenger Heated Seat Inoperative, Slow to Warm, DTC(s) Set (Repair Connector, Re-Route Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Silverado, Suburban, Tahoe 2011 Chevrolet Silverado Heavy Duty 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2011 GMC Sierra Heavy Duty All Equipped with Heated Front Seat (RPO AN3, KA1) or Heated and Cooled Seat (RPO KB6) and/or Luxury Package (RPO PCK) Supercede: This bulletin is being revised to update the RPOs. Please discard Corporate Bulletin Number 10-08-50-008A (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger heated seat system exhibits the following symptoms: - Heated seat turns on and then turns off within 1 to 10 minutes (at any 60 second interval). - The system doesn't get warm enough, or gets warm very slowly. - The heated seat system is completely inoperative. Upon further review, DTCs B2430 0D and/or B2180 0D may be set as a current or history code if the vehicle is equipped with heated seats only (RPO KA1). Also, the LED indicator for the heated seats may come On and then flash after approximately 1 minute, then go out. If the vehicle is equipped with heated and cooled seats (KB6), the switch LED indicator may stay On, but the heated and cooled seat is inoperative. The fan will continue to blow air. Cause Heated Seats (RPO AN3, KA1) The heated seat control circuit terminal and/or ground terminal in harness connector X1 to the memory seat module (MSM) may have lost tension and is loose. The reduced terminal tension increases resistance in the connector, which may result in the symptoms described above. Heated and Cooled Seats (RPO KB6) The thermo-electric device (TED) in the seat cushion/seat back ventilation heating and cooling module may have become inoperative. Correction Heated Seats (RPO AN3, KA1) Follow the steps below to correct the concern with the heated seats. Note This repair requires a unique anti-abrasion electrical tape and harness clip from Kent Automotive. Refer to the Parts Information below. 1. Access and remove the seat bolts/nuts. 2. Adjust the seat rearward about halfway. Adjust the seat recline full forward. 3. Tilt the seat backward to access the bottom of the seat. Prop the seat up with a suitable tool if required. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 12702 4. Disconnect seat harness connectors (1) X1, X2, X3 and X4 from the MSM. 5. Identify connector X1. Refer to Component Connector End Views in SI. 6. Perform a terminal drag test on connector X1, paying special attention to terminals 1, 4, 6, 11 and 14. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Refer to Testing for Intermittent Conditions and Poor Connections in SI. 7. Replace any terminal in question including connector X1 terminals 1, 4, 6, 11 and 14 if necessary. Refer to Repairing Connector Terminals in SI. 8. Identify connector X4. Refer to Component Connector End Views in SI. 9. Perform the terminal drag test described in step 6, paying special attention to terminal 14. 10. Replace any terminal in question including connector X4 terminal 14 if necessary. Refer to Repairing Connector Terminals in SI. 11. Remove the harness clip (1) from the plastic carrier. 12. Cut the electrical tape holding the harness in the plastic carrier using a sharp utility knife in the area shown (1). 13. Free the harness from the carrier back to the area shown (1). 14. Obtain "*Woven Polyester (PET) Electrical Tape" (Special Order P/N RZ97156A00) from Kent Automotive. Refer to Parts Information below. Important Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 12703 DO NOT substitute with vinyl electrical tape or friction tape. Use only the tape specified above. 15. Tape the harness starting at the MSM connectors (1) extending back to the new break-out location (2) in the plastic carrier. 16. Install a plastic tie strap around the harness and the plastic carrier at the break-out point (1). 17. Install the new harness edge clip (1) 10 mm (0.4 in) further from the connectors and the existing harness clip. Ensure the clip is installed in the orientation shown. 18. Install the harness with the new harness clip in the location shown (1). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 12704 19. Reinstall the harness connectors (1) to the MSM. 20. Reinstall the seat to the vehicle. Heated and Cooled Seats (RPO KB6) Follow the steps below to correct the concern with the heated and cooled seats. 1. Inspect the ventilation heating and cooling module for a concern with the TED. Refer to Seat Heating and Cooling, Diagnostic Information and Procedures in SI. Note If the heated and cooled seat function is inoperative, but the heat switch indicators are On, the MSM is functioning properly and the concern is with the TED. 2. If the TED is found to be the concern, replace the seat cushion or seat back ventilation heating and cooling module. Refer to Driver or Passenger Seat Back Ventilation Heating and Cooling Blower Replacement or Driver or Passenger Seat Cushion Ventilation Heating and Cooling Blower Replacement in SI. If the TED is not the concern, follow normal diagnostics and repair in SI. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Use the appropriate Labor Operation based on the repair completed. Heated Seats (RPO AN3, KA1) For vehicles repaired under warranty, use: Heated and Cooled Seats (RPO KB6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 12705 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 12710 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 12711 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 12712 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power Wiring Harness: Customer Interest Electrical - Intermittent MIL/DTC P2138/Reduced Power TECHNICAL Bulletin No.: 07-06-04-019D Date: June 28, 2010 Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced Engine Power (Repair Instrument Panel (IP) to Body Harness Connector) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years and warranty information. Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion System) Condition - Some customers may comment on an intermittent malfunction indicator lamp (MIL) being Illuminated with a message or an indicator that displays Reduced Engine Power. - The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP) Sensor 1-2 Correlation set as Current or in History. Cause This condition may be caused by water intrusion into the instrument panel (IP) to body harness connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value for more than a calibrated period of time, setting P2138. Correction Note Aftermarket equipment can generate DTC P2138 and/or other DTCs. 1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or low reference circuits or to any other ECM/PCM 5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI. 2. Perform the Diagnostic System Check - Vehicle. ‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any 5V reference DTCs are not set, proceed to Step 3. 3. Locate the IP to body harness connector, which may be located in and around the left hand kick panel area or inside the IP. Depending on the vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI. Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped) and windshield/cowl sealing. 4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the leak. Refer to General Information > Water Leaks in SI. ‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair. 5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for Intermittent Conditions and Poor Connections in SI. ‹› If any corrosion and/or debris is observed, repair as necessary. 6. After completing the repair, verify the proper operation of the system. Depending on the vehicle and model year, perform the Diagnostic Repair Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power > Page 12717 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the appropriate labor operation for the source of the water leak Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 10-08-42-001 > May > 10 > Lighting - Low Beam Headlamp(s) Inoperative Wiring Harness: Customer Interest Lighting - Low Beam Headlamp(s) Inoperative TECHNICAL Bulletin No.: 10-08-42-001 Date: May 14, 2010 Subject: Low Beam Headlamp Bulb Diagnosis/Replacement (Inspect Bulb and Connector) Models: 2008-2010 Buick Enclave 2008-2010 Cadillac CTS, CTS-V 2010 Cadillac CTS Sport Wagon, SRX 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Malibu 2009-2010 Chevrolet Traverse 2007-2010 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2006-2010 Pontiac G6 2007-2010 Saturn AURA Attention: This bulletin DOES NOT apply to vehicles equipped with High Intensity Discharge (HID) lamps. Condition Some customers may comment that the low beam headlamp is inoperative. Correction DO NOT replace the entire headlamp assembly for this condition. Replace the bulb and inspect the connector following the procedure below. 1. Remove the lamp assembly, then remove the bulb. Refer to Headlamp Assembly Replacement in SI. 2. Inspect the connector. - If the connector is NOT discolored or damaged, replace the bulb only. For bulb part numbers, see Headlamp Bulb (Low Beam) in Group 02.727 of the appropriate Parts Catalog. - If the connector is discolored at the bulb interface, replace the connector (service pigtail listed below) and bulb. Important Use only Duraseal splice sleeves (salmon, P/N 12089189). Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Refer to Splicing Copper Wire Using Splice Sleeves in SI for splicing procedures. 1. Cut the wires of the connector approximately 45 mm (1-3/4 in) from the connector and splice in the service pigtail connector. Ensure that the splices are not above the connector when re-installing. 2. Replace the bulb. 3. Verify that the headlamp is fully functional. Parts Information Warranty Information For vehicles repaired under warranty, use: Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 10-08-42-001 > May > 10 > Lighting - Low Beam Headlamp(s) Inoperative > Page 12722 If only bulbs are replaced, use labor operation N0440 or N0441. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 08-08-45-002A > May > 10 > Body - L/H/R/H Power Mirror(s) Inoperative Wiring Harness: Customer Interest Body - L/H/R/H Power Mirror(s) Inoperative TECHNICAL Bulletin No.: 08-08-45-002A Date: May 13, 2010 Subject: Left Or Right Power Outside Mirror Inoperative (Inspect Wire Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2010 GMC Sierra, Sierra Denali, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Supercede: This bulletin is being revised to add the 2010 model year and update the Warranty Information. Please discard Corporate Bulletin Number 08-08-45-002 (Section 08 - Body and Accessories). Condition Some customers may comment that the left or right outside power mirror is inoperative. Cause This condition may be caused by two different concerns. 1. The wiring harness may be damaged from a screw that retains the door trim to the door. 2. The wiring harness connector at the mirror glass actuator may not be locked in place. Correction Inspect the wiring harness and connector. 1. Remove the door trim and inspect the wiring harness. Refer to Front Side Door Trim Panel Replacement in SI if necessary. If the harness is damaged , refer to Repairing Damaged Wire Insulation in SI. After making the repair, reposition the harness. 2. Inspect the connector at the mirror actuator. Refer to Outside Rearview Mirror Motor Replacement in SI if necessary. If the connector is loose, remove and reinstall the connector. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 08-08-45-002A > May > 10 > Body - Left/Right Power Outside Mirror Inoperative Wiring Harness: Customer Interest Body - Left/Right Power Outside Mirror Inoperative TECHNICAL Bulletin No.: 08-08-45-002A Date: May 13, 2010 Subject: Left Or Right Power Outside Mirror Inoperative (Inspect Wire Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2010 GMC Sierra, Sierra Denali, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Supercede: This bulletin is being revised to add the 2010 model year and update the Warranty Information. Please discard Corporate Bulletin Number 08-08-45-002 (Section 08 - Body and Accessories). Condition Some customers may comment that the left or right outside power mirror is inoperative. Cause This condition may be caused by two different concerns. 1. The wiring harness may be damaged from a screw that retains the door trim to the door. 2. The wiring harness connector at the mirror glass actuator may not be locked in place. Correction Inspect the wiring harness and connector. 1. Remove the door trim and inspect the wiring harness. Refer to Front Side Door Trim Panel Replacement in SI if necessary. If the harness is damaged , refer to Repairing Damaged Wire Insulation in SI. After making the repair, reposition the harness. 2. Inspect the connector at the mirror actuator. Refer to Outside Rearview Mirror Motor Replacement in SI if necessary. If the connector is loose, remove and reinstall the connector. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 11-09-41-002 > Mar > 11 > Restraint System - Air Bag Warning Lamp On Repeat DTC's Wiring Harness: All Technical Service Bulletins Restraint System - Air Bag Warning Lamp On Repeat DTC's TECHNICAL Bulletin No.: 11-09-41-002 Date: March 17, 2011 Subject: Air Bag Warning Lamp Illuminated, Repeat History DTC B0083 0F - B0088 0F (Follow SI and Procedure Outlined Below if necessary) Models: 2010-2011 Cadillac Escalade, Escalade ESV, Escalade EXT, Escalade Hybrid 2010-2011 Chevrolet Avalanche, Silverado, Silverado Hybrid, Suburban, Tahoe, Tahoe Hybrid 2010-2011 GMC Sierra, Sierra Denali, Sierra Hybrid, Yukon, Yukon XL, Yukon XL Denali, Yukon Hybrid, Yukon Denali Hybrid Condition In extremely rare cases, some customers may comment that the air bag warning lamp is illuminated. This condition may be intermittent and when checking the vehicle for DTCs, the SDM may report B0083, B0084, B0085, B0086, B0087 and/or B0088 with symptom code 0F. The code will be stored in history and may be repeated. The code probably will not be current. Cause This condition may be caused by possible electro-magnetic interference (EMI) in the Amarillo, Texas area from external sources such as aviation airspace traffic radar, creating erratic sensor information to the SDM. Correction Perform all diagnostics and repairs documented in SI. Notice If published SI repair information does not resolve the condition, perform the procedure below. Install a steward clamp ferrite bead following the procedure below: 1. Disconnect battery. Refer to SIR Disabling and Enabling in SI. 2. Remove the door trim. Refer to SI door trim removal. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 11-09-41-002 > Mar > 11 > Restraint System - Air Bag Warning Lamp On Repeat DTC's > Page 12736 3. Install the steward clamp ferrite bead on the wire harness (1). 4. Place tape around the steward clamp ferrite bead (1) to avoid vibration or movement. Verify that the door glass does not come in contact with it. 5. Reinstall the door trim. Refer to SI door trim removal. 6. Reconnect the battery. Refer to SIR Disabling and Enabling in SI. Parts Information Parts (Laird HFA100049-0A2) can be purchased from Digi-Key Corporation at www.digikey.com. Material allowance for repair is $1.10 each (in Canada, $1.21). Warranty Information For vehicle repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-42-001B > Jan > 11 > Lighting - Low Beam Headlamp(s) Inoperative Wiring Harness: All Technical Service Bulletins Lighting - Low Beam Headlamp(s) Inoperative TECHNICAL Bulletin No.: 10-08-42-001B Date: January 24, 2011 Subject: Low Beam Headlamp Bulb Diagnosis/Replacement (Inspect Bulb and Connector) Models: 2008-2011 Buick Enclave 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2008-2011 Cadillac CTS, CTS-V 2010-2011 Cadillac CTS Sport Wagon, SRX 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2011 Chevrolet Malibu 2009-2011 Chevrolet Traverse 2010-2011 Chevrolet Equinox 2007-2011 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2010-2011 GMC Terrain 2006-2010 Pontiac G6 2007-2010 Saturn AURA, OUTLOOK Attention: This bulletin DOES NOT apply to vehicles equipped with High Intensity Discharge (HID) lamps. Supercede: This bulletin is being revised to update the part number for the recommended splice sleeve. Please discard Corporate Bulletin Number 10-08-42-001A (Section 08 - Body and Accessories). Condition Some customers may comment that the low beam headlamp is inoperative. Correction DO NOT replace the entire headlamp assembly for this condition. Replace the bulb and inspect the connector following the procedure below. 1. Remove the headlamp bulb. Refer to Headlamp Bulb Replacement procedure in SI. 2. Inspect the connector. - If the connector is NOT discolored or damaged, replace the bulb only. For bulb part numbers, see Headlamp Bulb (Low Beam) in Group 02.727 of the appropriate Parts Catalog. - If the connector is discolored at the bulb interface, replace the connector (service pigtail listed below) and bulb. Important Use only Duraseal splice sleeves (salmon, P/N 19168446). Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Refer to Splicing Copper Wire Using Splice Sleeves in SI for splicing procedures. 1. Cut the wires of the connector approximately 45 mm (13/4 in) from the connector and splice in the service pigtail connector. Ensure that the splices are not above the connector when re-installing. 2. Replace the bulb. 3. Verify that the headlamp is fully functional. Parts Information Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-42-001B > Jan > 11 > Lighting - Low Beam Headlamp(s) Inoperative > Page 12741 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-50-008B > Jan > 11 > Seats Driver/Passenger Heated Seats Inop./Slow to Warm Wiring Harness: All Technical Service Bulletins Seats - Driver/Passenger Heated Seats Inop./Slow to Warm TECHNICAL Bulletin No.: 10-08-50-008B Date: January 13, 2011 Subject: Driver or Passenger Heated Seat Inoperative, Slow to Warm, DTC(s) Set (Repair Connector, Re-Route Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Silverado, Suburban, Tahoe 2011 Chevrolet Silverado Heavy Duty 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2011 GMC Sierra Heavy Duty All Equipped with Heated Front Seat (RPO AN3, KA1) or Heated and Cooled Seat (RPO KB6) and/or Luxury Package (RPO PCK) Supercede: This bulletin is being revised to update the RPOs. Please discard Corporate Bulletin Number 10-08-50-008A (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger heated seat system exhibits the following symptoms: - Heated seat turns on and then turns off within 1 to 10 minutes (at any 60 second interval). - The system doesn't get warm enough, or gets warm very slowly. - The heated seat system is completely inoperative. Upon further review, DTCs B2430 0D and/or B2180 0D may be set as a current or history code if the vehicle is equipped with heated seats only (RPO KA1). Also, the LED indicator for the heated seats may come On and then flash after approximately 1 minute, then go out. If the vehicle is equipped with heated and cooled seats (KB6), the switch LED indicator may stay On, but the heated and cooled seat is inoperative. The fan will continue to blow air. Cause Heated Seats (RPO AN3, KA1) The heated seat control circuit terminal and/or ground terminal in harness connector X1 to the memory seat module (MSM) may have lost tension and is loose. The reduced terminal tension increases resistance in the connector, which may result in the symptoms described above. Heated and Cooled Seats (RPO KB6) The thermo-electric device (TED) in the seat cushion/seat back ventilation heating and cooling module may have become inoperative. Correction Heated Seats (RPO AN3, KA1) Follow the steps below to correct the concern with the heated seats. Note This repair requires a unique anti-abrasion electrical tape and harness clip from Kent Automotive. Refer to the Parts Information below. 1. Access and remove the seat bolts/nuts. 2. Adjust the seat rearward about halfway. Adjust the seat recline full forward. 3. Tilt the seat backward to access the bottom of the seat. Prop the seat up with a suitable tool if required. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-50-008B > Jan > 11 > Seats Driver/Passenger Heated Seats Inop./Slow to Warm > Page 12746 4. Disconnect seat harness connectors (1) X1, X2, X3 and X4 from the MSM. 5. Identify connector X1. Refer to Component Connector End Views in SI. 6. Perform a terminal drag test on connector X1, paying special attention to terminals 1, 4, 6, 11 and 14. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Refer to Testing for Intermittent Conditions and Poor Connections in SI. 7. Replace any terminal in question including connector X1 terminals 1, 4, 6, 11 and 14 if necessary. Refer to Repairing Connector Terminals in SI. 8. Identify connector X4. Refer to Component Connector End Views in SI. 9. Perform the terminal drag test described in step 6, paying special attention to terminal 14. 10. Replace any terminal in question including connector X4 terminal 14 if necessary. Refer to Repairing Connector Terminals in SI. 11. Remove the harness clip (1) from the plastic carrier. 12. Cut the electrical tape holding the harness in the plastic carrier using a sharp utility knife in the area shown (1). 13. Free the harness from the carrier back to the area shown (1). 14. Obtain "*Woven Polyester (PET) Electrical Tape" (Special Order P/N RZ97156A00) from Kent Automotive. Refer to Parts Information below. Important Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-50-008B > Jan > 11 > Seats Driver/Passenger Heated Seats Inop./Slow to Warm > Page 12747 DO NOT substitute with vinyl electrical tape or friction tape. Use only the tape specified above. 15. Tape the harness starting at the MSM connectors (1) extending back to the new break-out location (2) in the plastic carrier. 16. Install a plastic tie strap around the harness and the plastic carrier at the break-out point (1). 17. Install the new harness edge clip (1) 10 mm (0.4 in) further from the connectors and the existing harness clip. Ensure the clip is installed in the orientation shown. 18. Install the harness with the new harness clip in the location shown (1). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-50-008B > Jan > 11 > Seats Driver/Passenger Heated Seats Inop./Slow to Warm > Page 12748 19. Reinstall the harness connectors (1) to the MSM. 20. Reinstall the seat to the vehicle. Heated and Cooled Seats (RPO KB6) Follow the steps below to correct the concern with the heated and cooled seats. 1. Inspect the ventilation heating and cooling module for a concern with the TED. Refer to Seat Heating and Cooling, Diagnostic Information and Procedures in SI. Note If the heated and cooled seat function is inoperative, but the heat switch indicators are On, the MSM is functioning properly and the concern is with the TED. 2. If the TED is found to be the concern, replace the seat cushion or seat back ventilation heating and cooling module. Refer to Driver or Passenger Seat Back Ventilation Heating and Cooling Blower Replacement or Driver or Passenger Seat Cushion Ventilation Heating and Cooling Blower Replacement in SI. If the TED is not the concern, follow normal diagnostics and repair in SI. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Use the appropriate Labor Operation based on the repair completed. Heated Seats (RPO AN3, KA1) For vehicles repaired under warranty, use: Heated and Cooled Seats (RPO KB6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-50-008B > Jan > 11 > Seats Driver/Passenger Heated Seats Inop./Slow to Warm > Page 12749 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 12754 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 12755 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 12756 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 12761 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 12762 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 12763 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 12764 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 12765 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 12766 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power Wiring Harness: All Technical Service Bulletins Electrical - Intermittent MIL/DTC P2138/Reduced Power TECHNICAL Bulletin No.: 07-06-04-019D Date: June 28, 2010 Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced Engine Power (Repair Instrument Panel (IP) to Body Harness Connector) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years and warranty information. Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion System) Condition - Some customers may comment on an intermittent malfunction indicator lamp (MIL) being Illuminated with a message or an indicator that displays Reduced Engine Power. - The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP) Sensor 1-2 Correlation set as Current or in History. Cause This condition may be caused by water intrusion into the instrument panel (IP) to body harness connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value for more than a calibrated period of time, setting P2138. Correction Note Aftermarket equipment can generate DTC P2138 and/or other DTCs. 1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or low reference circuits or to any other ECM/PCM 5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI. 2. Perform the Diagnostic System Check - Vehicle. ‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any 5V reference DTCs are not set, proceed to Step 3. 3. Locate the IP to body harness connector, which may be located in and around the left hand kick panel area or inside the IP. Depending on the vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI. Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped) and windshield/cowl sealing. 4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the leak. Refer to General Information > Water Leaks in SI. ‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair. 5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for Intermittent Conditions and Poor Connections in SI. ‹› If any corrosion and/or debris is observed, repair as necessary. 6. After completing the repair, verify the proper operation of the system. Depending on the vehicle and model year, perform the Diagnostic Repair Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 07-06-04-019D > Jun > 10 > Electrical - Intermittent MIL/DTC P2138/Reduced Power > Page 12771 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the appropriate labor operation for the source of the water leak Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-42-001 > May > 10 > Lighting - Low Beam Headlamp(s) Inoperative Wiring Harness: All Technical Service Bulletins Lighting - Low Beam Headlamp(s) Inoperative TECHNICAL Bulletin No.: 10-08-42-001 Date: May 14, 2010 Subject: Low Beam Headlamp Bulb Diagnosis/Replacement (Inspect Bulb and Connector) Models: 2008-2010 Buick Enclave 2008-2010 Cadillac CTS, CTS-V 2010 Cadillac CTS Sport Wagon, SRX 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Malibu 2009-2010 Chevrolet Traverse 2007-2010 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2006-2010 Pontiac G6 2007-2010 Saturn AURA Attention: This bulletin DOES NOT apply to vehicles equipped with High Intensity Discharge (HID) lamps. Condition Some customers may comment that the low beam headlamp is inoperative. Correction DO NOT replace the entire headlamp assembly for this condition. Replace the bulb and inspect the connector following the procedure below. 1. Remove the lamp assembly, then remove the bulb. Refer to Headlamp Assembly Replacement in SI. 2. Inspect the connector. - If the connector is NOT discolored or damaged, replace the bulb only. For bulb part numbers, see Headlamp Bulb (Low Beam) in Group 02.727 of the appropriate Parts Catalog. - If the connector is discolored at the bulb interface, replace the connector (service pigtail listed below) and bulb. Important Use only Duraseal splice sleeves (salmon, P/N 12089189). Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Refer to Splicing Copper Wire Using Splice Sleeves in SI for splicing procedures. 1. Cut the wires of the connector approximately 45 mm (1-3/4 in) from the connector and splice in the service pigtail connector. Ensure that the splices are not above the connector when re-installing. 2. Replace the bulb. 3. Verify that the headlamp is fully functional. Parts Information Warranty Information For vehicles repaired under warranty, use: Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-42-001 > May > 10 > Lighting - Low Beam Headlamp(s) Inoperative > Page 12776 If only bulbs are replaced, use labor operation N0440 or N0441. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 08-08-45-002A > May > 10 > Body - L/H/R/H Power Mirror(s) Inoperative Wiring Harness: All Technical Service Bulletins Body - L/H/R/H Power Mirror(s) Inoperative TECHNICAL Bulletin No.: 08-08-45-002A Date: May 13, 2010 Subject: Left Or Right Power Outside Mirror Inoperative (Inspect Wire Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2010 GMC Sierra, Sierra Denali, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Supercede: This bulletin is being revised to add the 2010 model year and update the Warranty Information. Please discard Corporate Bulletin Number 08-08-45-002 (Section 08 - Body and Accessories). Condition Some customers may comment that the left or right outside power mirror is inoperative. Cause This condition may be caused by two different concerns. 1. The wiring harness may be damaged from a screw that retains the door trim to the door. 2. The wiring harness connector at the mirror glass actuator may not be locked in place. Correction Inspect the wiring harness and connector. 1. Remove the door trim and inspect the wiring harness. Refer to Front Side Door Trim Panel Replacement in SI if necessary. If the harness is damaged , refer to Repairing Damaged Wire Insulation in SI. After making the repair, reposition the harness. 2. Inspect the connector at the mirror actuator. Refer to Outside Rearview Mirror Motor Replacement in SI if necessary. If the connector is loose, remove and reinstall the connector. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 08-08-45-002A > May > 10 > Body - Left/Right Power Outside Mirror Inoperative Wiring Harness: All Technical Service Bulletins Body - Left/Right Power Outside Mirror Inoperative TECHNICAL Bulletin No.: 08-08-45-002A Date: May 13, 2010 Subject: Left Or Right Power Outside Mirror Inoperative (Inspect Wire Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2010 GMC Sierra, Sierra Denali, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Supercede: This bulletin is being revised to add the 2010 model year and update the Warranty Information. Please discard Corporate Bulletin Number 08-08-45-002 (Section 08 - Body and Accessories). Condition Some customers may comment that the left or right outside power mirror is inoperative. Cause This condition may be caused by two different concerns. 1. The wiring harness may be damaged from a screw that retains the door trim to the door. 2. The wiring harness connector at the mirror glass actuator may not be locked in place. Correction Inspect the wiring harness and connector. 1. Remove the door trim and inspect the wiring harness. Refer to Front Side Door Trim Panel Replacement in SI if necessary. If the harness is damaged , refer to Repairing Damaged Wire Insulation in SI. After making the repair, reposition the harness. 2. Inspect the connector at the mirror actuator. Refer to Outside Rearview Mirror Motor Replacement in SI if necessary. If the connector is loose, remove and reinstall the connector. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 12790 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 12791 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 12792 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 12793 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 12794 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 12795 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications Alignment: Technical Service Bulletins Steering/Suspension - Wheel Alignment Specifications WARRANTY ADMINISTRATION Bulletin No.: 05-03-07-009C Date: December 09, 2010 Subject: Wheel Alignment Specifications, Requirements and Recommendations for GM Vehicles Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks Supercede: This bulletin is being extensively revised to provide technicians and warranty administrators with an all inclusive guide for wheel alignments. PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM WHEEL ALIGNMENT SERVICE. Please discard Corporate Bulletin Number 05-03-07-009B (Section 03 - Suspension). Purpose The purpose of this bulletin is to provide retail, wholesale and fleet personnel with General Motors' warranty service requirements and recommendations for customer concerns related to wheel alignment. For your convenience, this bulletin updates and centralizes all of GM's Standard Wheel Alignment Service Procedures, Policy Guidelines and bulletins on wheel alignment warranty service. Important PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM WHEEL ALIGNMENT SERVICE. The following five (5) key steps are a summary of this bulletin and are REQUIRED in completing a successful wheel alignment service. 1. Verify the vehicle is in an Original Equipment condition for curb weight, tires, wheels, suspension and steering configurations. Vehicles modified in any of these areas are not covered for wheel alignment warranty. 2. Review the customer concern relative to "Normal Operation" definitions. 3. Verify that vehicle is within the "Mileage Policy" range. 4. Document wheel alignment warranty claims appropriately for labor operations E2000 and E2020. The following information must be documented or attached to the repair order: - Customer concern in detail - What corrected the customer concern? - If a wheel alignment is performed: - Consult SI for proper specifications. - Document the "Before" AND "After" wheel alignment measurements/settings. - Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin) 5. Use the proper wheel alignment equipment (preferred with print-out capability), process and the appropriate calibration maintenance schedules. Important If it is determined that a wheel alignment is necessary under warranty, use the proper labor code for the repair. E2000 for Steering Wheel Angle and/or Front Toe set or E2020 for Wheel Alignment Check/Adjust includes Caster, Camber and Toe set (Wheel alignment labor time for other component repairs is to be charged to the component that causes a wheel alignment operation.). The following flowchart is to help summarize the information detailed in this bulletin and should be used whenever a wheel alignment is performed. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 12801 Verify Original Equipment Condition of the Vehicle - Verify that Original Equipment Tires and Wheels or Official GM Accessory Tires and Wheels are on the vehicle. - Verify that aftermarket suspension "Lift" or "Lowering" Kits or other suspension alterations have NOT been done to the vehicle. - Check for accidental damage to the vehicle; for example, severe pothole or curb impacts, collision damage that may have affected the wheel alignment of the vehicle; e.g., engine cradles, suspension control arms, axles, wheels, wheel covers, tires may show evidence of damage/impact. - Check to be sure vehicle has seen "Normal Use" rather than abuse; e.g., very aggressive driving may show up by looking at the tires and condition of the vehicle. - Check for other additional equipment items that may significantly affect vehicle mass such as large tool boxes, campers, snow plow packages (without the snowplow RPO), etc., especially in trucks and cutaway/incomplete vehicles. Significant additional mass can affect trim height and wheel alignment of the vehicle and may necessitate a customer pay wheel alignment when placed semi-permanently in the vehicle (Upfitter instructions are to realign the vehicle after placement of these types of items. (This typically applies to trucks and incomplete vehicles that can be upfit with equipment such as the above.) Customer Concerns, "Normal Operation" Conditions and "Mileage Policy" Possible Concerns The following are typical conditions that may require wheel alignment warranty service: 1. Lead/Pull: defined as "at a constant highway speed on a typical straight road, the amount of effort required at the steering wheel to maintain the vehicle's straight heading." Important Please evaluate for the condition with hands-on the steering wheel. Follow the "Vehicle Leads/Pulls" diagnostic tree located in SI to determine the cause of a lead/pull concern. Lead/Pull concerns can be due to road crown or road slope, tires, wheel alignment or even in rare circumstances a steering gear issue. Lead/pull concerns due to road crown are considered "Normal Operation" and are NOT a warrantable condition -- the customer should be advised that this is "Normal Operation." Important Some customers may comment on a "Lead/Pull" when they hold the steering wheel in a level condition. If so, this is more likely a "steering wheel angle" concern because the customer is "steering" the vehicle to obtain a "level" steering wheel. 2. Steering wheel angle to the left or right (counter-clockwise or clockwise, respectively): Defined as the steering wheel angle (clocking) deviation from "level" while maintaining a straight heading on a typical straight road. 3. Irregular or Premature tire wear: Slight to very slight "feathering" or "edge" wear on the shoulders of tires is NOT considered unusual and should even out with a tire rotation; if the customer is concerned about a "feathering" condition of the tires, the customer could be advised to rotate the tires earlier than the next scheduled mileage/maintenance interval (but no later than the next interval). Be sure to understand the customer's driving habits as this will also heavily influence the tire wear performance; tire wear from aggressive or abusive driving habits is NOT a warrantable condition. Important Slight or mild feathering, cupping, edge or heel/toe wear of tire tread shoulders is "normal" and can show up very early in a tire/vehicle service mileage; in fact, some new tires can show evidence of feathering from the factory. These issues do NOT affect the overall performance and tread life of the tire. Dealer personnel should always check the customer's maintenance records to ensure that tire inflation pressure is being maintained to placard and that the tires are being rotated (modified-X pattern) at the proper mileage intervals. Wheel alignments are NOT to be performed for the types of "Normal" Tire Feathering shown in Figures 1-4 below. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 12802 Figure 1: Full Tread View - "NORMAL" Tire "Feathering" Wear on the Shoulder/Adjacent/Center Ribs Figure 2: Tire Shoulder View Example 1 - "NORMAL" Tire "Feathering" Wear on the Shoulder Figure 3: Tire Shoulder View Example 2 - "NORMAL" Tire "Feathering" Wear Figure 4: Detail Side View of Tire Shoulder Area - "NORMAL" Tire "Feathering" Wear Important When a wheel alignment is deemed necessary for tire wear, be sure to document on the repair order, in as much detail as possible, the severity and type of tire wear (e.g., severe center wear or severe inside or outside shoulder wear) and the position of the tire on the vehicle (RF, LF, LR, RR). Please note the customer's concern with the wear such as, noise, appearance, wear life, etc. A field product report with pictures of the tire wear condition is recommended. Refer to Corporate Bulletin Number 02-00-89-002J and #07-00-89-036C. 4. Other repairs that affect wheel alignment; e.g., certain component replacement such as suspension control arm replacement, engine cradle adjustment/replace, steering gear replacement, steering tie rod replace, suspension strut/shock, steering knuckle, etc. may require a wheel alignment. Important If other components or repairs are identified as affecting the wheel alignment, policy calls for the wheel alignment labor time to be charged to the replaced/repaired component's labor operation time rather than the wheel alignment labor operations. Important Vibration type customer concerns are generally NOT due to wheel alignment except in the rare cases; e.g., extreme diagonal wear across the tread. In general, wheel alignments are NOT to be performed as an investigation/correction for vibration concerns. "Normal Operation" Conditions Vehicle Lead/Pull Due to Road Crown or Slope: As part of "Normal Operation," vehicles will follow side-to-side or left to right road crown or slope. Be sure to verify from the customer the types of roads they are driving as they may not recognize the influence of road crown on vehicle lead/pull and steering wheel angle. If a vehicle requires significant steering effort to prevent it from "climbing" the road crown there may be an issue to be looked into further. Important Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 12803 A wheel alignment will generally NOT correct vehicles that follow the road crown since this is within "Normal Operation." Mileage Policy The following mileage policy applies for E2020 and E2000 labor operations: Note Wheel Alignment is NOT covered under the New Vehicle Limited Warranty for Express and Savana Cutaway vehicles as these vehicles require Upfitters to set the wheel alignment after completing the vehicles. - 0-800 km (0-500 mi): E2000/E2020 claims ONLY allowed with Call Center Authorization. Due to the tie down during shipping, the vehicle's suspension requires some time to reach normal operating position. For this reason, new vehicles are generally NOT to be aligned until they have accumulated at least 800 km (500 mi). A field product report should accompany any claim within this mileage range. - 801-12,000 km (501-7,500 mi): - If a vehicle came from the factory with incorrect alignment settings, any resulting off-angle steering wheel, lead/pull characteristics or the rare occurrence of excessive tire wear would be apparent early in the life of the vehicle. The following policy applies: - Vehicles 100% Factory Set/Measured for Caster/Camber/Toe - Escalade/ESV/EXT, Tahoe/Suburban, Yukon/XL/Denali, Silverado/Sierra, Express/Savana, Corvette and Colorado/Canyon: E2000/E2020 Claims: Call Center Authorization Required - All Vehicles NOT 100% Factory Set/Measured for Caster/Camber/Toe as noted above: E2000/E2020 Claims: Dealer Service Manager Authorization Required - 12,001 km and beyond (7,501 miles and beyond): During this period, customers are responsible for the wheel alignment expense or dealers may provide on a case-by case basis a one-time customer enthusiasm claim up to 16,000 km (10,000 mi). In the event that a defective component required the use of the subject labor operations, the identified defective component labor operation will include the appropriate labor time for a wheel alignment as an add condition to the component repair. Important Only one wheel alignment labor operation claim (E2000 or E2020) may be used per VIN. Warranty Documentation Requirements When a wheel alignment service has been deemed necessary, the following items will need to be clearly documented on/with the repair order: - Customer concern in detail - What corrected the customer concern? - If a wheel alignment is performed: - Consult SI for proper specifications. - Document the "Before" AND "After" wheel alignment measurements/settings. - Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin) 1. Document the customer concern in as much detail as possible on the repair order and in the warranty administration system. Preferred examples: - Steering wheel is off angle in the counterclockwise direction by approximately x degrees or clocking position. - Vehicle lead/pulls to the right at approximately x-y mph. Vehicle will climb the road crown. Severe, Moderate or Slight. - RF and LF tires are wearing on the outside shoulders with severe feathering. Important In the event of a lead/pull or steering wheel angle concern, please note the direction of lead/pull (left or right) or direction of steering wheel angle (clockwise or counterclockwise) on the repair order and within the warranty claim verbatim. Important In the event of a tire wear concern, please note the position on the vehicle and where the wear is occurring on the tire; i.e., the RF tire is wearing on the inside shoulder. 2. Document the technician's findings on cause and correction of the issue. Examples: - Reset LF toe from 0.45 degrees to 0.10 degrees and RF toe from -0.25 degrees to 0.10 degrees to correct the steering wheel angle from 5 degrees counterclockwise to 0 degrees. - Reset LF camber from 0.25 degrees to -0.05 degrees to correct the cross-camber condition of +0.30 degrees to 0.00 degrees on the vehicle. - Front Sum toe was found to be 0.50 degrees, reset to 0.20 degrees. 3. Print-out the "Before" and "After" wheel alignment measurements/settings and attach them to the Repair Order or if print-out capability is not Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 12804 available, measurements may also be clearly and legibly handwritten into the Wheel Alignment Repair Order Questionnaire attached to this bulletin. 4. Attach the Wheel Alignment Repair Order Questionnaire below along with the print-out of "Before" and "After" wheel alignment measurements to the Repair Order and retain for use by GM. Wheel Alignment Equipment and Process Wheel alignments must be performed with a quality machine that will give accurate results when performing checks. "External Reference" (image-based camera technology) is preferred. Please refer to Corporate Bulletin Number 05-00-89-029B: General Motors Dealership Critical Equipment Requirements and Recommendations. Requirements: - Computerized four wheel alignment system. - Computer capable of printing before and after alignment reports. - Computer capable of time and date stamp printout. - Racking system must have jacking capability - Racking system must be capable of level to 1.6 mm (1/16 in) - Appropriate wheel stops and safety certification - Built-in turn plates and slip plates - Wheel clamps capable of attaching to 20" or larger wheels - Racking capable of accepting any GM passenger car or light duty truck - Operator properly trained and ASE-certified (U.S. only) in wheel alignment Recommendations: Racking should have front and rear jacking capability. Equipment Maintenance and Calibration: Alignment machines must be regularly calibrated in order to give correct information. Most manufacturers recommend the following: - Alignment machines with "internal reference" sensors should be checked (and calibrated, if necessary) every six months. - Alignment machines with "external reference" (image-based camera technology) should be checked (and calibrated, if necessary) once a year. - Racks must be kept level to within 1.6 mm (1/16 in). - If any instrument that is part of the alignment machine is dropped or damaged in some way, check the calibration immediately. Check with the manufacturer of your specific equipment for their recommended service/calibration schedule. Wheel Alignment Process When performing wheel alignment measurement and/or adjustment, the following steps should be taken: Preliminary Steps: 1. Verify that the vehicle has a full tank of fuel (compensate as necessary). 2. Inspect the wheels and the tires for damage. 3. Inspect the tires for the proper inflation and irregular tire wear. 4. Inspect the wheel bearings for excessive play. 5. Inspect all suspension and steering parts for looseness, wear, or damage. 6. Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or suspension components. 7. Inspect the vehicle trim height. 8. Compensate for frame angle on targeted vehicles (refer to Wheel Alignment Specifications in SI). Satisfactory vehicle operation may occur over a wide range of alignment angles. However, if the wheel alignment angles are not within the range of specifications, adjust the wheel alignment to the specifications. Refer to Wheel Alignment Specifications in SI. Give consideration to excess loads, such as tool boxes, sample cases, etc. Follow the wheel alignment equipment manufacturer's instructions. Measure/Adjust: Important Prior to making any adjustments to wheel alignment on a vehicle, technicians must verify that the wheel alignment specifications loaded into their wheel alignment machine are up-to-date by comparing these to the wheel alignment specifications for the appropriate model and model year in SI. Using incorrect and/or outdated specifications may result in unnecessary adjustments, irregular and/or premature tire wear and repeat customer concerns Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 12805 Important When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear wheel alignment angles first in order to obtain proper front wheel alignment angles. Perform the following steps in order to measure the front and rear alignment angles: 1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment angles and record the readings. If necessary, adjust the wheel alignment to vehicle specification and record the before and after measurements. Refer to Wheel Alignment Specifications in SI. Important Technicians must refer to SI for the correct wheel alignment specifications. SI is the only source of GM wheel alignment specifications that is kept up-to-date throughout the year. Test drive vehicle to ensure proper repair. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 12806 Frame Angle Measurement (Express / Savana Only) ........ Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 12807 What corrected the customer concern and was the repair verified? Please Explain: ............. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Trim Height Specifications Alignment: Specifications Trim Height Specifications Trim Height Specifications Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Trim Height Specifications > Page 12810 Alignment: Specifications Wheel Alignment Specifications Wheel Alignment Specifications Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Trim Height Specifications > Page 12811 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Caster Description Alignment: Description and Operation Caster Description Caster Description Caster is the tilting of the uppermost point of the steering axis either forward or backward, when viewed from the side of the vehicle. A backward tilt is positive (+) and a forward tilt is negative (-). Caster influences directional control of the steering but does not affect the tire wear. Caster is affected by the vehicle height, therefore it is important to keep the body at its designed height. Overloading the vehicle or a weak or sagging rear spring will affect caster. When the rear of the vehicle is lower than its designated trim height, the front suspension moves to a more positive caster. If the rear of the vehicle is higher than its designated trim height, the front suspension moves to a less positive caster. With too little positive caster, steering may be touchy at high speed and wheel returnability may be diminished when coming out of a turn. If one wheel has more positive caster than the other, that wheel will pull toward the center of the vehicle. This condition will cause the vehicle to pull or lead to the side with the least amount of positive caster. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Caster Description > Page 12814 Alignment: Description and Operation Camber Description Camber Description Camber is the tilting of the wheels from the vertical when viewed from the front of the vehicle. When the wheels tilt outward at the top, the camber is positive (+). When the wheel tilts inward at the top, the camber is negative (-). The amount of tilt is measured in degrees from the vertical. Camber settings influence the directional control and the tire wear. Too much positive camber will result in premature wear on the outside of the tire and cause excessive wear on the suspension parts. Too much negative camber will result in premature wear on the inside of the tire and cause excessive wear on the suspension parts. Unequal side-to-side camber of 1 degree or more will cause the vehicle to pull or lead to the side with the most positive camber. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Caster Description > Page 12815 Alignment: Description and Operation Toe Description Toe Description Toe is a measurement of how much the front and/or rear wheels are turned in or out from a straight-ahead position. When the wheels are turned in, toe is positive (+). When the wheels are turned out, toe is negative (-). The actual amount of toe is normally only a fraction of a degree. The purpose of toe is to ensure that the wheels roll parallel. Toe also offsets the small deflections of the wheel support system that occur when the vehicle is rolling forward. In other words, with the vehicle standing still and the wheels set with toe-in, the wheels tend to roll parallel on the road when the vehicle is moving. Improper toe adjustment will cause premature tire wear and cause steering instability. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Caster Description > Page 12816 Alignment: Description and Operation Setback Description Setback Description Setback applies to both the front and the rear wheels. Setback is the amount that one wheel may be aligned behind the other wheel. Setback may be the result of a road hazard or a collision. The first clue is a caster difference from side-to-side of more than 1 degree. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Caster Description > Page 12817 Alignment: Description and Operation Caster Description Caster Description Caster is the tilting of the uppermost point of the steering axis either forward or backward, when viewed from the side of the vehicle. A backward tilt is positive (+) and a forward tilt is negative (-). Caster influences directional control of the steering but does not affect the tire wear. Caster is affected by the vehicle height, therefore it is important to keep the body at its designed height. Overloading the vehicle or a weak or sagging rear spring will affect caster. When the rear of the vehicle is lower than its designated trim height, the front suspension moves to a more positive caster. If the rear of the vehicle is higher than its designated trim height, the front suspension moves to a less positive caster. With too little positive caster, steering may be touchy at high speed and wheel returnability may be diminished when coming out of a turn. If one wheel has more positive caster than the other, that wheel will pull toward the center of the vehicle. This condition will cause the vehicle to pull or lead to the side with the least amount of positive caster. Camber Description Camber Description Camber is the tilting of the wheels from the vertical when viewed from the front of the vehicle. When the wheels tilt outward at the top, the camber is positive (+). When the wheel tilts inward at the top, the camber is negative (-). The amount of tilt is measured in degrees from the vertical. Camber settings influence the directional control and the tire wear. Too much positive camber will result in premature wear on the outside of the tire and cause excessive wear on the suspension parts. Too much negative camber will result in premature wear on the inside of the tire and cause excessive wear on the suspension parts. Unequal side-to-side camber of 1 degree or more will cause the vehicle to pull or lead to the side with the most positive camber. Toe Description Toe Description Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Caster Description > Page 12818 Toe is a measurement of how much the front and/or rear wheels are turned in or out from a straight-ahead position. When the wheels are turned in, toe is positive (+). When the wheels are turned out, toe is negative (-). The actual amount of toe is normally only a fraction of a degree. The purpose of toe is to ensure that the wheels roll parallel. Toe also offsets the small deflections of the wheel support system that occur when the vehicle is rolling forward. In other words, with the vehicle standing still and the wheels set with toe-in, the wheels tend to roll parallel on the road when the vehicle is moving. Improper toe adjustment will cause premature tire wear and cause steering instability. Setback Description Setback Description Setback applies to both the front and the rear wheels. Setback is the amount that one wheel may be aligned behind the other wheel. Setback may be the result of a road hazard or a collision. The first clue is a caster difference from side-to-side of more than 1 degree. Thrust Angles Description Thrust Angles Description The front wheels aim or steer the vehicle. The rear wheels control tracking. This tracking action relates to the thrust angle (3). The thrust angle is the path that the rear wheels take. Ideally, the thrust angle is geometrically aligned with the body centerline (2). In the illustration, toe-in is shown on the left rear wheel, moving the thrust line (1) off center. The resulting deviation from the centerline is the thrust angle. If the thrust angle is not set properly the vehicle may "dog track", the steering wheel may not be centered or it could be perceived as a bent axle. Thrust angle can be checked during a wheel alignment. Positive thrust angle means the thrust line is pointing to the right hand side (RHS) of the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Caster Description > Page 12819 Negative thrust angle means the thrust line is pointing to the left hand side (LHS) of the vehicle. If the thrust angle is out of specification, moving the axle to body relationship will change the thrust angle reading. If the vehicle is out in the Positive (+) direction-moving the RHS forward and/or LHS rearward will move the thrust angle towards zero degrees. If the vehicle is out in the Negative (-) direction-moving the RHS rearward and/or LHS forward will move the thrust angle towards zero degrees. Lead/Pull Description Lead/Pull Description At a constant highway speed on a typical straight road, lead/pull is the amount of effort required at the steering wheel to maintain the vehicle's straight path. Important: Vehicles will tend to lead/pull in the direction of the road slope as part of normal operation. Lead/pull is usually caused by the following factors: * Road slope * Variability in tire construction * Wheel alignment (front cross caster and camber) * Unbalanced steering gear * Electronic Power Steering (EPS) steering position and torque sensors not calibrated correctly, if equipped. Wander Description Wander Description Wander is the undesired drifting or deviation of a vehicle to either side from a straight path with hand pressure on the steering wheel. Wander is a symptom of the vehicle's sensitivity to external disturbances, such as road crown and crosswind, and accentuated by poor on-center steering feel. Scrub Radius Description Scrub Radius Description Ideally, the scrub radius is as small as possible. Normally, the SAI angle and the centerline of the tire and the wheel intersect below the road surface, causing a positive scrub radius. With struts, the SAI angle is much larger than the long arm/short arm type of suspension. This allows the SAI angle to intersect the camber angle above the road surface, forming a negative scrub radius. The smaller the scrub radius, the better the directional stability. Installing aftermarket wheels that have additional offset will dramatically increase the scrub radius. The newly installed wheels may cause the centerline of the tires to move further away from the spindle. This will increase the scrub radius. A large amount of scrub radius can cause severe shimmy after hitting a bump. Four-wheel drive vehicles with large tires use a steering damper to compensate for an increased scrub radius. Scrub radius is not directly measurable by the conventional methods. Scrub radius is projected geometrically by engineers during the design phase of the suspension. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Page 12820 Alignment: Testing and Inspection Trim Height Inspection Note: Before performing any of the following adjustment procedures, inspect the entire suspension system for worn or damaged suspension components. Replace those components before any measurements or adjustments are performed. Also check for any collision damage. Trim Height Measurements Trim height is a predetermined measurement relating to vehicle ride height. Incorrect trim heights can cause the vehicle to bottom over bumps, damage to the suspension components, and symptoms similar to wheel alignment problems. Check the trim heights when diagnosing suspension concerns and before checking the wheel alignment. Perform the following before measuring the trim heights: * Ensure the vehicle is on a level surface, such as an alignment rack. * Set the tire pressures to the pressure shown on the certification label. Refer to Vehicle Certification, Tire Placard, Anti-Theft, and Service Parts ID Label (See: Application and ID/Vehicle Certification, Tire Placard, Anti-Theft and Service Parts ID Label). * Ensure that the suspension is fully supporting the vehicle. * If the vehicle is equipped with automatic level control, ensure that the system is functioning properly. * Check for installed after market accessories or modifications that could affect trim height measurements: - Tire and wheel sizes other than production - Lifting or lowering kits - Wheel Opening Flares - Ground Effects * Ensure that the passenger and rear compartments are empty, except for the spare tire. * Check the fuel level. Add additional weight if necessary to simulate a full tank of fuel. (One U.S. gallon of gasoline weighs approximate 6.5 lbs. One liter of gasoline weighs 0.70 kg.) * Close all doors, lift gate/trunk and the hood. * Remove the alignment rack floating pins. Z Height Measurement Note: For vehicles equipped with torsion bars, check the Z height before performing the alignment. The Z height dimension measurement determines the proper ride height for the front end of the vehicle. Vehicles equipped with torsion bars use adjust arms in order to adjust the Z height dimension. Vehicles without torsion bars have no adjustment and could require replacement of suspension components. 1. Jounce the front suspension of the vehicle by pushing the vehicle down and lifting up. 2. Allow the vehicle to settle and take a measurement. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Page 12821 Note: Perform steps 3-9 for both sides of the vehicle. 3. Point A is the contact surface of the steering knuckle for the levels. 4. Set the top edge of the level on the reference surface of the steering knuckle (C) and extend the level directly under the front end of the front attachment bolt of the lower control arm (A). 5. While keeping the level in contact with the knuckle reference surface, adjust the level up/down until the bubble indicates it is horizontally level. 6. Measure the distance between the center of the bolt and the top of the level for your first measurement 7. Keep the top edge of the level on the reference surface of the steering knuckle (C) and move the level directly under the rear end of the rear attachment bolt of the lower control arm (B). 8. Measure the distance between the center of the bolt and the top of the level for your second measurement. 9. Average the measurements between the step 6 and step 8. 10. Record the measurement. Z Height Adjustment Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Page 12822 1. For vehicles equipped with a torsion bar suspension, turn the bolt (1) that contacts the torsion bar adjusting arm as needed. 2. For vehicles without torsion bars, replace worn or damaged components as necessary. D Height Measurement 1. Jounce the rear suspension of the vehicle by pushing the vehicle down and lifting up. 2. Allow the vehicle to settle and take a measurement. 3. Measure between the axle bracket and jounce bumper mount bracket as shown in graphic. 4. If any of these measurements are out of specifications, inspect for the following conditions: * Worn or damaged suspension components * Collision damage Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Wheel Alignment Measurement Alignment: Service and Repair Wheel Alignment Measurement Wheel Alignment Measurement Steering and vibration complaints are not always the result of improper alignment. One possible cause is wheel and tire imbalance. Another possibility is tire lead due to worn or improperly manufactured tires. Lead/pull is defined as follows: At a constant highway speed on a typical straight road, lead/pull is the amount of effort required at the steering wheel to maintain the vehicle's straight path. Lead is the vehicle deviation from a straight path on a level road without pressure on the steering wheel. Refer to Radial Tire Lead/Pull Correction (See: Wheels and Tires/Testing and Inspection/Symptom Related Diagnostic Procedures/Radial Tire Lead/Pull Correction) in order to determine if the vehicle has a tire lead problem. Before performing any adjustment affecting wheel alignment, perform the following inspections in order to ensure correct alignment readings: * Inspect for visible damage to the suspension components and replace as necessary. * Inspect the tires for the proper inflation and irregular tire wear. Refer to Vehicle Certification, Tire Placard, Anti-Theft, and Service Parts ID Label (See: Application and ID/Vehicle Certification, Tire Placard, Anti-Theft and Service Parts ID Label) and Tire Diagnosis - Irregular or Premature Wear (See: Wheels and Tires/Testing and Inspection/Symptom Related Diagnostic Procedures/Tire Diagnosis - Irregular or Premature Wear). * Inspect the runout of the wheels and the tires. Refer to Tire and Wheel Runout Specifications (See: Body and Frame/Testing and Inspection/Vibration Diagnosis and Correction/Specifications/Tire and Wheel Runout Specifications). * Inspect the wheel bearings for backlash and excessive play. Refer to Wheel Bearings Diagnosis (See: Suspension/Testing and Inspection/Component Tests and General Diagnostics/Wheel Bearings Diagnosis). * Inspect the ball joints for looseness or wear. * Inspect the tie rod ends for looseness or wear. * Inspect the control arms and stabilizer shaft for looseness or wear. * Inspect the steering gear for looseness at the frame. Refer to Fastener Tightening Specifications (See: Steering/Specifications/Power Steering). * Inspect the struts/shock absorbers for wear, leaks, and any noticeable noises. Refer to Suspension Strut and Shock Absorber Testing - On Vehicle (See: Suspension/Testing and Inspection/Component Tests and General Diagnostics/Suspension Strut and Shock Absorber Testing - On Vehicle). * Inspect the vehicle trim height. Refer to Trim Height Inspection (See: Suspension/Testing and Inspection/Component Tests and General Diagnostics/Trim Height Inspection). * Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or suspension components. * Inspect the fuel level. The fuel tank should be full or the vehicle should have a compensating load added. Give consideration to excess loads, such as tool boxes, sample cases, etc. If normally carried in the vehicle, these items should remain in the vehicle during alignment adjustments. Give consideration also to the condition of the equipment being used for the alignment. Follow the equipment manufacturer's instructions. Satisfactory vehicle operation may occur over a wide range of alignment settings. However, if the setting exceeds the service allowable specifications, correct the alignment to the service preferred specifications. Refer to Wheel Alignment Specifications (See: Specifications/Wheel Alignment Specifications). Perform the following steps in order to measure the front and rear alignment angles: 1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment angles and record the readings. Note: * Record the "Before" and "After" alignment measurements. * When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear toe adjustment first in order to obtain proper front alignment angles. 4. Adjust alignment angles to vehicle specification, if necessary. Refer to Wheel Alignment Specifications (See: Specifications/Wheel Alignment Specifications). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Wheel Alignment Measurement > Page 12825 Alignment: Service and Repair Front Caster and Camber Adjustment Front Caster and Camber Adjustment Note: Caster measurements are now relative to ground. 1. The caster and camber adjustments are made by rotating the offset cam bolt and the cam in the slotted frame bracket in order to reposition the control arm. Note: Before adjusting the caster and camber angles, jounce the front bumper 3 times to allow the vehicle to return to normal height. Measure and adjust the caster and the camber with the vehicle at curb height. The front suspension Z dimension is indicated in Trim Heights. Refer to Trim Height Inspection (See: Suspension/Testing and Inspection/Component Tests and General Diagnostics/Trim Height Inspection). 2. For an accurate reading, do not push or pull on the tires during the alignment process. 3. Determine the caster angle (2). 4. Determine the positive camber (2) or negative camber (3) angle. 5. Remove the pinned adjusting cam insert. Do not reinstall the cam insert. 6. Loosen the upper control arm cam adjustment bolts. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 7. Adjust the caster and the camber angle by turning the cam bolts until the specifications have been met. When the adjustments are complete, hold the cam bolt head in order to ensure the cam bolt position does not change while tightening the nut. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Wheel Alignment Measurement > Page 12826 Tighten the cam nuts to 190 Nm (140 lb ft). 8. Verify that the caster and the camber are still within specifications. Refer to Wheel Alignment Specifications (See: Specifications/Wheel Alignment Specifications). When the caster and camber are within specifications, adjust the toe. Refer to Wheel Alignment - Steering Wheel Angle and/or Front Toe Adjustment (See: Wheel Alignment - Steering Wheel Angle and/or Front Toe Adjustment). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Wheel Alignment Measurement > Page 12827 Alignment: Service and Repair Wheel Alignment - Steering Wheel Angle and/or Front Toe Adjustment Wheel Alignment - Steering Wheel Angle and/or Front Toe Adjustment 1. Loosen the jam nut on the inner tie rod (1). 2. Rotate the inner tie rod (2) to the required toe specification setting. Refer to Wheel Alignment Specifications (See: Specifications/Wheel Alignment Specifications). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the jam nut (1) on the tie rod and tighten to 75 Nm (55 lb ft). 4. Check the toe setting after tightening. 5. Re-adjust the toe setting if necessary. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Wheel Heater Control Module > Component Information > Service and Repair Steering Wheel Heater Control Module: Service and Repair Steering Wheel Heat Control Module Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Module > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Diagrams Steering Angle Sensor: Diagrams Component Connector End Views Steering Angle Sensor (JL4) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor Replacement Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor Replacement Steering Wheel Position Sensor Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor Replacement > Page 12845 Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor Centering Steering Wheel Position Sensor Centering Removal Procedure Caution: With wheels of the vehicle facing straight ahead, secure the steering wheel utilizing steering column anti-rotation pin, steering column lock, or a strap to prevent rotation. Locking of the steering column will prevent damage and a possible malfunction of the SIR system. The steering wheel must be secured in position before disconnecting the following components: * The steering column * The intermediate shaft(s) * The steering gear After disconnecting these components, do not rotate the steering wheel or move the front tires and wheels. Failure to follow this procedure may cause the SIR coil assembly to become un-centered and cause possible damage to the SIR coil. If you think the SIR coil has became un-centered, refer to your specific SIR coil's centering procedure to re-center SIR Coil. 1. With the wheels of the vehicle in the straight ahead position, secure the steering wheel or the steering column with a steering column anti-rotation pin, a steering column lock, or a strap, as applicable, in order to prevent rotation. Note: Identify the type of steering wheel position sensor from the illustrations shown BEFORE removing the sensor from the steering column. Once you have identified the steering wheel position sensor, follow the instructions listed in the removal procedure. 2. Verify the type of steering wheel position sensor. 3. From the technicians point of view of the FRONT of the sensor (1), the connector will be on the right. Note: If you are reusing the existing sensor, you do not have to align the sensor before removal. Centering is not necessary in order to install the old sensor. 4. Remove the connector from the sensor. 5. Remove the sensor from the adapter and bearing assembly. 6. To install the sensor, proceed to step 1 in the installation procedure. 7. From the technicians point of view, the FRONT of the sensor will have: * A foam ring (2) * A pin hole (1) for the centering the pin-Note the location of the pin hole. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor Replacement > Page 12846 * A flush rotor flange cuff (4) Note: If you are reusing the existing sensor, make an alignment mark (3) on the rotor flange cuff before removing the sensor. Failure to do so will cause misalignment of the old sensor. Replace a misaligned sensor with a new sensor. 8. Make an alignment mark on the flush rotor flange cuff. 9. Remove the connector from the sensor. 10. Remove the sensor from the adapter and bearing assembly. 11. To install the sensor, proceed to step 4 in the installation procedure. 12. From the technicians point of view, the FRONT of the sensor will have: * A raised rotor flange cuff (3) * An alignment mark (2) on the rotor flange cuff for installation * A pin hole (1) for the centering pin-Note the location of the pin hole. 13. Remove the connector from the sensor. 14. Remove the sensor from the adapter and bearing assembly. 15. To install the sensor, proceed to step 8 in the installation procedure. 16. From the technicians point of view, the FRONT of the sensor will have: * A raised rotor flange cuff (3) * An alignment mark (2) on the rotor flange cuff for installation * A pin hole (1) for the centering pin-Note location of the pin hole. * A sensor clip in FRONT of the sensor 17. Remove the connector from the sensor. 18. Remove the sensor clip from the sensor. 19. Remove the sensor from the adapter and bearing assembly. 20. To install the sensor, proceed to step 12 in the installation procedure. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor Replacement > Page 12847 21. From the technicians point of view, the FRONT of the sensor will have: * A flush rotor flange cuff (3) * A pin hole (1) for the centering pin-Note the location of the pin hole. * An alignment mark (2) on the flush rotor flange cuff for installation 22. Remove the connector from the sensor. 23. Remove the sensor from the adapter and bearing assembly. 24. To install the sensor, proceed to step 16 in the installation procedure. 25. From the technicians point of view, the FRONT of the sensor will have: * A flush rotor flange cuff (4) * A pin hole (2) for the centering pin-Note the location of the pin hole. * An alignment mark (3) on the flush rotor flange cuff for installation * A foam ring (1) 26. Remove the connector from the sensor. 27. Remove the sensor from the adapter and bearing assembly. 28. To install the sensor, proceed to step 20 in the installation procedure. Installation Procedure Note: If you are reusing the existing sensor, centering of the old sensor is not necessary. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. 1. From the technicians point of view of the FRONT of the sensor (1), the connector will be on your right. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor Replacement > Page 12848 From the technicians point of view of the BACK of the sensor (2), the connector will be on your left. 2. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 3. Install the connector to the sensor. 4. From the technicians point of view, the FRONT of the sensor will have: * A foam ring (4) * A pin hole (7) for the centering pin-Note the location of the pin hole. * A flush rotor flange cuff (6) * An alignment mark (5) for installation 5. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * A foam ring (3) * An alignment tab (2) for installing the sensor to the adapter and bearing assembly * A view of the inside of the connector Note: If you are reusing the existing sensor, align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 6. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 7. Install the connector to the sensor. 8. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (3) for the centering pin-Note location of the pin hole. * A raised rotor flange cuff (5) * An alignment mark (4) for installation 9. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * An alignment tab (2) for installing the sensor to the adapter and bearing assembly Note: If you are reusing the existing sensor, align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor Replacement > Page 12849 If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 10. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 11. Install the connector to the sensor. 12. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (2) for the centering pin-Note the location of the pin hole. * A raised rotor flange cuff (4) * An alignment mark (3) for installation 13. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Note: If you are reusing the existing sensor, align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 14. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 15. Install the connector to the sensor. 16. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (2) for the centering pin-Note the location of the pin hole. * A flush rotor flange cuff (4) * An alignment mark (3) for installation 17. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Note: If you are reusing the existing sensor, align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 18. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor Replacement > Page 12850 19. Install the connector to the sensor. 20. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (3) for the centering pin-Note location of the pin hole. * A flush rotor flange cuff (5) * An alignment mark (4) for installation * A foam ring (6) 21. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * An alignment tab (2) for installing the sensor to the adapter and bearing assembly Note: If you are reusing the existing sensor, align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 22. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 23. Install the connector to the sensor. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Diagrams Steering Angle Sensor: Diagrams Component Connector End Views Steering Angle Sensor (JL4) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor Replacement Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor Replacement Steering Wheel Position Sensor Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor Replacement > Page 12857 Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor Centering Steering Wheel Position Sensor Centering Removal Procedure Caution: With wheels of the vehicle facing straight ahead, secure the steering wheel utilizing steering column anti-rotation pin, steering column lock, or a strap to prevent rotation. Locking of the steering column will prevent damage and a possible malfunction of the SIR system. The steering wheel must be secured in position before disconnecting the following components: * The steering column * The intermediate shaft(s) * The steering gear After disconnecting these components, do not rotate the steering wheel or move the front tires and wheels. Failure to follow this procedure may cause the SIR coil assembly to become un-centered and cause possible damage to the SIR coil. If you think the SIR coil has became un-centered, refer to your specific SIR coil's centering procedure to re-center SIR Coil. 1. With the wheels of the vehicle in the straight ahead position, secure the steering wheel or the steering column with a steering column anti-rotation pin, a steering column lock, or a strap, as applicable, in order to prevent rotation. Note: Identify the type of steering wheel position sensor from the illustrations shown BEFORE removing the sensor from the steering column. Once you have identified the steering wheel position sensor, follow the instructions listed in the removal procedure. 2. Verify the type of steering wheel position sensor. 3. From the technicians point of view of the FRONT of the sensor (1), the connector will be on the right. Note: If you are reusing the existing sensor, you do not have to align the sensor before removal. Centering is not necessary in order to install the old sensor. 4. Remove the connector from the sensor. 5. Remove the sensor from the adapter and bearing assembly. 6. To install the sensor, proceed to step 1 in the installation procedure. 7. From the technicians point of view, the FRONT of the sensor will have: * A foam ring (2) * A pin hole (1) for the centering the pin-Note the location of the pin hole. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor Replacement > Page 12858 * A flush rotor flange cuff (4) Note: If you are reusing the existing sensor, make an alignment mark (3) on the rotor flange cuff before removing the sensor. Failure to do so will cause misalignment of the old sensor. Replace a misaligned sensor with a new sensor. 8. Make an alignment mark on the flush rotor flange cuff. 9. Remove the connector from the sensor. 10. Remove the sensor from the adapter and bearing assembly. 11. To install the sensor, proceed to step 4 in the installation procedure. 12. From the technicians point of view, the FRONT of the sensor will have: * A raised rotor flange cuff (3) * An alignment mark (2) on the rotor flange cuff for installation * A pin hole (1) for the centering pin-Note the location of the pin hole. 13. Remove the connector from the sensor. 14. Remove the sensor from the adapter and bearing assembly. 15. To install the sensor, proceed to step 8 in the installation procedure. 16. From the technicians point of view, the FRONT of the sensor will have: * A raised rotor flange cuff (3) * An alignment mark (2) on the rotor flange cuff for installation * A pin hole (1) for the centering pin-Note location of the pin hole. * A sensor clip in FRONT of the sensor 17. Remove the connector from the sensor. 18. Remove the sensor clip from the sensor. 19. Remove the sensor from the adapter and bearing assembly. 20. To install the sensor, proceed to step 12 in the installation procedure. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor Replacement > Page 12859 21. From the technicians point of view, the FRONT of the sensor will have: * A flush rotor flange cuff (3) * A pin hole (1) for the centering pin-Note the location of the pin hole. * An alignment mark (2) on the flush rotor flange cuff for installation 22. Remove the connector from the sensor. 23. Remove the sensor from the adapter and bearing assembly. 24. To install the sensor, proceed to step 16 in the installation procedure. 25. From the technicians point of view, the FRONT of the sensor will have: * A flush rotor flange cuff (4) * A pin hole (2) for the centering pin-Note the location of the pin hole. * An alignment mark (3) on the flush rotor flange cuff for installation * A foam ring (1) 26. Remove the connector from the sensor. 27. Remove the sensor from the adapter and bearing assembly. 28. To install the sensor, proceed to step 20 in the installation procedure. Installation Procedure Note: If you are reusing the existing sensor, centering of the old sensor is not necessary. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. 1. From the technicians point of view of the FRONT of the sensor (1), the connector will be on your right. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor Replacement > Page 12860 From the technicians point of view of the BACK of the sensor (2), the connector will be on your left. 2. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 3. Install the connector to the sensor. 4. From the technicians point of view, the FRONT of the sensor will have: * A foam ring (4) * A pin hole (7) for the centering pin-Note the location of the pin hole. * A flush rotor flange cuff (6) * An alignment mark (5) for installation 5. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * A foam ring (3) * An alignment tab (2) for installing the sensor to the adapter and bearing assembly * A view of the inside of the connector Note: If you are reusing the existing sensor, align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 6. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 7. Install the connector to the sensor. 8. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (3) for the centering pin-Note location of the pin hole. * A raised rotor flange cuff (5) * An alignment mark (4) for installation 9. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * An alignment tab (2) for installing the sensor to the adapter and bearing assembly Note: If you are reusing the existing sensor, align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor Replacement > Page 12861 If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 10. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 11. Install the connector to the sensor. 12. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (2) for the centering pin-Note the location of the pin hole. * A raised rotor flange cuff (4) * An alignment mark (3) for installation 13. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Note: If you are reusing the existing sensor, align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 14. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 15. Install the connector to the sensor. 16. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (2) for the centering pin-Note the location of the pin hole. * A flush rotor flange cuff (4) * An alignment mark (3) for installation 17. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Note: If you are reusing the existing sensor, align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 18. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor Replacement > Page 12862 19. Install the connector to the sensor. 20. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (3) for the centering pin-Note location of the pin hole. * A flush rotor flange cuff (5) * An alignment mark (4) for installation * A foam ring (6) 21. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * An alignment tab (2) for installing the sensor to the adapter and bearing assembly Note: If you are reusing the existing sensor, align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 22. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 23. Install the connector to the sensor. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > Page 12868 Tire Pressure Sensor: Testing and Inspection Tire Pressure Indicator Sensor Learn Special Tools J-46079 Tire Pressure Monitor Diagnostic Tool Learn Mode Description The tire pressure monitor (TPM) system uses the instrument panel cluster (IPC), body control module (BCM), remote control door lock receiver (RCDLR), keyless entry transmitter, 4 radio frequency transmitting pressure sensors, and the serial data circuit to perform the TPM learn mode functions. The sensor learn procedure must be performed after every tire rotation, RCDLR replacement, or sensor replacement. Once the learn mode has been enabled, each of the sensors unique identification codes can be learned into the RCDLR memory. When a sensor ID has been learned, the RCDLR sends a serial data message to the BCM to sound a horn chirp. This verifies the sensor has transmitted its ID and the RCDLR has received and learned it. The RCDLR must learn the sensor IDs in the proper sequence to determine correct sensor location. The first learned ID is assigned to the left front location, the second to right front, the third to right rear and the fourth to left rear. The turn signals will individually illuminate indicating which location is to be learned in the proper sequence. Sensor Functions Using J-46079 Each sensor has an internal low frequency coil. When the J-46079 is used in activate mode, it produces a low frequency transmission that activates the sensor. The sensor responds to a low frequency activation by transmitting in learn mode. When the RCDLR receives a learn mode transmission while in TPM learn mode, it will assign that sensors ID to the location on the vehicle relative to the order in which it was learned. Sensor Functions Using Pressure Increase/Decrease Method Each sensor takes a pressure measurement sample once every 30 seconds while in stationary mode. If the tire pressure increases, or decreases by more than 8.3 kPa (1.2 psi) from the last pressure measurement, another measurement will occur immediately to verify the change in pressure. If a pressure change has indeed occurred, the sensor transmits in Learn mode. When the RCDLR receives a Learn mode transmission while in TPM learn mode, it will assign that sensor's ID to the location on the vehicle relative to the order in which it was learned. Learn Mode Cancellation The learn mode will cancel if the ignition is cycled to OFF or if more than 2 minutes has elapsed for any sensor that has not been learned. If the learn mode is cancelled before the first sensor is learned, the original sensor IDs will be maintained. If the learn mode is canceled after the first sensor is learned, the following will occur: * All stored sensor IDs will be invalidated in the RCDLR memory. * If equipped, the DIC will display dashes instead of tire pressures. * DTC C0775 will be set. These conditions will now require the learn procedure to be repeated for the system to function properly. TPM Learn Procedure Note: If using the scan tool to enable the learn mode, the J-46079 must be used to activate the sensors. When this preferred method is used, any stray sensor signals will not affect the learn procedure. In the event a particular sensor's information is displayed on the special tool upon activation but the horn does not chirp, it may be necessary to rotate the wheel valve stem to a different position due to the sensor signal is being blocked by another component. If using the keyless entry transmitter or DIC buttons to enable the learn mode, the J-46079 or Pressure Increase/Decrease Method may be used. Before proceeding with this method, ensure that no other learn procedure is being performed simultaneously or that tire pressures are not being adjusted on another TPM equipped vehicle within close proximity. Stray signals from other TPM equipped vehicles just driving by can be inadvertently learned. If any random horn chirps are heard from the vehicle while performing the learn procedure, most likely a stray sensor has been learned and the procedure will need to be cancelled and repeated. Under these circumstances, performing the TPM Learn Procedure away from other vehicles would be highly recommended. In the event a particular sensor activation does not cause the horn to chirp, it may be necessary to rotate the wheel valve stem to a different position due to the sensor signal is being blocked by another component. Preferred Scan Tool Learn Enable Method 1. Using a scan tool, initiate the TPM Learn Mode. A double horn chirp will sound indicating the Learn Mode has been enabled. The left front turn signal will also be illuminated. 2. Starting with the left front tire, active the sensor by holding the antenna of the J-46079 aimed upward against the tire sidewall close to the wheel rim at the valve stem location. Press and release the Activate button and wait for a horn chirp. Once the horn chirp has sounded, the sensor information is learned and the turn signal in the next location to be learned will illuminate. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > Page 12869 3. After the horn chirp has sounded and the right front turn signal is illuminated, repeat step 2 for the remaining 3 sensors in the following order: 1. Right front 2. Right rear 3. Left rear 4. When the left rear sensor has been learned and a double horn chirp has sounded, the learn process is complete and the RCDLR exits the learn mode. 5. Ignition OFF, adjust all tires to the recommended pressures. Refer to Vehicle Certification, Tire Placard, Anti-Theft, and Service Parts ID Label ( See: Application and ID/Vehicle Certification, Tire Placard, Anti-Theft and Service Parts ID Label). Alternate Keyless Entry Transmitter or DIC Learn Enable Method 1. Ignition ON, initiate the TPM Learn Mode using one of the following procedures: * On vehicles equipped with keyless entry, simultaneously press the keyless entry transmitters lock and unlock buttons until a double horn chirp sounds indicating the Learn Mode has been enabled. The left front turn signal will also be illuminated. * On vehicles not equipped with keyless entry, press and release the driver information center (DIC) INFO button until the TIRE LEARN message appears on the DIC display. Press and hold the SET/RESET button until a double horn chirp sounds indicating the Learn Mode has been enabled. The left front turn signal will also be illuminated. 2. Starting with the left front tire, learn the tire pressure using one of the following methods: * Hold the antenna of the J-46079 aimed upward against the tire sidewall close to the wheel rim at the valve stem location. Press and release the activate button and wait for a horn chirp. Once the horn chirp has sounded, the sensor information is learned and the turn signal in the next location to be learned will illuminate. Warning Over inflating tires may cause personal injury or damage to the tires and wheels. When increasing tire pressure do not exceed the maximum inflation pressure as noted on the tire sidewall. * Increase/decrease the tire pressure for 8-10 seconds then wait for a horn chirp. The horn chirp may occur before or up to 30 seconds after the 8-10 second pressure increase/decrease time period has been reached. Once the horn chirp has sounded, the sensor information is learned and the turn signal in the next location to be learned will illuminate. 3. After the horn chirp has sounded and the right front turn signal is illuminated, repeat step 2 for the remaining 3 sensors in the following order: 1. Right front 2. Right rear 3. Left rear 4. When the left rear sensor has been learned and a double horn chirp has sounded, the learn process is complete and the RCDLR exits the learn mode. 5. Ignition OFF, adjust all tires to the recommended pressures. Refer to Vehicle Certification, Tire Placard, Anti-Theft, and Service Parts ID Label ( See: Application and ID/Vehicle Certification, Tire Placard, Anti-Theft and Service Parts ID Label). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement (Clamp In Style) Tire Pressure Sensor: Service and Repair Tire Pressure Indicator Sensor Replacement (Clamp In Style) Tire Pressure Indicator Sensor Replacement (Clamp In Style) Removal Procedure 1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair). 2. Remove the tire/wheel assembly from the vehicle. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair). Note: Before the tire is removed from the wheel, note the following items to avoid tire pressure sensor damage upon tire dismounting: * Place the sensors cap and valve on a dry clean surface after removal. The cap is aluminum and the valve is nickel plated to prevent corrosion and are not to be substituted with a cap or valve made of any other material. * When separating the tire bead from the wheel, position the bead breaking fixture 90 degrees from the valve stem. * Position the mounting/dismounting head so the tire iron, or pry bar can be inserted slightly clockwise of the sensor body when prying the tire bead up and over the mounting/dismounting head. * Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the out side of the wheel rim. * Repeat items for inner bead. 3. Remove the tire from the wheel. Refer to Tire Dismounting and Mounting (See: Wheels and Tires/Tires/Service and Repair/Removal and Replacement). Note: If any tire sealant is noted upon tire dismounting, remove all residual liquid sealant from the inside of the tire and wheel surfaces. 4. Remove the tire pressure sensor nut. 5. Remove the tire pressure sensor. Installation Procedure 1. Clean any dirt or debris from the grommet sealing area. 2. Insert the sensor in the wheel hole with the air passage facing away from the wheel. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the sensor nut and position the sensor body parallel to the inside wheel surface while torquing. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement (Clamp In Style) > Page 12872 Tighten the sensor nut to 7 Nm (62 lb in). Note: Before reinstalling the tire on the wheel, note the following items to avoid tire pressure sensor damage upon tire mounting: * Position the mounting/dismounting head 180 degrees from the valve stem. * Position the bead transition area 45 degrees counterclockwise of the valve stem. * Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the inside of the wheel rim. * Repeat items for outer bead. 4. Install the tire on the wheel. Refer to Tire Dismounting and Mounting (See: Wheels and Tires/Tires/Service and Repair/Removal and Replacement). Note: A service replacement tire pressure sensor is shipped in OFF mode. In this mode the sensor unique identification code cannot be learned into the remote control door lock receiver (RCDLR) memory. The sensor must be taken out of OFF mode by spinning the tire/wheel assembly above 32 km/h (20 mph) in order to close the sensors internal roll switch for at least 10 seconds. 5. Install the tire/wheel assembly on the vehicle. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair). 6. Lower the vehicle. 7. Learn the tire pressure sensors. Refer to Tire Pressure Indicator Sensor Learn (See: Wheels and Tires/Tire Monitoring System/Service and Repair/Service Manual Tire Pressure Sensor Learn). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement (Clamp In Style) > Page 12873 Tire Pressure Sensor: Service and Repair Tire Pressure Indicator Sensor Replacement (Snap In Style) Tire Pressure Indicator Sensor Replacement (Snap In Style) Removal Procedure 1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair). 2. Remove the tire/wheel assembly from the vehicle. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair). 3. Dismount the tire from the rim. Refer to Tire Dismounting and Mounting (See: Wheels and Tires/Tires/Service and Repair/Removal and Replacement). Note: When servicing the tire pressure sensor always use a new Schrader(R) tire pressure monitor (TPM) and a new TORX screw during installation. 4. Remove the TORX screw (1) from the tire pressure sensor (2) and pull it straight off the tire pressure valve stem (3). Caution: Do not scratch or damage the clear coating on aluminum wheels with the tire changing equipment. Scratching the clear coating could cause the aluminum wheel to corrode and the clear coating to peel from the wheel. 5. Remove the tire pressure valve stem by pulling it through the rim. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement (Clamp In Style) > Page 12874 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Note: * Ensure the flat of the valve, lines up with the flats of the snap in the enclosure. * TPM valves and TORX screws are one-time use only. 1. Assemble the tire pressure sensor (2) to the valve stem and install the new TORX screw (3) and tighten to 1.3 Nm (11.5 lb in). Note: Use and approved tire mounting lubricant. DO NOT use silicon or corrosive base compounds to lubricate the tire bead and the wheel rim. A corrosive type compound can cause tire or rim deterioration. 2. Apply tire soap to the rubber portion of the valve stem (1). 3. Using a tire valve stem mounting tool, pull the valve stem through in a direction parallel to the valve hole on the rim. Note: Snap Fit TPM sensors are still shipped in the OFF mode. However, the TPM no longer needs to be spun to remove it from the OFF mode. The sensor will exit its OFF state when the tire is inflated. The technician can then program the vehicle as normal. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement (Clamp In Style) > Page 12875 4. Mount the tire to the rim. Refer to Tire Dismounting and Mounting (See: Wheels and Tires/Tires/Service and Repair/Removal and Replacement). 5. Install the tire/wheel assembly on the vehicle. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair). 6. Lower the vehicle. 7. Learn the tire pressure sensors. Refer to Tire Pressure Indicator Sensor Learn (See: Wheels and Tires/Tire Monitoring System/Service and Repair/Service Manual Tire Pressure Sensor Learn). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Service and Repair Center Link: Service and Repair Relay Rod Replacement Special Tools J 24319-B - Steering Linkage and Tie Rod Puller Removal Procedure 1. Remove the engine shield, if equipped. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement). 2. Remove the steering linkage shock absorber from the relay rod, if equipped. Refer to Steering Linkage Shock Absorber Replacement (See: Steering Damper/Service and Repair). 3. Remove the steering linkage outer tie rods. Refer to Steering Linkage Outer Tie Rod Replacement (See: Tie Rod/Service and Repair/Steering Linkage Outer Tie Rod Replacement). 4. Remove the idler arm nut (6). Discard the nut. 5. Separate the idler arm (1) from the relay rod (5) using the J 24319-B - Puller. 6. Remove the pitman arm nut (4). Discard the nut. 7. Separate the pitman arm (2) from the relay rod using the J 24319-B - Puller. 8. Remove the relay rod from the vehicle. 9. Inspect the threads and seals on all steering related components. Repair or replace the components as necessary. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Service and Repair > Page 12880 1. Position the relay rod (5) in the vehicle. 2. Install the pitman arm (2) to the relay rod (5). 3. Install the idler arm (1) to the relay rod. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install a NEW pitman arm nut (4) and tighten to 62 Nm (46 lb ft). 5. Install a NEW idler arm nut (6) and tighten to 62 Nm (46 lb ft). 6. Install the steering linkage outer tie rods. Refer to Steering Linkage Outer Tie Rod Replacement (See: Tie Rod/Service and Repair/Steering Linkage Outer Tie Rod Replacement). 7. Install the steering linkage shock absorber to the relay rod, if equipped. Refer to Steering Linkage Shock Absorber Replacement (See: Steering Damper/Service and Repair). 8. Install the engine shield, if equipped. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement). 9. Measure the wheel alignment. Refer to Wheel Alignment Measurement (See: Alignment/Service and Repair/Wheel Alignment Measurement). 10. Adjust the front toe. Refer to Wheel Alignment - Steering Wheel Angle and/or Front Toe Adjustment (See: Alignment/Service and Repair/Wheel Alignment - Steering Wheel Angle and/or Front Toe Adjustment). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Idler Arm > Component Information > Testing and Inspection Idler Arm: Testing and Inspection Idler Arm Inspection Special Tools * J 35999 Spring Scale * J 42640 Steering Column Anti-Rotation Pin * J 45101 Hub and Wheel Runout Gauge 1. Raise the vehicle on a hoist and support it with jackstands. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair). Caution: With wheels of the vehicle facing straight ahead, secure the steering wheel utilizing steering column anti-rotation pin, steering column lock, or a strap to prevent rotation. Locking of the steering column will prevent damage and a possible malfunction of the SIR system. The steering wheel must be secured in position before disconnecting the following components: * The steering column * The intermediate shaft(s) * The steering gear After disconnecting these components, do not rotate the steering wheel or move the front tires and wheels. Failure to follow this procedure may cause the SIR coil assembly to become un-centered and cause possible damage to the SIR coil. If you think the SIR coil has became un-centered, refer to your specific SIR coil's centering procedure to re-center SIR Coil. 2. Position the wheels straight-ahead and install anti-rotation pin J 42640 . 3. Install runout gauge J 45101 between the idler arm and the vehicle frame. Ensure the runout gauge is at zero before taking the measurement. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Idler Arm > Component Information > Testing and Inspection > Page 12884 4. Place scale J 35999 near the relay rod end of the idler arm. 5. Exert a 110 Nm (25 lb) force upward and then downward while measuring the total distance the idler arm moves. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Idler Arm > Component Information > Testing and Inspection > Page 12885 6. If the movement exceeds 2 mm (0.078 in) then replace the idler arm. 7. Install the runout gauge at the idler arm. 8. Push the tire inward slowly with one hand to remove any lash. Zero out the runout gauge and pull outward in order to take a reading. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Idler Arm > Component Information > Testing and Inspection > Page 12886 9. Allow only 1 mm (0.039 in) of movement at the idler arm ball stud. If the movement is more than 1 mm (0.039 in) then replace the idler arm. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Idler Arm > Component Information > Testing and Inspection > Page 12887 Idler Arm: Service and Repair Idler Arm Replacement Special Tools J 24319-B Steering Linkage and Tie Rod Puller Removal Procedure Caution: Do not attempt to free the ball stud by using a pickle fork or wedge type tool, because seal or bushing damage could result. Use the proper tool to separate all ball joints. 1. Remove the engine shield, if equipped. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement). Note: Discard the idler arm nut. 2. Remove the idler arm nut (3) from the idler arm (1). 3. Separate the idler arm (1) from the relay rod (2). 4. Remove the idler arm from the relay rod using puller J 24319-B . Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Idler Arm > Component Information > Testing and Inspection > Page 12888 5. Remove the idler arm bolts (3) and the nuts (1) at the vehicle frame. 6. Remove the idler arm (2) from the vehicle. Installation Procedure 1. Position the idler arm (2) to the vehicle frame. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the idler arm bolts (3) and nuts (1) to the frame and tighten to 105 Nm (78 lb ft). 3. Install the idler arm (1) to the relay rod (2). Note: Do not reuse the old idler arm nut. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Idler Arm > Component Information > Testing and Inspection > Page 12889 4. Install the new idler arm nut (3) to the idler arm (1) and tighten to 62 Nm (46 lb ft). 5. Install the engine shield, if equipped. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement). 6. Adjust the front toe. Refer to Wheel Alignment - Steering Wheel Angle and/or Front Toe Adjustment (See: Alignment/Service and Repair/Wheel Alignment - Steering Wheel Angle and/or Front Toe Adjustment). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Pitman Arm > Component Information > Technical Service Bulletins > Steering/Suspension - Pitman Arm Shaft Seal Service Kit Pitman Arm: Technical Service Bulletins Steering/Suspension - Pitman Arm Shaft Seal Service Kit INFORMATION Bulletin No.: 10-02-33-001A Date: October 13, 2010 Subject: Information on Pitman Arm Shaft Seal Service Kit Models: 2004-2005 Buick Rainier 2000-2006 Cadillac Escalade, Escalade ESV, Escalade EXT 2000-2005 Chevrolet Blazer, S-10 2000-2011 Chevrolet Avalanche, Express, Silverado, Suburban, Tahoe 2000-2005 GMC Jimmy, Sonoma 2000-2011 GMC Savana, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2000-2004 Oldsmobile Bravada 2003-2009 HUMMER H2 with Recirculating Ball Steering Gears Supercede: This bulletin is being revised to update the model years and models involved. Please discard Corporate Bulletin Number 10-02-33-001 (Section 02 - Steering). Note Do not replace the entire steering gear for a pitman seal leak. Technicians have been replacing entire steering gears due to not being able to service just the leaking pitman shaft seal. The seal is serviced as a kit and is not called out separately in the catalog illustration. The seal package is cataloged in Group 06.855 as Seal Kit - GM Part Number 26002516 - Steering Gear Pitman Shaft, which includes the seal, washer, retaining ring and dust seal or G/M P/N 19256667, which includes the seal and retainer. Refer to Steering Gear Pitman Shaft Seal in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Pitman Arm > Component Information > Technical Service Bulletins > Page 12894 Pitman Arm: Service and Repair Pitman Arm Replacement Special Tools * J 6632-01 Pitman Arm Puller * J 29107-A Pitman Arm Puller Removal Procedure 1. Remove the steering gear. Refer to Steering Gear Replacement (Hydraulic Rack and Pinion) (See: Steering Gear)Steering Gear Replacement (Recirculating Ball Without LMM) (See: Steering Gear)Steering Gear Replacement (HP2) (See: Steering Gear)Steering Gear Replacement (LMM) (See: Steering Gear). 2. Place the steering gear into a vise. 3. Remove the pitman arm nut (1) and washer (2). 4. Remove the pitman arm from the pitman arm shaft using puller J 6632-01 or puller J 29107-A . Installation Procedure 1. Install the pitman arm onto the steering gear. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Pitman Arm > Component Information > Technical Service Bulletins > Page 12895 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install a new pitman arm washer (2) and nut (1). Tighten the nut to 250 Nm (184 lb ft). 3. Remove the steering gear from the vise. 4. Install the steering gear. Refer to Steering Gear Replacement (Hydraulic Rack and Pinion) (See: Steering Gear)Steering Gear Replacement (Recirculating Ball Without LMM) (See: Steering Gear)Steering Gear Replacement (HP2) (See: Steering Gear)Steering Gear Replacement (LMM) (See: Steering Gear). 5. Adjust the front toe. Refer to Wheel Alignment - Steering Wheel Angle and/or Front Toe Adjustment (See: Alignment/Service and Repair/Wheel Alignment - Steering Wheel Angle and/or Front Toe Adjustment). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System Information > Service and Repair Power Steering Bleeding: Service and Repair Power Steering System Bleeding Important: * Use clean, new power steering fluid type only. See the Maintenance and Lubrication subsection for fluid specifications. Refer to Fluid and Lubricant Recommendations (USA and Canada) (See: Maintenance). * Hoses touching the frame, body or engine may cause system noise. Verify that the hoses do not touch any other part of the vehicle. * Loose connections may not leak, but could allow air into the steering system. Verify that all hose connections are tight. Important: Power steering fluid level must be maintained throughout bleed procedure. 1. Fill pump reservoir with fluid to minimum system level, FULL COLD level, or middle of hash mark on cap stick fluid level indicator. Important: With hydro-boost only, the oil level will appear falsely high if the hydro-boost accumulator is not fully charged. Do not apply the brake pedal with the engine OFF. This will discharge the hydro-boost accumulator. 2. If equipped with hydro-boost, fully charge the hydro-boost accumulator using the following procedure: 1. Start the engine. 2. Firmly apply the brake pedal 10-15 times. 3. Turn the engine OFF. 3. Raise the vehicle until the front wheels are off the ground. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair). 4. Key on engine OFF, turn the steering wheel from stop to stop 12 times. Vehicles equipped with hydro-boost systems or longer length power steering hoses may require turns up to 15 to 20 stop to stops. 5. Verify power steering fluid level per operating specification. Refer to Checking and Adding Power Steering Fluid (Without Hydroboost) (See: Service and Repair/Checking and Adding Power Steering Fluid (Without Hydroboost))Checking and Adding Power Steering Fluid (With Hydroboost) (See: Service and Repair/Checking and Adding Power Steering Fluid (With Hydroboost)). 6. Start the engine. Rotate steering wheel from left to right. Check for sign of cavitation or fluid aeration (pump noise/whining). 7. Verify the fluid level. Repeat the bleed procedure, if necessary. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Specifications Power Steering Fluid: Specifications POWER STEERING SYSTEM GM Power Steering Fluid GM P/N 89021184 (Canadian P/N 89021186) or equivalent. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Service and Repair > Power Steering Fluid Cooler Replacement (Without Hydroboost) Power Steering Fluid Cooler: Service and Repair Power Steering Fluid Cooler Replacement (Without Hydroboost) Power Steering Fluid Cooler Replacement (Without Hydroboost) Removal Procedure 1. Remove the radiator grille. Refer to Radiator Grille Replacement (Chevrolet) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement)Radiator Grille Replacement (GMC) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement)Radiator Grille Replacement (Chevrolet HD) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement (Chevrolet HD))Radiator Grille Replacement (GMC HD) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement (GMC HD)). 2. Remove as much power steering fluid as possible from the power steering fluid reservoir. 3. Place drain pans under the vehicle as needed. Caution: Refer to Power Steering Hose Disconnected Caution (See: Power Steering Line/Hose/Service Precautions). 4. Disconnect the power steering gear outlet hose (2) from the power steering fluid cooler (4). 5. Disconnect the power steering fluid cooler hose (3) from the power steering pump (1). 6. Remove the power steering fluid cooler bolts (2) from the power steering fluid cooler (1). 7. Remove the power steering fluid cooler from the vehicle. Installation Procedure 1. Install the power steering fluid cooler to the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Service and Repair > Power Steering Fluid Cooler Replacement (Without Hydroboost) > Page 12907 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the power steering fluid cooler bolts (2) to the power steering fluid cooler (1). Tighten the bolts to 9 Nm (80 lb in). 3. Connect the power steering fluid cooler hose (3) to the power steering pump (1). 4. Connect the power steering gear outlet hose (2) to the power steering fluid cooler (4). 5. Clean any excess fluid from the vehicle and remove the drain pans. 6. Fill and bleed the power steering system. Refer to Power Steering System Bleeding (See: Power Steering Bleeding/Service and Repair). 7. Install the radiator grille. Refer to Radiator Grille Replacement (Chevrolet) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement)Radiator Grille Replacement (GMC) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement)Radiator Grille Replacement (Chevrolet HD) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement (Chevrolet HD))Radiator Grille Replacement (GMC HD) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement (GMC HD)). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Service and Repair > Power Steering Fluid Cooler Replacement (Without Hydroboost) > Page 12908 Power Steering Fluid Cooler: Service and Repair Power Steering Fluid Cooler Replacement (With Hydroboost) Power Steering Fluid Cooler Replacement (With Hydroboost) Removal Procedure 1. Remove the radiator grille. Refer to Radiator Grille Replacement (Chevrolet) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement)Radiator Grille Replacement (GMC) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement)Radiator Grille Replacement (Chevrolet HD) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement (Chevrolet HD))Radiator Grille Replacement (GMC HD) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement (GMC HD)). 2. Remove as much power steering fluid from the power steering fluid reservoir as possible. 3. Place drain pans under the vehicle as needed. Caution: Refer to Power Steering Hose Disconnected Caution (See: Power Steering Line/Hose/Service Precautions). 4. Disconnect the power steering fluid cooler hose (3) from the steering gear (2). 5. Disconnect the power steering fluid cooler hose (4) from the power steering pump (1). 6. Remove the power steering fluid cooler bolts (2). 7. Remove the power steering fluid cooler (1) from the vehicle. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Service and Repair > Power Steering Fluid Cooler Replacement (Without Hydroboost) > Page 12909 1. Install the power steering fluid cooler (1) to the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the power steering fluid cooler bolts (2). Tighten the bolts to 9 Nm (80 lb in) 3. Connect the power steering fluid cooler hose (4) to the power steering pump (1). 4. Connect the power steering fluid cooler hose (3) to the steering gear (2). 5. Clean any excess fluid from the vehicle and remove the drain pans. 6. Install the radiator grille. Refer to Radiator Grille Replacement (Chevrolet) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement)Radiator Grille Replacement (GMC) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement)Radiator Grille Replacement (Chevrolet HD) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement (Chevrolet HD))Radiator Grille Replacement (GMC HD) (See: Body and Frame/Grille/Service and Repair/Radiator Grille Replacement (GMC HD)). 7. Fill and bleed the power steering system. Refer to Power Steering System Bleeding (See: Power Steering Bleeding/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Locations Power Steering Fluid Reservoir: Locations Power Steering Pump Disassembled View 1 - Power Steering Fluid Reservoir 2 - Power Steering Fluid Reservoir Cap 3 - Power Steering Fluid Reservoir Stud 4 - Power Steering Fluid Reservoir Stud 5 - Power Steering Pump Fitting 6 Power Steering Pump Fitting Seal 7 - Power Steering Pump Flow Control Valve 8 - Power Steering Pump Flow Control Valve Spring 9 - Power Steering Pump Housing Seal 10 - Power Steering Pump Housing Seals 11 - Power Steering Fluid Reservoir Seal 12 - Power Steering Pump 13 Power Steering Pump Shaft Seal 14 - Power Steering Fluid Reservoir Magnet Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Locations > Page 12913 Power Steering Fluid Reservoir: Service and Repair Power Steering Fluid Reservoir Replacement - Off Vehicle Disassembly Procedure 1. Remove the power steering pump assembly from the vehicle. Refer to Power Steering Pump Replacement (4.8L, 5.3L, 6.0L, and 6.2L) (See: Power Steering Pump/Service and Repair)Power Steering Pump Replacement (4.3L) (See: Power Steering Pump/Service and Repair)Power Steering Pump Replacement (6.6L) (See: Power Steering Pump/Service and Repair). 2. Remove the power steering fluid reservoir studs (2) from the power steering pump assembly (1). 3. Remove the power steering pump fitting (4). 4. Remove the power steering pump fitting seal (3). 5. Remove the power steering pump flow control valve (2) and the power steering pump flow control valve spring (3) from the power steering pump assembly (1). 6. Separate the power steering fluid reservoir (1) and the power steering pump (2). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Locations > Page 12914 7. Remove the power steering pump seals (1, 4, 5). 8. Remove and clean the power steering fluid reservoir magnet (3). 9. Inspect the welch plug in the power steering pump (2). DO NOT REMOVE IT. If the welch plug is deformed or dislodged then replace the power steering pump (2). Assembly Procedure 1. Clean and install the power steering fluid reservoir magnet (3). 2. Install the power steering pump seals (1, 4, 5) to the power steering pump (2). 3. Connect the power steering fluid reservoir (1) and the power steering pump (2). 4. Install the power steering pump flow control valve spring (3) and the power steering pump flow control valve (2) to the power steering pump assembly (1). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Locations > Page 12915 5. Install the power steering pump fitting seal (3) to the power steering pump assembly (1). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Note: Start the power steering fluid reservoir studs and the power steering pump flow control valve fitting by hand before finalizing any torques. 6. Install the power steering pump fitting (4) to the power steering pump assembly (1). Tighten the fitting to 75 Nm (55 lb ft). 7. Install the power steering fluid reservoir studs (2) to the power steering pump assembly (1). Tighten the studs to 58 Nm (44 lb ft). 8. Install the power steering pump assembly to the vehicle. Refer to Power Steering Pump Replacement (4.8L, 5.3L, 6.0L, and 6.2L) (See: Power Steering Pump/Service and Repair)Power Steering Pump Replacement (4.3L) (See: Power Steering Pump/Service and Repair)Power Steering Pump Replacement (6.6L) (See: Power Steering Pump/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service Precautions Power Steering Line/Hose: Service Precautions Power Steering Hose Disconnected Caution Caution: Do not start the vehicle with any power steering gear inlet or outlet hoses disconnected. When disconnected, plug or cap all openings of components. Failure to do so could result in contamination or loss of power steering fluid and damage to the system. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service Precautions > Page 12919 Power Steering Line/Hose: Service and Repair Power Steering Gear Inlet Pipe/Hose Replacement (Diesel) Removal Procedure 1. Place drain pans under the vehicle as needed. 2. Disconnect the power steering gear inlet hose (1) from the power brake booster. 3. Remove the power steering gear inlet hose clip bolt (3). 4. Disconnect the power steering gear inlet hose (4) from the steering gear. 5. Remove the power steering gear inlet hose (2) from the vehicle. Installation Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service Precautions > Page 12920 1. Install the power steering gear inlet hose (2) to the vehicle. 2. Connect the power steering gear inlet hose (4) to the steering gear. Tighten the fitting to 32 Nm (24 lb ft). 3. Install the power steering gear inlet hose clip bolt (3). Tighten the bolt to 12 Nm (106 lb in). 4. Connect the power steering gear inlet hose (1) to the power brake booster. Tighten the fitting to 32 Nm (24 lb ft). 5. Clean any excess power steering fluid from the vehicle and remove the drain pans. 6. Fill and bleed the power steering system. Refer to Power Steering System Bleeding (See: Power Steering Bleeding/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pressure Control Valve > Component Information > Service and Repair Power Steering Pressure Control Valve: Service and Repair Power Steering Pump Flow Control Valve Replacement - Off Vehicle Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Power Steering Pump Seal > Component Information > Service and Repair Power Steering Pump Seal: Service and Repair Power Steering Pump Shaft Seal Replacement Removal Procedure 1. Remove the power steering pump from the vehicle. Refer to Power Steering Pump Replacement (4.8L, 5.3L, 6.0L, and 6.2L) (See: Service and Repair)Power Steering Pump Replacement (4.3L) (See: Service and Repair)Power Steering Pump Replacement (6.6L) (See: Service and Repair ). Important: Use the shim stock in order to protect the drive shaft. 2. Use a chisel in order to cut and remove the power steering pump shaft seal. Installation Procedure 1. Lubricate the new power steering pump shaft seal with power steering fluid. 2. Use a deep 1 inch tall socket in order to install the new power steering pump shaft seal. 3. Install the power steering pump. Refer to Power Steering Pump Replacement (4.8L, 5.3L, 6.0L, and 6.2L) (See: Service and Repair)Power Steering Pump Replacement (4.3L) (See: Service and Repair)Power Steering Pump Replacement (6.6L) (See: Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Wheel Heater Control Module > Component Information > Service and Repair Steering Wheel Heater Control Module: Service and Repair Steering Wheel Heat Control Module Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Diagrams Steering Angle Sensor: Diagrams Component Connector End Views Steering Angle Sensor (JL4) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor Replacement Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor Replacement Steering Wheel Position Sensor Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor Replacement > Page 12938 Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor Centering Steering Wheel Position Sensor Centering Removal Procedure Caution: With wheels of the vehicle facing straight ahead, secure the steering wheel utilizing steering column anti-rotation pin, steering column lock, or a strap to prevent rotation. Locking of the steering column will prevent damage and a possible malfunction of the SIR system. The steering wheel must be secured in position before disconnecting the following components: * The steering column * The intermediate shaft(s) * The steering gear After disconnecting these components, do not rotate the steering wheel or move the front tires and wheels. Failure to follow this procedure may cause the SIR coil assembly to become un-centered and cause possible damage to the SIR coil. If you think the SIR coil has became un-centered, refer to your specific SIR coil's centering procedure to re-center SIR Coil. 1. With the wheels of the vehicle in the straight ahead position, secure the steering wheel or the steering column with a steering column anti-rotation pin, a steering column lock, or a strap, as applicable, in order to prevent rotation. Note: Identify the type of steering wheel position sensor from the illustrations shown BEFORE removing the sensor from the steering column. Once you have identified the steering wheel position sensor, follow the instructions listed in the removal procedure. 2. Verify the type of steering wheel position sensor. 3. From the technicians point of view of the FRONT of the sensor (1), the connector will be on the right. Note: If you are reusing the existing sensor, you do not have to align the sensor before removal. Centering is not necessary in order to install the old sensor. 4. Remove the connector from the sensor. 5. Remove the sensor from the adapter and bearing assembly. 6. To install the sensor, proceed to step 1 in the installation procedure. 7. From the technicians point of view, the FRONT of the sensor will have: * A foam ring (2) * A pin hole (1) for the centering the pin-Note the location of the pin hole. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor Replacement > Page 12939 * A flush rotor flange cuff (4) Note: If you are reusing the existing sensor, make an alignment mark (3) on the rotor flange cuff before removing the sensor. Failure to do so will cause misalignment of the old sensor. Replace a misaligned sensor with a new sensor. 8. Make an alignment mark on the flush rotor flange cuff. 9. Remove the connector from the sensor. 10. Remove the sensor from the adapter and bearing assembly. 11. To install the sensor, proceed to step 4 in the installation procedure. 12. From the technicians point of view, the FRONT of the sensor will have: * A raised rotor flange cuff (3) * An alignment mark (2) on the rotor flange cuff for installation * A pin hole (1) for the centering pin-Note the location of the pin hole. 13. Remove the connector from the sensor. 14. Remove the sensor from the adapter and bearing assembly. 15. To install the sensor, proceed to step 8 in the installation procedure. 16. From the technicians point of view, the FRONT of the sensor will have: * A raised rotor flange cuff (3) * An alignment mark (2) on the rotor flange cuff for installation * A pin hole (1) for the centering pin-Note location of the pin hole. * A sensor clip in FRONT of the sensor 17. Remove the connector from the sensor. 18. Remove the sensor clip from the sensor. 19. Remove the sensor from the adapter and bearing assembly. 20. To install the sensor, proceed to step 12 in the installation procedure. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor Replacement > Page 12940 21. From the technicians point of view, the FRONT of the sensor will have: * A flush rotor flange cuff (3) * A pin hole (1) for the centering pin-Note the location of the pin hole. * An alignment mark (2) on the flush rotor flange cuff for installation 22. Remove the connector from the sensor. 23. Remove the sensor from the adapter and bearing assembly. 24. To install the sensor, proceed to step 16 in the installation procedure. 25. From the technicians point of view, the FRONT of the sensor will have: * A flush rotor flange cuff (4) * A pin hole (2) for the centering pin-Note the location of the pin hole. * An alignment mark (3) on the flush rotor flange cuff for installation * A foam ring (1) 26. Remove the connector from the sensor. 27. Remove the sensor from the adapter and bearing assembly. 28. To install the sensor, proceed to step 20 in the installation procedure. Installation Procedure Note: If you are reusing the existing sensor, centering of the old sensor is not necessary. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. 1. From the technicians point of view of the FRONT of the sensor (1), the connector will be on your right. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor Replacement > Page 12941 From the technicians point of view of the BACK of the sensor (2), the connector will be on your left. 2. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 3. Install the connector to the sensor. 4. From the technicians point of view, the FRONT of the sensor will have: * A foam ring (4) * A pin hole (7) for the centering pin-Note the location of the pin hole. * A flush rotor flange cuff (6) * An alignment mark (5) for installation 5. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * A foam ring (3) * An alignment tab (2) for installing the sensor to the adapter and bearing assembly * A view of the inside of the connector Note: If you are reusing the existing sensor, align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 6. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 7. Install the connector to the sensor. 8. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (3) for the centering pin-Note location of the pin hole. * A raised rotor flange cuff (5) * An alignment mark (4) for installation 9. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * An alignment tab (2) for installing the sensor to the adapter and bearing assembly Note: If you are reusing the existing sensor, align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor Replacement > Page 12942 If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 10. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 11. Install the connector to the sensor. 12. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (2) for the centering pin-Note the location of the pin hole. * A raised rotor flange cuff (4) * An alignment mark (3) for installation 13. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Note: If you are reusing the existing sensor, align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 14. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 15. Install the connector to the sensor. 16. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (2) for the centering pin-Note the location of the pin hole. * A flush rotor flange cuff (4) * An alignment mark (3) for installation 17. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Note: If you are reusing the existing sensor, align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 18. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor Replacement > Page 12943 19. Install the connector to the sensor. 20. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (3) for the centering pin-Note location of the pin hole. * A flush rotor flange cuff (5) * An alignment mark (4) for installation * A foam ring (6) 21. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * An alignment tab (2) for installing the sensor to the adapter and bearing assembly Note: If you are reusing the existing sensor, align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 22. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 23. Install the connector to the sensor. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information > Diagrams Steering Angle Sensor: Diagrams Component Connector End Views Steering Angle Sensor (JL4) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor Replacement Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor Replacement Steering Wheel Position Sensor Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor Replacement > Page 12949 Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor Centering Steering Wheel Position Sensor Centering Removal Procedure Caution: With wheels of the vehicle facing straight ahead, secure the steering wheel utilizing steering column anti-rotation pin, steering column lock, or a strap to prevent rotation. Locking of the steering column will prevent damage and a possible malfunction of the SIR system. The steering wheel must be secured in position before disconnecting the following components: * The steering column * The intermediate shaft(s) * The steering gear After disconnecting these components, do not rotate the steering wheel or move the front tires and wheels. Failure to follow this procedure may cause the SIR coil assembly to become un-centered and cause possible damage to the SIR coil. If you think the SIR coil has became un-centered, refer to your specific SIR coil's centering procedure to re-center SIR Coil. 1. With the wheels of the vehicle in the straight ahead position, secure the steering wheel or the steering column with a steering column anti-rotation pin, a steering column lock, or a strap, as applicable, in order to prevent rotation. Note: Identify the type of steering wheel position sensor from the illustrations shown BEFORE removing the sensor from the steering column. Once you have identified the steering wheel position sensor, follow the instructions listed in the removal procedure. 2. Verify the type of steering wheel position sensor. 3. From the technicians point of view of the FRONT of the sensor (1), the connector will be on the right. Note: If you are reusing the existing sensor, you do not have to align the sensor before removal. Centering is not necessary in order to install the old sensor. 4. Remove the connector from the sensor. 5. Remove the sensor from the adapter and bearing assembly. 6. To install the sensor, proceed to step 1 in the installation procedure. 7. From the technicians point of view, the FRONT of the sensor will have: * A foam ring (2) * A pin hole (1) for the centering the pin-Note the location of the pin hole. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor Replacement > Page 12950 * A flush rotor flange cuff (4) Note: If you are reusing the existing sensor, make an alignment mark (3) on the rotor flange cuff before removing the sensor. Failure to do so will cause misalignment of the old sensor. Replace a misaligned sensor with a new sensor. 8. Make an alignment mark on the flush rotor flange cuff. 9. Remove the connector from the sensor. 10. Remove the sensor from the adapter and bearing assembly. 11. To install the sensor, proceed to step 4 in the installation procedure. 12. From the technicians point of view, the FRONT of the sensor will have: * A raised rotor flange cuff (3) * An alignment mark (2) on the rotor flange cuff for installation * A pin hole (1) for the centering pin-Note the location of the pin hole. 13. Remove the connector from the sensor. 14. Remove the sensor from the adapter and bearing assembly. 15. To install the sensor, proceed to step 8 in the installation procedure. 16. From the technicians point of view, the FRONT of the sensor will have: * A raised rotor flange cuff (3) * An alignment mark (2) on the rotor flange cuff for installation * A pin hole (1) for the centering pin-Note location of the pin hole. * A sensor clip in FRONT of the sensor 17. Remove the connector from the sensor. 18. Remove the sensor clip from the sensor. 19. Remove the sensor from the adapter and bearing assembly. 20. To install the sensor, proceed to step 12 in the installation procedure. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor Replacement > Page 12951 21. From the technicians point of view, the FRONT of the sensor will have: * A flush rotor flange cuff (3) * A pin hole (1) for the centering pin-Note the location of the pin hole. * An alignment mark (2) on the flush rotor flange cuff for installation 22. Remove the connector from the sensor. 23. Remove the sensor from the adapter and bearing assembly. 24. To install the sensor, proceed to step 16 in the installation procedure. 25. From the technicians point of view, the FRONT of the sensor will have: * A flush rotor flange cuff (4) * A pin hole (2) for the centering pin-Note the location of the pin hole. * An alignment mark (3) on the flush rotor flange cuff for installation * A foam ring (1) 26. Remove the connector from the sensor. 27. Remove the sensor from the adapter and bearing assembly. 28. To install the sensor, proceed to step 20 in the installation procedure. Installation Procedure Note: If you are reusing the existing sensor, centering of the old sensor is not necessary. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. 1. From the technicians point of view of the FRONT of the sensor (1), the connector will be on your right. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor Replacement > Page 12952 From the technicians point of view of the BACK of the sensor (2), the connector will be on your left. 2. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 3. Install the connector to the sensor. 4. From the technicians point of view, the FRONT of the sensor will have: * A foam ring (4) * A pin hole (7) for the centering pin-Note the location of the pin hole. * A flush rotor flange cuff (6) * An alignment mark (5) for installation 5. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * A foam ring (3) * An alignment tab (2) for installing the sensor to the adapter and bearing assembly * A view of the inside of the connector Note: If you are reusing the existing sensor, align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 6. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 7. Install the connector to the sensor. 8. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (3) for the centering pin-Note location of the pin hole. * A raised rotor flange cuff (5) * An alignment mark (4) for installation 9. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * An alignment tab (2) for installing the sensor to the adapter and bearing assembly Note: If you are reusing the existing sensor, align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor Replacement > Page 12953 If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 10. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 11. Install the connector to the sensor. 12. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (2) for the centering pin-Note the location of the pin hole. * A raised rotor flange cuff (4) * An alignment mark (3) for installation 13. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Note: If you are reusing the existing sensor, align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 14. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 15. Install the connector to the sensor. 16. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (2) for the centering pin-Note the location of the pin hole. * A flush rotor flange cuff (4) * An alignment mark (3) for installation 17. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Note: If you are reusing the existing sensor, align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 18. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor Replacement > Page 12954 19. Install the connector to the sensor. 20. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (3) for the centering pin-Note location of the pin hole. * A flush rotor flange cuff (5) * An alignment mark (4) for installation * A foam ring (6) 21. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * An alignment tab (2) for installing the sensor to the adapter and bearing assembly Note: If you are reusing the existing sensor, align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 22. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 23. Install the connector to the sensor. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling SIR component location affects how a vehicle should be serviced. There are parts of the SIR system installed in various locations around a vehicle. To find the location of the SIR components refer to SIR Identification Views (See: Restraint Systems/Air Bag Systems/Locations). There are several reasons for disabling the SIR system, such as repairs to the SIR system or servicing a component near or attached to an SIR component. There are several ways to disable the SIR system depending on what type of service is being performed. The following information covers the proper procedures for disabling/enabling the SIR system. SIR Service Precautions Warning When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. The inflatable restraint sensing and diagnostic module (SDM) maintains a reserved energy supply. The reserved energy supply provides deployment power for the air bags if the SDM loses battery power during a collision. Deployment power is available for as much as 1 minute after disconnecting the vehicle power. Waiting 1 minute before working on the system after disabling the SIR system prevents deployment of the air bags from the reserved energy supply. General Service Instructions The following are general service instructions which must be followed in order to properly repair the vehicle and return it to its original integrity: * Do not expose air bags to temperatures above 65°C (149°F). * Verify the correct replacement part number. Do not substitute a component from a different vehicle. * Use only original GM replacement parts available from your authorized GM dealer. Do not use salvaged parts for repairs to the SIR system. Discard any of the following components if it has been dropped from a height of 92 cm (3 feet) or greater: * Inflatable restraint sensing and diagnostic module (SDM) * Any air bag * Driver steering wheel air bag coil * Any impact sensor * Seat belt anchor and/or retractor pretensioners * Passenger presence module and/or occupant sensor Disabling Procedure - Air Bag Fuse 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. Note: The SDM may have more than one fused power input. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove all fuses supplying power to the SDM. With all SDM fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate a SIR system malfunction. 3. Locate and remove the fuse(s) supplying power to the SDM. Refer to SIR Schematics (See: Diagrams/Electrical Diagrams/Air Bag Systems) or Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse/Application and ID). 4. Wait 1 minute before working on the system. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Page 12959 Enabling Procedure - Air Bag Fuse 1. Place the ignition in the OFF position. 2. Install the fuse(s) supplying power to the SDM. Refer to SIR Schematics (See: Diagrams/Electrical Diagrams/Air Bag Systems) or Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse/Application and ID). 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle). Disabling Procedure - Negative Battery Cable 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. 3. Disconnect the negative battery cable from the battery. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 4. Wait 1 minute before working on system. Enabling Procedure - Negative Battery Cable 1. Place the ignition in the OFF position. 2. Connect the negative battery cable to the battery. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Damper > Component Information > Service and Repair Steering Damper: Service and Repair Steering Linkage Shock Absorber Replacement Special Tools J 24319-B Steering Linkage and Tie Rod Puller Removal Procedure 1. Remove the engine shield, if equipped. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement). Note: Discard the steering linkage shock absorber nut. 2. Remove the steering linkage shock absorber nut (1) from the steering linkage shock absorber (2). 3. Remove the steering linkage shock absorber from the relay rod using puller J 24319-B . Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Damper > Component Information > Service and Repair > Page 12963 Note: Discard the steering linkage shock absorber nut. 4. Remove the steering linkage shock absorber bolt (2) and nut (3). 5. Remove the steering linkage shock absorber (1) from the vehicle. 6. Inspect the following parts: * The steering linkage shock absorber for leaks and damage * The steering linkage shock absorber bolt for damage or corrosion Installation Procedure Note: Use new steering linkage shock absorber nuts. 1. Install the steering linkage shock absorber (2) to the vehicle. 2. Install the steering linkage shock absorber (4) and nuts (1, 3). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Damper > Component Information > Service and Repair > Page 12964 3. Install the steering linkage shock absorber nuts (1, 3) and tighten to 40 Nm (30 lb ft). 4. Install the engine shield, if equipped. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Steering Gear Seal > Component Information > Technical Service Bulletins > Steering/Suspension - Pitman Arm Shaft Seal Service Kit Steering Gear Seal: Technical Service Bulletins Steering/Suspension - Pitman Arm Shaft Seal Service Kit INFORMATION Bulletin No.: 10-02-33-001A Date: October 13, 2010 Subject: Information on Pitman Arm Shaft Seal Service Kit Models: 2004-2005 Buick Rainier 2000-2006 Cadillac Escalade, Escalade ESV, Escalade EXT 2000-2005 Chevrolet Blazer, S-10 2000-2011 Chevrolet Avalanche, Express, Silverado, Suburban, Tahoe 2000-2005 GMC Jimmy, Sonoma 2000-2011 GMC Savana, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2000-2004 Oldsmobile Bravada 2003-2009 HUMMER H2 with Recirculating Ball Steering Gears Supercede: This bulletin is being revised to update the model years and models involved. Please discard Corporate Bulletin Number 10-02-33-001 (Section 02 - Steering). Note Do not replace the entire steering gear for a pitman seal leak. Technicians have been replacing entire steering gears due to not being able to service just the leaking pitman shaft seal. The seal is serviced as a kit and is not called out separately in the catalog illustration. The seal package is cataloged in Group 06.855 as Seal Kit - GM Part Number 26002516 - Steering Gear Pitman Shaft, which includes the seal, washer, retaining ring and dust seal or G/M P/N 19256667, which includes the seal and retainer. Refer to Steering Gear Pitman Shaft Seal in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Assembly > Component Information > Service and Repair Steering Mounted Controls Assembly: Service and Repair Steering Wheel Control Switch Assembly Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams Steering Mounted Controls Transmitter: Diagrams Component Connector End Views Steering Wheel Control Switch - Left (K34 or KA9) Steering Wheel Control Switch - Right (UK3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Page 12976 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Service and Repair > Steering Shaft Upper Bearing Replacement Steering Shaft: Service and Repair Steering Shaft Upper Bearing Replacement Steering Shaft Upper Bearing Replacement Special Tools * J 21854-01 Pivot Pin Remover * J 23653-SIR Steering Column Lock Plate Compressor * J 42137 Cam Orientation Plate Adapter * J 42640 Steering Column Anti-Rotation Pin Removal Procedure Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). 1. Remove the steering column. Refer to Steering Column Replacement (Without HP2) (See: Steering Column/Service and Repair/Steering Column Replacement (Without HP2))Steering Column Replacement (HP2) (). 2. Remove the inflatable restraint steering wheel module coil. Refer to Steering Wheel Inflatable Restraint Module Coil Replacement (See: Restraint Systems/Air Bag Systems/Clockspring Assembly / Spiral Cable/Service and Repair/Removal and Replacement). 3. Remove the turn signal multifunction switch. Refer to Turn Signal Multifunction Switch Replacement (See: Lighting and Horns/Sensors and Switches - Lighting and Horns/Turn Signal Switch/Service and Repair/Turn Signal Multifunction Switch Replacement). 4. Remove the ignition lock cylinder case. Refer to Ignition Lock Cylinder Case Replacement (See: Powertrain Management/Ignition System/Sensors and Switches - Ignition System/Ignition Switch/Ignition Switch Lock Cylinder/Service and Repair/Ignition Lock Cylinder Case Replacement). 5. Remove the tilt spring. Refer to Steering Column Tilt Spring Replacement (See: Steering Column/Service and Repair/Steering Column Tilt Spring Replacement). 6. Remove the automatic transmission control. Refer to Transmission Control Replacement (See: Steering Column/Service and Repair/Transmission Control Replacement). 7. Using compressor J 23653-SIR and adapter J 42137 , remove and discard the steering shaft lock plate retaining ring. 8. Remove the following parts from the steering column shaft assembly: 1. The turn signal switch cancel cam position plate (5) 2. The turn signal switch cancel cam (4) 3. The steering shaft upper bearing spring (3) 4. The steering shaft upper bearing inner race seat (2) 5. The steering shaft upper bearing inner race (1) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Service and Repair > Steering Shaft Upper Bearing Replacement > Page 12981 9. Remove the 2 pivot pins (3) from the steering column tilt head assembly (1) by using remover J 21854-01 (2). 10. Install the tilt lever into the steering column tilt head assembly (1). 11. Pull back on the tilt lever and at the same time, pull the steering column tilt head assembly (1) down and away from the steering column. 12. Remove the steering column tilt head assembly. 13. Remove anti-rotation pin J 42640 . 14. Remove the tilt lever. 15. Remove the steering shaft upper bearing from the steering column tilt head assembly. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Service and Repair > Steering Shaft Upper Bearing Replacement > Page 12982 1. Install the steering shaft upper bearing to the steering column tilt head assembly. 2. Install the steering column shaft assembly. 3. Maneuver and push the steering column tilt head assembly (1) towards the steering column in order to lock the steering wheel lock shoes in place. 4. Lubricate the pivot pins (1) with GM P/N 12346293 (Canadian P/N 992723). 5. Firmly seat each pivot pin (1) into the steering column tilt head assembly. 6. Stake the steering column in 3 locations around each pivot pin. 7. Install anti-rotation pin J 42640 . Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Service and Repair > Steering Shaft Upper Bearing Replacement > Page 12983 8. Install the following parts onto the steering column shaft assembly: 1. Lubricate the steering shaft upper bearing inner race (1) with GM P/N 12345718 (Canadian P/N 10953516). 2. The steering shaft upper bearing inner race (1) 3. The steering shaft upper bearing inner race seat (2) 4. The steering shaft upper bearing spring (3) 5. Lubricate the turn signal switch cancel cam (4) with GM P/N 12377900 (Canadian P/N 10953529). 6. The turn signal switch cancel cam (4) 7. The turn signal switch cancel cam position plate (5) 9. Install the new steering shaft lock plate retaining ring onto the steering shaft using compressor J 23653-SIR and adapter J 42137 . 10. Install the automatic transmission control assembly. Refer to Transmission Control Replacement (See: Steering Column/Service and Repair/Transmission Control Replacement). 11. Install the tilt spring. Refer to Steering Column Tilt Spring Replacement (See: Steering Column/Service and Repair/Steering Column Tilt Spring Replacement). 12. Install the ignition lock cylinder case. Refer to Ignition Lock Cylinder Case Replacement (See: Powertrain Management/Ignition System/Sensors and Switches - Ignition System/Ignition Switch/Ignition Switch Lock Cylinder/Service and Repair/Ignition Lock Cylinder Case Replacement). 13. Install the turn signal multifunction switch. Refer to Turn Signal Multifunction Switch Replacement (See: Lighting and Horns/Sensors and Switches - Lighting and Horns/Turn Signal Switch/Service and Repair/Turn Signal Multifunction Switch Replacement). 14. Install the inflatable restraint steering wheel module coil. Refer to Steering Wheel Inflatable Restraint Module Coil Replacement (See: Restraint Systems/Air Bag Systems/Clockspring Assembly / Spiral Cable/Service and Repair/Removal and Replacement). 15. Install the steering column. Refer to Steering Column Replacement (Without HP2) (See: Steering Column/Service and Repair/Steering Column Replacement (Without HP2))Steering Column Replacement (HP2) (). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Service and Repair > Steering Shaft Upper Bearing Replacement > Page 12984 Steering Shaft: Service and Repair Steering Shaft Lower Bearing Replacement Steering Shaft Lower Bearing Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Service and Repair > Steering Shaft Upper Bearing Replacement > Page 12985 Steering Shaft: Service and Repair Steering Shaft Coupling Replacement Steering Shaft Coupling Replacement Special Tools J-42640 - Steering Column Anti-rotation Pin Removal Procedure Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). Caution: With wheels of the vehicle facing straight ahead, secure the steering wheel utilizing steering column anti-rotation pin, steering column lock, or a strap to prevent rotation. Locking of the steering column will prevent damage and a possible malfunction of the SIR system. The steering wheel must be secured in position before disconnecting the following components: * The steering column * The intermediate shaft(s) * The steering gear After disconnecting these components, do not rotate the steering wheel or move the front tires and wheels. Failure to follow this procedure may cause the SIR coil assembly to become un-centered and cause possible damage to the SIR coil. If you think the SIR coil has became un-centered, refer to your specific SIR coil's centering procedure to re-center SIR Coil. 1. Ensure the front wheels are in the straight-ahead position. 2. Install the J-42640 - pin in the steering column lower access hole. 3. Remove the engine shield. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement). 4. Use paint in order to mark the relationship of the upper intermediate steering shaft to the steering shaft coupling. 5. Use paint in order to mark the relationship of the steering shaft coupling to the steering gear. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Service and Repair > Steering Shaft Upper Bearing Replacement > Page 12986 Note: DO NOT pull on the steering shaft coupling (1) in order to separate the coupling from the steering gear. 6. Remove the steering shaft coupling bolt (2) at the steering gear. 7. Remove the steering shaft coupling nut (1) and the bolt (2) at the upper intermediate steering shaft. 8. Remove the steering shaft coupling from the vehicle. Installation Procedure Note: Failure to transfer the alignment marks may result in an off-center steering wheel after installation. 1. If a new steering shaft coupling is being installed, copy the alignment marks from the old component to the same locations on the new component. 2. Position the steering shaft coupling in the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Service and Repair > Steering Shaft Upper Bearing Replacement > Page 12987 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the steering shaft coupling nut (1) and the bolt (2) to the upper intermediate steering shaft and tighten to 50 Nm (37 lb ft). 4. Install the steering shaft coupling bolt (2) to the steering gear and tighten to 47 Nm (35 lb ft). 5. Install the engine shield. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Service and Repair > Steering Shaft Upper Bearing Replacement > Page 12988 6. Remove the J-42640 - pin from the steering column lower access hole. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Steering Wheel Heater Control Module > Component Information > Service and Repair Steering Wheel Heater Control Module: Service and Repair Steering Wheel Heat Control Module Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Testing and Inspection > Steering Linkage Inner Tie Rod Inspection Tie Rod: Testing and Inspection Steering Linkage Inner Tie Rod Inspection Steering Linkage Inner Tie Rod Inspection Special Tools J-8001 - Dial Indicator Set For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Note: This inspection procedure does not supersede local government required inspections that have more stringent requirements. 1. Turn the ignition key to the ON position with the engine OFF. 2. With the aid of an assistant, turn the steering wheel to the full stop position and hold the steering wheel in that position until the test is complete. The tie rod being tested should be inside the steering gear housing seated against the steering stop. 3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair). 4. If there is not a good location for the J-8001 - Dial Indicator pointer at the steering gear housing, install a large worm gear hose clamp to the steering gear housing over the larger steering gear boot clamp and align the clamp so that the screw can be a location for the J-8001 - Dial Indicator pointer. 5. Install the J-8001 - Dial Indicator between the inner tie rod (2) and the steering gear housing or the worm gear clamp in such a way as to measure the lash between the inner tie rod and the steering gear housing. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Testing and Inspection > Steering Linkage Inner Tie Rod Inspection > Page 12997 Note: Only move the tire enough to feel any lash between the inner tie rod and the inner tie rod housing without moving the steering gear rack. 6. Grasping the tire at the 3 o'clock (2) and 9 o'clock (1) positions, gently push in on one side of the tire in order to remove any lash. 7. Zero the J-8001 - Dial Indicator. 8. On the same side of the tire previously pushed in, gently pull out and measure the lash. 9. Record the measurement seen on the J-8001 - Dial Indicator. 10. If the measured value exceeds 0.5 mm (0.02 in), replace the inner tie rod. Refer to Steering Linkage Inner Tie Rod Replacement (HP2) ()Steering Linkage Inner Tie Rod Replacement (Hydraulic Rack and Pinion) (See: Service and Repair/Steering Linkage Inner Tie Rod Replacement (Hydraulic Rack and Pinion)). 11. Repeat the procedure for the other side. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Testing and Inspection > Steering Linkage Inner Tie Rod Inspection > Page 12998 Tie Rod: Testing and Inspection Steering Linkage Outer Tie Rod Inspection Steering Linkage Outer Tie Rod Inspection Special Tools J-8001 - Dial Indicator Set For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Note: This inspection procedure does not supersede local government required inspections that have more stringent requirements. 1. Inspect the outer tie rod end seal. If the outer tie rod end seal is torn, replace the outer tie rod end. Refer to Steering Linkage Outer Tie Rod Replacement (See: Service and Repair/Steering Linkage Outer Tie Rod Replacement). 2. Raise the side of the vehicle being inspected with a floor jack while maintaining contact between the opposite wheel and the shop floor. Support the lower control arm with a floor jack stand as far outboard as possible and remove the floor jack. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair). 3. Install the J-8001 - Dial Indicator between the outer tie rod end and the steering knuckle as shown in the graphic. Note that the tire and wheel assembly is shown removed only for clarification of the dial indicator position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Testing and Inspection > Steering Linkage Inner Tie Rod Inspection > Page 12999 4. Grasping the tire at the 3 o'clock (2) and 9 o'clock (1) positions, gently push in on one side of the tire to remove any lash. 5. Zero the J-8001 - Dial Indicator. 6. On the same side of the tire previously pushed inwards, gently pull outwards and measure the lash. 7. Record the measurement seen on the J-8001 - Dial Indicator. 8. If the measured value exceeds 1 mm (0.04 in) then replace the outer tie rod. Refer to Steering Linkage Outer Tie Rod Replacement (See: Service and Repair/Steering Linkage Outer Tie Rod Replacement). 9. Repeat the procedure for the other side. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Service and Repair > Steering Linkage Outer Tie Rod Replacement Tie Rod: Service and Repair Steering Linkage Outer Tie Rod Replacement Power Steering Steering Linkage Outer Tie Rod Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Service and Repair > Steering Linkage Outer Tie Rod Replacement > Page 13002 Steering Linkage Steering Linkage Outer Tie Rod Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Service and Repair > Steering Linkage Outer Tie Rod Replacement > Page 13003 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Service and Repair > Steering Linkage Outer Tie Rod Replacement > Page 13004 Tie Rod: Service and Repair Steering Linkage Inner Tie Rod Replacement (Hydraulic Rack and Pinion) Steering Linkage Inner Tie Rod Replacement (Hydraulic Rack and Pinion) Removal Procedure Note: After removing the boot, inspect the inner tie rod for evidence of corrosion or contamination. If none is evident, continue with the repair. If corrosion or contamination is evident, replace the steering gear. 1. Remove the steering gear boot. Refer to Steering Gear Boot Replacement (HP2) (See: Steering Gear)Steering Gear Boot Replacement (Without HP2) (See: Steering Gear). Caution: Do not change the steering gear preload adjustment before moving the inner tie rod from the steering gear. Changing the steering gear preload adjustment before moving the inner tie rod could result in damage to the pinion and the steering gear. Caution: The pipe wrench must be placed at the valve end of the steering gear and positioned up against the inner tie rod housing. Placing the pipe wrench in any other location will cause damage to the steering gear. 2. Place a pipe wrench on the steering gear rack (1) next to the steering linkage inner tie rod housing (2). 3. Place a wrench on the flats of the steering linkage inner tie rod housing (2). 4. Rotate the steering linkage inner tie rod housing (2) counterclockwise, while holding the steering gear rack stationary, until the steering linkage inner tie rod separates from the steering gear rack (1). Installation Procedure Note: All threads must be clean prior to LOCTITE(R) application. Check the LOCTITE(R), or equivalent, container for the expiration date. Use only enough LOCTITE(R) to evenly coat the threads. 1. Apply LOCTITE(R) 262, or equivalent, to the steering gear inner tie rod threads. 2. Attach the steering linkage inner tie rod onto the steering gear rack. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Service and Repair > Steering Linkage Outer Tie Rod Replacement > Page 13005 Caution: Refer to Pipe Wrench Positioning Caution (See: Service Precautions/Vehicle Damage Warnings/Pipe Wrench Positioning Caution). 3. Place a pipe wrench on the steering gear rack (1) next to the steering linkage inner tie rod housing (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) 4. Tighten the steering linkage inner tie rod housing (2). Tighten the steering linkage inner tie rod to 150 Nm (111 lb ft). 5. Install the steering gear boot. Refer to Steering Gear Boot Replacement (HP2) (See: Steering Gear)Steering Gear Boot Replacement (Without HP2) (See: Steering Gear). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Component Information > Service and Repair > Steering Linkage Outer Tie Rod Replacement > Page 13006 Tie Rod: Service and Repair Steering Linkage (Non-Rack & Pinion) Steering Linkage Inner Tie Rod Replacement Special Tools J 34028 Inner Tie Rod Wrench Removal Procedure 1. Remove the engine shield, if equipped. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement). 2. Remove the steering linkage outer tie rod. Refer to Steering Linkage Outer Tie Rod Replacement (See: Steering Linkage Outer Tie Rod Replacement). 3. Remove the steering linkage inner tie rod (1) from the relay rod using wrench J 34028 (2). Installation Procedure 1. Remove all traces of oil, grease, or other contaminants. 2. Clean the threads of the steering linkage inner tie rod with denatured alcohol or the equivalent and allow to dry. 3. Apply red LOCTITE(TM) threadlocker, GM P/N 12345493 (Canadian P/N 10953488) to the threads of the steering linkage inner tie rod. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the steering linkage inner tie rod (1) to the relay rod using wrench J 34028 (2) and tighten to 100 Nm (74 lb ft). 5. Install the steering linkage outer tie rod. Refer to Steering Linkage Outer Tie Rod Replacement (See: Steering Linkage Outer Tie Rod Replacement). 6. Install the engine shield, if equipped. Refer to Engine Shield Replacement (See: Body and Frame/Frame/Skid Plate/Service and Repair/Engine Shield Replacement). 7. Adjust the front toe. Refer to Wheel Alignment - Steering Wheel Angle and/or Front Toe Adjustment (See: Alignment/Service and Repair/Wheel Alignment - Steering Wheel Angle and/or Front Toe Adjustment). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications Ball Joint: Specifications Ball Joint Inspection (Lower Ball Joint) ......................................................................................................................... No More Than 0.50 mm (0.020 in) Ball Joint Inspection (Upper Ball Joint) ......................................................................................................................... No More Than 0.50 mm (0.020 in) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Ball Joint Inspection (Lower Ball Joint) Ball Joint: Testing and Inspection Ball Joint Inspection (Lower Ball Joint) Lower Control Arm Ball Joint Inspection Special Tools J 8001 - Dial Indicator For equivalent regional tools, refer to Special Tools (See: Tools and Equipment/Front Suspension). Note: * The vehicle must rest on a level surface. * The vehicle must be stable. Do not rock the vehicle on the floor stands. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair). 2. Clean and inspect the ball joint seal for cuts or tears. If the ball joint seal is damaged, replace the ball joint or the lower control arm as applicable for this vehicle. 3. Support the lower control arm with a floor stand as far outboard as possible and raise the suspension until the lower control arm moves 25 mm (1 in). 4. Install the J 8001 - dial indicator , or suitable dial indicator, to measure the vertical lash in the ball joint. Caution: Do not pry in such a way that the ball joint seal is contacted. Damage to the seal may result. 5. Lift the knuckle towards the lower control arm and record the dial indicator measurement. 6. If the dial indicator reading is more than 0.50 mm (0.020 in) , replace the ball joint or the lower control arm as applicable for this vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Ball Joint Inspection (Lower Ball Joint) > Page 13013 Ball Joint: Testing and Inspection Upper Control Arm Ball Joint Inspection Upper Control Arm Ball Joint Inspection Special Tools J 8001 - Dial Indicator Set For equivalent regional tools, refer to Special Tools (See: Tools and Equipment/Front Suspension). Note: * The vehicle must rest on a level surface. * The vehicle must be stable. Do not rock the vehicle on the floor stands. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair). 2. Clean and inspect the ball joint seal for cuts or tears. If the ball joint seal is damaged, replace the ball joint or upper control arm as applicable for this vehicle. 3. Support the lower control arm with a floor stand as far outboard as possible and raise the suspension until the lower control arm moves 25 mm (1 in). 4. Install the J 8001 - dial indicator , or suitable dial indicator, to measure the vertical lash in the ball joint. Caution: Do not pry in such a way that the ball joint seal is contacted. Damage to the seal may result. 5. Apply downward force to the upper control arm and zero the indicator. 6. Apply upward force to the upper control arm and check the dial indicator. Record the measurement 7. If the dial indicator reading is more than 0.50 mm (0.020 in) , replace the ball joint or the upper control arm as applicable for this vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Page 13014 Ball Joint: Service and Repair Lower Control Arm Ball Joint Replacement (2500 , 3500 ) Special Tools * CH 41805 - Ball Joint remover/Installer * CH 49240 - Ball Joint Crimper and Install Kit For equivalent regional tools, refer to Special Tools (See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft Assembly/Tools and Equipment). Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair). Note: When removing the knuckle, DO NOT remove any of the brake or electrical components from the knuckle. Secure the knuckle assembly to the side. 2. Remove the knuckle from the vehicle. Refer to Steering Knuckle Replacement (See: Rear Knuckle/Service and Repair). 3. Using a hammer and a chisel, remove the lock tabs (1) from the lower ball joint. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Page 13015 4. Using the CH 41805 - remover/installer (1) and the appropriate adapter, remove the lower ball joint (2). Installation Procedure 1. Position the lower ball joint (1) in the lower control arm. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Page 13016 2. Align the lower ball joint grease fitting (1) with the channel (2) in the lower control arm 3. Using the CH 41805 - remover/installer (1), the appropriate adapter (3), and the CH 49240 install Kit (2), install the lower ball joint. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Page 13017 4. Ensure that the ball joint (2) is fully seated against the lower control arm (1). 5. Using a hammer and a punch, created the lock tabs (1) for the lower ball joint. 6. Install the knuckle. Refer to Steering Knuckle Replacement (See: Rear Knuckle/Service and Repair). 7. Install the lower ball joint stud nut and tighten to: * First Pass 50 Nm (37 lb ft) * Final Pass additional 95 degrees 8. Remove the support and lower the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Upper Control Arm Replacement Control Arm: Service and Repair Upper Control Arm Replacement Upper Control Arm Replacement (2500, 3500) Special Tools J-42188-B Ball Joint Separator Removal Procedure 1. Remove the tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair). 2. Lower the vehicle and support the lower control arm. 3. Remove the retaining bolt for the brake hose and the wheel speed sensor brackets. 4. Remove the nut at the upper ball joint. Discard the nut. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Upper Control Arm Replacement > Page 13022 5. Disconnect the upper control arm from the steering knuckle using the J-42188-B . 6. Remove the upper control arm nuts and the adjustment cams. 7. Remove the upper control arm. Installation Procedure 1. Install the upper control arm. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the upper control arm bolts. Tighten the nuts to 190 Nm (140 lb ft). 3. Connect the upper control arm to the steering knuckle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Upper Control Arm Replacement > Page 13023 4. Install the new nut to the upper ball joint stud. Tighten the nut to 50 Nm (39 lb ft). 5. Install the retaining bolts for the brake hose and wheel speed sensor brackets. Tighten the bolts to 9 Nm (80 lb in). 6. Raise the vehicle and remove the support for the lower control arm. 7. Install the tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair). 8. Verify the wheel alignment. Refer to Wheel Alignment Specifications (See: Alignment/Specifications/Wheel Alignment Specifications). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Upper Control Arm Replacement > Page 13024 Control Arm: Service and Repair Lower Control Arm Replacement Lower Control Arm Replacement (2500, 3500) Special Tools * J 43631 - Ball Joint Separator * J 45851 - Ball Joint Separator Protector Adapters Removal Procedure Note: For vehicles equipped with the aluminum control arm, the ball joint is NOT serviced separately. If the ball joint is found to have excessive wear and is damaged, replace the lower control arm as an assembly. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair). 3. Remove the stabilizer shaft links from the lower control arm. Refer to Stabilizer Shaft Replacement (1500) (See: Stabilizer Bar/Service and Repair/Front Suspension)Stabilizer Shaft Replacement (2500, 3500) (See: Stabilizer Bar/Service and Repair/Front Suspension). 4. Remove the torsion bars. Refer to Torsion Bar and Support Assembly Replacement (Bushing Style) (See: Torsion Bar/Service and Repair/Torsion Bar and Support Assembly Replacement (Bushing Style))Torsion Bar and Support Assembly Replacement (Link Style) (See: Torsion Bar/Service and Repair/Torsion Bar and Support Assembly Replacement (Link Style)). 5. Remove the shock absorber module. Refer to Shock Absorber Replacement (2500 Series) (). 6. Remove the wheel drive shafts. Refer to Wheel Drive Shaft Replacement (2500) (See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft Assembly/Service and Repair)Wheel Drive Shaft Replacement (1500) (See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft Assembly/Service and Repair). 7. Remove and discard the lower ball joint retaining nut. 8. Using the J 43631 - separator and the J 45851 - adapters , remove the lower ball joint from the steering knuckle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Upper Control Arm Replacement > Page 13025 9. Remove the lower control arm nuts (1) and washers (2). 10. Remove the control arm bolts (3). 11. Remove the control arm (4). Installation Procedure 1. Install the lower control arm (4). 2. Install the lower control arm bolts (3). 3. Install the washers (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the lower control arm retaining nuts (1) and tighten to 175 Nm (129 lb ft). 5. Install the lower ball joint in the steering knuckle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Upper Control Arm Replacement > Page 13026 6. Install the NEW lower ball joint retaining nut and tighten to 125 Nm (92 lb ft). 7. Install the wheel drive shaft. Refer to Wheel Drive Shaft Replacement (2500) (See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft Assembly/Service and Repair)Wheel Drive Shaft Replacement (1500) (See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft Assembly/Service and Repair). 8. Install the shock module. Refer to Shock Absorber Replacement (2500 Series) (). 9. Install the torsion bars. Refer to Torsion Bar and Support Assembly Replacement (Bushing Style) (See: Torsion Bar/Service and Repair/Torsion Bar and Support Assembly Replacement (Bushing Style))Torsion Bar and Support Assembly Replacement (Link Style) (See: Torsion Bar/Service and Repair/Torsion Bar and Support Assembly Replacement (Link Style)). 10. Install the stabilizer shaft links to the lower control arm. Refer to Stabilizer Shaft Replacement (1500) (See: Stabilizer Bar/Service and Repair/Front Suspension)Stabilizer Shaft Replacement (2500, 3500) (See: Stabilizer Bar/Service and Repair/Front Suspension). 11. Install the tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair). 12. Remove the supports and lower the vehicle. 13. Align the front end. Refer to Wheel Alignment Measurement (See: Alignment/Service and Repair/Wheel Alignment Measurement). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Service and Repair > Transmission Support Crossmember Replacement Cross-Member: Service and Repair Transmission Support Crossmember Replacement Transmission Support Crossmember Replacement (4WD 2500 HD/3500) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Service and Repair > Transmission Support Crossmember Replacement > Page 13031 Cross-Member: Service and Repair Drivetrain and Front Suspension Frame Front Crossmember Replacement (HD) Drivetrain and Front Suspension Frame Front Crossmember Replacement (4WD 2500 HD, 3500) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair Rear Knuckle: Service and Repair Steering Knuckle Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair). 3. Remove the wheel bearing and hub assembly. Refer to Front Wheel Hub, Bearing, and Seal Replacement (2500) (See: Wheel Hub/Service and Repair)Front Wheel Hub, Bearing, and Seal Replacement (1500) (). 4. Remove the outer tie rod end from the knuckle. Refer to Steering Linkage Outer Tie Rod Replacement (See: Steering/Tie Rod/Service and Repair/Steering Linkage Outer Tie Rod Replacement). 5. Separate the upper control arm from the knuckle. Refer to Upper Control Arm Replacement (2500, 3500) (See: Control Arm/Service and Repair/Upper Control Arm Replacement)Upper Control Arm Replacement (1500) (See: Control Arm/Service and Repair/Upper Control Arm Replacement). 6. Separate the lower control arm from the knuckle. Refer to Lower Control Arm Replacement (2500, 3500) (See: Control Arm/Service and Repair/Lower Control Arm Replacement)Lower Control Arm Replacement (2500) (See: Control Arm/Service and Repair/Lower Control Arm Replacement)Lower Control Arm Replacement (1500) (See: Control Arm/Service and Repair/Lower Control Arm Replacement). 7. Remove the knuckle from the vehicle. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair > Page 13035 1. Install the lower ball joint in the knuckle. Refer to Lower Control Arm Replacement (2500, 3500) (See: Control Arm/Service and Repair/Lower Control Arm Replacement)Lower Control Arm Replacement (2500) (See: Control Arm/Service and Repair/Lower Control Arm Replacement )Lower Control Arm Replacement (1500) (See: Control Arm/Service and Repair/Lower Control Arm Replacement). 2. Install upper ball joint in the knuckle. Refer to Upper Control Arm Replacement (2500, 3500) (See: Control Arm/Service and Repair/Upper Control Arm Replacement)Upper Control Arm Replacement (1500) (See: Control Arm/Service and Repair/Upper Control Arm Replacement). 3. Install the outer tie rod end in the knuckle. Refer to Steering Linkage Outer Tie Rod Replacement (See: Steering/Tie Rod/Service and Repair/Steering Linkage Outer Tie Rod Replacement). 4. Install the wheel bearing and hub assembly. Refer to Front Wheel Hub, Bearing, and Seal Replacement (2500) (See: Wheel Hub/Service and Repair)Front Wheel Hub, Bearing, and Seal Replacement (1500) (). 5. Install the tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair). 6. Remove the support and lower the vehicle. 7. Verify the wheel alignment. Refer to Wheel Alignment Specifications (See: Alignment/Specifications/Wheel Alignment Specifications). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Diagrams Steering Angle Sensor: Diagrams Component Connector End Views Steering Angle Sensor (JL4) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor Replacement Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor Replacement Steering Wheel Position Sensor Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor Replacement > Page 13042 Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor Centering Steering Wheel Position Sensor Centering Removal Procedure Caution: With wheels of the vehicle facing straight ahead, secure the steering wheel utilizing steering column anti-rotation pin, steering column lock, or a strap to prevent rotation. Locking of the steering column will prevent damage and a possible malfunction of the SIR system. The steering wheel must be secured in position before disconnecting the following components: * The steering column * The intermediate shaft(s) * The steering gear After disconnecting these components, do not rotate the steering wheel or move the front tires and wheels. Failure to follow this procedure may cause the SIR coil assembly to become un-centered and cause possible damage to the SIR coil. If you think the SIR coil has became un-centered, refer to your specific SIR coil's centering procedure to re-center SIR Coil. 1. With the wheels of the vehicle in the straight ahead position, secure the steering wheel or the steering column with a steering column anti-rotation pin, a steering column lock, or a strap, as applicable, in order to prevent rotation. Note: Identify the type of steering wheel position sensor from the illustrations shown BEFORE removing the sensor from the steering column. Once you have identified the steering wheel position sensor, follow the instructions listed in the removal procedure. 2. Verify the type of steering wheel position sensor. 3. From the technicians point of view of the FRONT of the sensor (1), the connector will be on the right. Note: If you are reusing the existing sensor, you do not have to align the sensor before removal. Centering is not necessary in order to install the old sensor. 4. Remove the connector from the sensor. 5. Remove the sensor from the adapter and bearing assembly. 6. To install the sensor, proceed to step 1 in the installation procedure. 7. From the technicians point of view, the FRONT of the sensor will have: * A foam ring (2) * A pin hole (1) for the centering the pin-Note the location of the pin hole. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor Replacement > Page 13043 * A flush rotor flange cuff (4) Note: If you are reusing the existing sensor, make an alignment mark (3) on the rotor flange cuff before removing the sensor. Failure to do so will cause misalignment of the old sensor. Replace a misaligned sensor with a new sensor. 8. Make an alignment mark on the flush rotor flange cuff. 9. Remove the connector from the sensor. 10. Remove the sensor from the adapter and bearing assembly. 11. To install the sensor, proceed to step 4 in the installation procedure. 12. From the technicians point of view, the FRONT of the sensor will have: * A raised rotor flange cuff (3) * An alignment mark (2) on the rotor flange cuff for installation * A pin hole (1) for the centering pin-Note the location of the pin hole. 13. Remove the connector from the sensor. 14. Remove the sensor from the adapter and bearing assembly. 15. To install the sensor, proceed to step 8 in the installation procedure. 16. From the technicians point of view, the FRONT of the sensor will have: * A raised rotor flange cuff (3) * An alignment mark (2) on the rotor flange cuff for installation * A pin hole (1) for the centering pin-Note location of the pin hole. * A sensor clip in FRONT of the sensor 17. Remove the connector from the sensor. 18. Remove the sensor clip from the sensor. 19. Remove the sensor from the adapter and bearing assembly. 20. To install the sensor, proceed to step 12 in the installation procedure. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor Replacement > Page 13044 21. From the technicians point of view, the FRONT of the sensor will have: * A flush rotor flange cuff (3) * A pin hole (1) for the centering pin-Note the location of the pin hole. * An alignment mark (2) on the flush rotor flange cuff for installation 22. Remove the connector from the sensor. 23. Remove the sensor from the adapter and bearing assembly. 24. To install the sensor, proceed to step 16 in the installation procedure. 25. From the technicians point of view, the FRONT of the sensor will have: * A flush rotor flange cuff (4) * A pin hole (2) for the centering pin-Note the location of the pin hole. * An alignment mark (3) on the flush rotor flange cuff for installation * A foam ring (1) 26. Remove the connector from the sensor. 27. Remove the sensor from the adapter and bearing assembly. 28. To install the sensor, proceed to step 20 in the installation procedure. Installation Procedure Note: If you are reusing the existing sensor, centering of the old sensor is not necessary. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. 1. From the technicians point of view of the FRONT of the sensor (1), the connector will be on your right. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor Replacement > Page 13045 From the technicians point of view of the BACK of the sensor (2), the connector will be on your left. 2. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 3. Install the connector to the sensor. 4. From the technicians point of view, the FRONT of the sensor will have: * A foam ring (4) * A pin hole (7) for the centering pin-Note the location of the pin hole. * A flush rotor flange cuff (6) * An alignment mark (5) for installation 5. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * A foam ring (3) * An alignment tab (2) for installing the sensor to the adapter and bearing assembly * A view of the inside of the connector Note: If you are reusing the existing sensor, align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 6. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 7. Install the connector to the sensor. 8. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (3) for the centering pin-Note location of the pin hole. * A raised rotor flange cuff (5) * An alignment mark (4) for installation 9. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * An alignment tab (2) for installing the sensor to the adapter and bearing assembly Note: If you are reusing the existing sensor, align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor Replacement > Page 13046 If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 10. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 11. Install the connector to the sensor. 12. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (2) for the centering pin-Note the location of the pin hole. * A raised rotor flange cuff (4) * An alignment mark (3) for installation 13. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Note: If you are reusing the existing sensor, align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 14. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 15. Install the connector to the sensor. 16. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (2) for the centering pin-Note the location of the pin hole. * A flush rotor flange cuff (4) * An alignment mark (3) for installation 17. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Note: If you are reusing the existing sensor, align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 18. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Steering Wheel Position Sensor Replacement > Page 13047 19. Install the connector to the sensor. 20. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (3) for the centering pin-Note location of the pin hole. * A flush rotor flange cuff (5) * An alignment mark (4) for installation * A foam ring (6) 21. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * An alignment tab (2) for installing the sensor to the adapter and bearing assembly Note: If you are reusing the existing sensor, align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 22. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 23. Install the connector to the sensor. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Bushing > Component Information > Service and Repair > Front Suspension Stabilizer Bushing: Service and Repair Front Suspension Stabilizer Shaft Insulator Replacement (2500, 3500) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Bushing > Component Information > Service and Repair > Front Suspension > Page 13053 Stabilizer Bushing: Service and Repair Rear Suspension Stabilizer Shaft Insulator Replacement (3500) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair > Front Suspension Stabilizer Link: Service and Repair Front Suspension Stabilizer Shaft Link Replacement (2500, 3500) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair > Front Suspension > Page 13058 Stabilizer Link: Service and Repair Rear Suspension Stabilizer Shaft Link Replacement (3500) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Customer Interest for Suspension Spring ( Coil / Leaf ): > 09-03-09-001A > Apr > 11 > Suspension - Clunking Noise from Rear Of Vehicle Suspension Spring ( Coil / Leaf ): Customer Interest Suspension - Clunking Noise from Rear Of Vehicle TECHNICAL Bulletin No.: 09-03-09-001A Date: April 13, 2011 Subject: Clunking Noise from Rear of Vehicle (Retorque Leaf Spring Bolts) Models: 2007-2012 Chevrolet Silverado 2007-2012 GMC Sierra Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 09-03-09-001 (Section 03 -- Suspension). Condition Some customers may comment about a clunking noise coming from the rear of the vehicle. Upon further investigation, the technician may diagnose the noise coming from the rear suspension leaf spring area. Correction The noise may be resolved by retorquing the joints of the leaf spring assembly. 1. Support the vehicle at curb height when retorquing the leaf spring bolts/nuts. Note Do not remove the fuel tank. 2. Loosen the shackle joint to the frame, front eye joint to the frame, rear eye to shackle joint and the anchor plate U-bolts. 3. Re-torque the shackle joint to the frame and to the rear eye. Tighten Tighten the shackle nut to 95 Nm (73 lb ft). 4. Re-torque the anchor plate U-bolts (1, 2, 3 and 4). Tighten Tighten the nut to 100 Nm (74 lb ft). 5. Re-torque the front rear spring mounting nut. Tighten. Tighten the front nut to 200 Nm (148 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Customer Interest for Suspension Spring ( Coil / Leaf ): > 09-03-09-001A > Apr > 11 > Suspension - Clunking Noise from Rear Of Vehicle > Page 13067 6. Repeat steps 2 through 5 for the right side leaf spring. 7. Re-test the vehicle for the same clunking noise. If the issue remains, follow the regular repair procedure. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Customer Interest for Suspension Spring ( Coil / Leaf ): > 06-03-09-004C > Nov > 10 > Suspension - Squeak Noise from Rear of Vehicle Suspension Spring ( Coil / Leaf ): Customer Interest Suspension - Squeak Noise from Rear of Vehicle TECHNICAL Bulletin No.: 06-03-09-004C Date: November 11, 2010 Subject: Squeak Noise from Rear of Vehicle (Lubricate Rear Leaf Springs) Models: 1999-2007 Chevrolet Silverado (Classic) 2007-2011 Chevrolet Colorado, Silverado 1999-2007 GMC Sierra (Classic) 2007-2011 GMC Canyon, Sierra 2007-2010 HUMMER H3, H3T Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 06-03-09-004B (Section 03 - Suspension). Condition Some customers may comment about a squeak noise coming from the rear of the vehicle. During normal operation, certain vehicles may exhibit a squeaking noise that may be traced to the rear leaf springs. While this noise is an operating characteristic of leaf springs, the frequency and severity of this noise will be affected by the roads that the vehicle is driven on. Cause This condition may be due to debris getting between the leaf springs. Correction To correct this condition, lubricate the rear leaf springs using the following procedure. Important It has been found that the application of grease to the rear leaf springs does a better job of preventing the noise from reoccurring than replacement of the spring. 1. Raise the vehicle on a frame lift-type hoist. 2. Inspect the springs for damage. If none is found, proceed to the next step. 3. Pressure wash the rear leaf springs to remove as much dirt and grit as possible. 4. Dry the springs with compressed air. Note Ensure any tool used to gently pry the tip inserts or spring leaves is protected to prevent damage to the spring leaves. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Customer Interest for Suspension Spring ( Coil / Leaf ): > 06-03-09-004C > Nov > 10 > Suspension - Squeak Noise from Rear of Vehicle > Page 13072 5. Apply a liberal amount of grease, P/N 12345996 (in Canada, use P/N 10953501), both underneath and on top of the front and rear tip inserts for the #2 and #3 leaves, as indicated below. A screwdriver can be used to gently pry up the tip insert; however, a rag around the screwdriver must be used to prevent damage to the spring. Use a flat-bladed tool, such as a gasket scraper to properly distribute the grease. 6. Lower the vehicle to the ground and test drive to verify the repair. Please inform the customer that this will offer relief, it is by no means a lifetime repair. Periodic cleanings and grease re-application may be necessary throughout the life of the vehicle. For 1500 Series (1/2 ton) models only: On vehicles built prior to October 2004, if the above procedure does not correct this noise, it could be caused by an incorrectly dimensioned splay clip (the band holding the ends of the leafs together) that interferes with the leaf springs. A 5 mm (0.197 in) wider splay clip was introduced in early 2005 model year to provide additional clearance. To correct this concern, replace the rear leaf spring assembly. There was no change to the part number. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Spring ( Coil / Leaf ): > 09-03-09-001A > Apr > 11 > Suspension - Clunking Noise from Rear Of Vehicle Suspension Spring ( Coil / Leaf ): All Technical Service Bulletins Suspension - Clunking Noise from Rear Of Vehicle TECHNICAL Bulletin No.: 09-03-09-001A Date: April 13, 2011 Subject: Clunking Noise from Rear of Vehicle (Retorque Leaf Spring Bolts) Models: 2007-2012 Chevrolet Silverado 2007-2012 GMC Sierra Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 09-03-09-001 (Section 03 -- Suspension). Condition Some customers may comment about a clunking noise coming from the rear of the vehicle. Upon further investigation, the technician may diagnose the noise coming from the rear suspension leaf spring area. Correction The noise may be resolved by retorquing the joints of the leaf spring assembly. 1. Support the vehicle at curb height when retorquing the leaf spring bolts/nuts. Note Do not remove the fuel tank. 2. Loosen the shackle joint to the frame, front eye joint to the frame, rear eye to shackle joint and the anchor plate U-bolts. 3. Re-torque the shackle joint to the frame and to the rear eye. Tighten Tighten the shackle nut to 95 Nm (73 lb ft). 4. Re-torque the anchor plate U-bolts (1, 2, 3 and 4). Tighten Tighten the nut to 100 Nm (74 lb ft). 5. Re-torque the front rear spring mounting nut. Tighten. Tighten the front nut to 200 Nm (148 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Spring ( Coil / Leaf ): > 09-03-09-001A > Apr > 11 > Suspension - Clunking Noise from Rear Of Vehicle > Page 13078 6. Repeat steps 2 through 5 for the right side leaf spring. 7. Re-test the vehicle for the same clunking noise. If the issue remains, follow the regular repair procedure. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Spring ( Coil / Leaf ): > 06-03-09-004C > Nov > 10 > Suspension - Squeak Noise from Rear of Vehicle Suspension Spring ( Coil / Leaf ): All Technical Service Bulletins Suspension - Squeak Noise from Rear of Vehicle TECHNICAL Bulletin No.: 06-03-09-004C Date: November 11, 2010 Subject: Squeak Noise from Rear of Vehicle (Lubricate Rear Leaf Springs) Models: 1999-2007 Chevrolet Silverado (Classic) 2007-2011 Chevrolet Colorado, Silverado 1999-2007 GMC Sierra (Classic) 2007-2011 GMC Canyon, Sierra 2007-2010 HUMMER H3, H3T Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 06-03-09-004B (Section 03 - Suspension). Condition Some customers may comment about a squeak noise coming from the rear of the vehicle. During normal operation, certain vehicles may exhibit a squeaking noise that may be traced to the rear leaf springs. While this noise is an operating characteristic of leaf springs, the frequency and severity of this noise will be affected by the roads that the vehicle is driven on. Cause This condition may be due to debris getting between the leaf springs. Correction To correct this condition, lubricate the rear leaf springs using the following procedure. Important It has been found that the application of grease to the rear leaf springs does a better job of preventing the noise from reoccurring than replacement of the spring. 1. Raise the vehicle on a frame lift-type hoist. 2. Inspect the springs for damage. If none is found, proceed to the next step. 3. Pressure wash the rear leaf springs to remove as much dirt and grit as possible. 4. Dry the springs with compressed air. Note Ensure any tool used to gently pry the tip inserts or spring leaves is protected to prevent damage to the spring leaves. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Spring ( Coil / Leaf ): > 06-03-09-004C > Nov > 10 > Suspension - Squeak Noise from Rear of Vehicle > Page 13083 5. Apply a liberal amount of grease, P/N 12345996 (in Canada, use P/N 10953501), both underneath and on top of the front and rear tip inserts for the #2 and #3 leaves, as indicated below. A screwdriver can be used to gently pry up the tip insert; however, a rag around the screwdriver must be used to prevent damage to the spring. Use a flat-bladed tool, such as a gasket scraper to properly distribute the grease. 6. Lower the vehicle to the ground and test drive to verify the repair. Please inform the customer that this will offer relief, it is by no means a lifetime repair. Periodic cleanings and grease re-application may be necessary throughout the life of the vehicle. For 1500 Series (1/2 ton) models only: On vehicles built prior to October 2004, if the above procedure does not correct this noise, it could be caused by an incorrectly dimensioned splay clip (the band holding the ends of the leafs together) that interferes with the leaf springs. A 5 mm (0.197 in) wider splay clip was introduced in early 2005 model year to provide additional clearance. To correct this concern, replace the rear leaf spring assembly. There was no change to the part number. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Front Suspension Coil Spring Suspension Spring ( Coil / Leaf ): Service and Repair Front Suspension Coil Spring Shock Absorber and Spring Assembly Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Front Suspension Coil Spring > Page 13086 Suspension Spring ( Coil / Leaf ): Service and Repair Rear Suspension Leaf Spring Leaf Spring Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair). 2. Support the rear axle independently in order to relieve the tension on the leaf springs. 3. Remove the trailer hitch, if equipped. Refer to Trailer Hitch Replacement (Light Duty) (See: Accessories and Optional Equipment/Towing / Trailer System/Trailer Hitch/Service and Repair/Trailer Hitch Replacement (Light Duty))Trailer Hitch Replacement (Heavy Duty) (See: Accessories and Optional Equipment/Towing / Trailer System/Trailer Hitch/Service and Repair/Trailer Hitch Replacement (Heavy Duty)). Note: For the 3500 Cab chassis vehicles, the auxiliary fuel tank must be removed to service the left or right rear shackle bolts. 4. Remove the fuel tank assembly. * For the fuel tank, refer to Fuel Tank Replacement (Pickup) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (Cab/Chassis - Front) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (Cab/Chassis - Rear) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement). * For the auxiliary fuel tank, refer to Auxiliary Fuel Tank Replacement (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement). 5. Remove the U-bolt nuts. 6. Remove the U-bolts and discard. 7. Remove the spring spacer. 8. Remove the anchor plate. 9. Remove the rear leaf spring shackle bolts and nuts. Refer to Rear Spring Shackle Replacement (1500 Series) (). 10. Remove the front bolt and nuts. 11. Remove the leaf spring assembly from the vehicle. Note: The following step is for replacement the shackle only. The shackle does not have to be replaced if removing the rear leaf to service other chassis or suspension components items. 12. Remove the rear leaf spring shackle, if needed. Refer to Rear Spring Shackle Replacement (1500 Series) (). Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Front Suspension Coil Spring > Page 13087 1. Install the leaf spring assembly to the vehicle. 2. Install the front bolt and nuts but do not tighten. 3. Install the rear leaf spring hanger to shackle nut and bolt. Note: Do not reuse the U-bolts. 4. Install the spring spacer, if equipped. 5. Install the U-bolts. 6. Raise the rear axle until it touches the leaf spring and applies light compression to the leaf spring. 7. Install the anchor plate. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 8. Install the U-bolt nuts and tighten the U-bolts in a criss-cross sequence to 100 Nm (74 lb ft) for the 1500 and 140 Nm + 180° (103 lb ft) + 180° for the 2500. 9. Tighten the front rear spring mounting nut to 170 Nm+ 48° (125 lb ft) + 48° . 10. Tighten the rear leaf spring hanger to shackle nut and bolt to 90 Nm (70 lb ft). 11. Install the fuel tank assembly. * For the fuel tank, refer to Fuel Tank Replacement (Pickup) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (Cab/Chassis - Front) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (Cab/Chassis - Rear) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement). * For the auxiliary fuel tank, refer to Auxiliary Fuel Tank Replacement (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Front Suspension Coil Spring > Page 13088 12. Install the trailer hitch, if equipped. Refer to Trailer Hitch Replacement (Light Duty) (See: Accessories and Optional Equipment/Towing / Trailer System/Trailer Hitch/Service and Repair/Trailer Hitch Replacement (Light Duty))Trailer Hitch Replacement (Heavy Duty) (See: Accessories and Optional Equipment/Towing / Trailer System/Trailer Hitch/Service and Repair/Trailer Hitch Replacement (Heavy Duty)). 13. Remove the rear axle support. 14. Remove the safety stands. 15. Lower the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Front Suspension Coil Spring > Page 13089 Suspension Spring ( Coil / Leaf ): Service and Repair Rear Suspension Coil Spring Rear Spring Front Stop Replacement Rear Spring Front Stop Replacement Rear Spring Rear Stop Replacement Rear Spring Rear Stop Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Front Suspension Coil Spring > Page 13090 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > Suspension - Shock Absorber/Strut Leakage Information Suspension Strut / Shock Absorber: Technical Service Bulletins Suspension - Shock Absorber/Strut Leakage Information INFORMATION Bulletin No.: 05-03-08-002C Date: October 16, 2009 Subject: Information on Replacement of Shock Absorbers and Struts Due to Fluid Leaks Models: 2010 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2010 model year and Inspection Procedures. Please discard Corporate Bulletin Number 05-03-08-002B (Section 03 - Suspension). This bulletin is intended to help identify the severity of shock absorber and strut fluid seepage. Improper diagnosis may lead to components being replaced that are within the manufacturer's specification. Shock absorbers and strut assemblies are fluid-filled components and will normally exhibit some seepage. Seepage is defined as oil film or dust accumulation on the exterior of the shock housing. Shock absorbers and struts are not to be replaced under warranty for seepage. Use the following information to determine if the condition is normal acceptable seepage or a defective component. Important Electronically controlled shock absorbers (MR) may have a tendency to attract dust to this oil film. Often this film and dust can be wiped off and will not return until similar mileage is accumulated again. Inspection Procedure Note The shock absorber or strut assembly DOES NOT have to be removed from the vehicle to perform the following inspection procedure. Use the following descriptions and graphics to determine the serviceability of the component. Shock Absorbers Do Not Replace shock absorbers displaying condition 1 or 2 levels of seepage. 1. Oil or fluid residue only on the bottom or top of the shock absorber and not originating from the shaft seal (the upper part of the lower shock tube). 2. Light film/residue on approximately 1/3 (a) or less of the lower shock tube (A) and originating from the shaft seal. Replace shock absorbers displaying conditions 3 and 4 levels of leaks. 3. Oil drip or trail down the lower shock tube and originating from the shaft seal. 4. An extreme wet film of oil covering more than 1/3 (b) of the lower shock tube and originating from the shaft seal. Coil-over Shock Absorber Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > Suspension - Shock Absorber/Strut Leakage Information > Page 13095 Do Not Replace coil-over shock absorbers displaying condition 1 or 2 levels of seepage. 1. Oil or fluid residue only on the bottom of the lower shock absorber tube or the coil-over shock absorber components and not originating from the shaft seal (located at the top of the coil-over shock tube). 2. Light film/residue on the shock absorber tube, but not on the spring seat and originating from the shaft seal. Replace coil-over shock absorbers displaying conditions 3 and 4 levels of leaks. 3. Oil drip or trail down the lower shock tube and originating from the shaft seal. 4. An extreme, wet film of oil covering the shock absorber tube and pooling in the spring seat and originating from the shaft seal. Struts Do Not Replace Struts displaying condition 1 or 2 levels of seepage. 1. Oil or fluid residue only on the bottom of the strut tube or on other strut components and not originating from the shaft seal. 2. Light film/residue on the strut tube, but not on the spring seat and originating from the shaft seal. Replace Struts displaying conditions 3 and 4 levels of leaks. 3. Oil drip or trail down the strut tube and originating from the shaft seal (located at the top of the strut tube). 4. Extreme wet film of oil covering the strut tube and pooling in the spring seat and originating from the shaft seal. Correction Use the information published in SI for diagnosis and repair. Use the applicable published labor operation. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Testing and Inspection > Front Suspension Suspension Strut / Shock Absorber: Testing and Inspection Front Suspension Strut and Shock Absorber Inspection (Shock Absorber) Strut and Shock Absorber Inspection (Shock Absorber) Note: The shock absorber assembly DOES NOT have to be removed from the vehicle to perform the following inspection procedure. Note: A light film of oil on the top portion of the lower shock absorber tube is normal. DO NOT replace the shock absorber for this condition. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Testing and Inspection > Front Suspension > Page 13098 Condition 1 Oil or fluid residue only on the bottom or top of the shock absorber and not originating from the shaft seal, is not a shock absorber related problem. DO NOT replace the shock absorber, look for other external leaks. Condition 2 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Testing and Inspection > Front Suspension > Page 13099 Light film/residue on approximately 1/3 (a) or less of the lower shock tube (A) and originating from the shaft seal, is a NORMAL condition. DO NOT replace the shock absorber. Condition 3 Oil drip or trail down the lower shock tube and originating from the shaft seal, is an ABNORMAL condition. Replace the shock absorber. Condition 4 An extreme wet film of oil covering more than 1/3 (b) of the lower shock tube and originating from the shaft seal (B), is an ABNORMAL condition. Replace the shock absorber. Refer to Shock Absorber Replacement (2500, 3500) (See: Service and Repair/Rear Suspension Shock Absorber/Shock Absorber Replacement)Shock Absorber Replacement (1500) (See: Service and Repair/Rear Suspension Shock Absorber/Shock Absorber Replacement ). Inspection 1. Verify the customer's concern is present. If the concern is present, continue to the next step. If the concern is not present, then the vehicle is operating normally. Note: The shock absorber assembly DOES NOT have to be removed from the vehicle to perform the following inspection procedure. 2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair). 3. Visually inspect each of the shock absorbers for external fluid leaks. Refer to the following conditions 1, 2 , 3 , and 4 for visual inspection. * If conditions 1 or 2 are found, continue to step 4. * If conditions 3 or 4 are found, replace shock absorber. Refer to Shock Absorber Replacement (2500, 3500) (See: Service and Repair/Rear Suspension Shock Absorber/Shock Absorber Replacement)Shock Absorber Replacement (1500) (See: Service and Repair/Rear Suspension Shock Absorber/Shock Absorber Replacement). 4. If equipped with electronic suspension control system, ensure that the system is working properly. Refer to Diagnostic Starting Point - Electronic Suspension Control. 5. Use your hands in order to lift up and push down on each corner of the vehicle 3 times. Remove your hands from the vehicle. If the corner motion exceeds 2 cycles, replace the shock absorber. If the shock absorber does not exceed 2 cycles, NO repair is necessary. Strut and Shock Absorber Inspection (Coil Over Shock) Strut and Shock Absorber Inspection (Coil Over Shock) Note: The coil over shock assembly DOES NOT have to be removed from the vehicle to perform the following inspection procedure. Note: A light film of oil on the top portion of the shock absorber tube is normal. DO NOT replace the shock absorber for this condition. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Testing and Inspection > Front Suspension > Page 13100 Condition 1 Oil or fluid residue only on the bottom of the lower shock absorber tube or other coil over shock absorber and originating from the shaft seal, is not a shock absorber related problem. DO NOT replace the shock absorber, look for other external leaks. Condition 2 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Testing and Inspection > Front Suspension > Page 13101 Light film/residue on the shock absorber tube, but not on the spring seat and originating from the shaft seal, is a NORMAL condition. DO NOT replace the shock absorber. Condition 3 Oil drip or trail down the shock absorber tube and originating from the shaft seal, is an ABNORMAL condition. Replace the shock absorber. Condition 4 An extreme wet film of oil covering the shock absorber tube and pooling in the spring seat and originating from the shaft seal, is an ABNORMAL condition. Replace the shock absorber. Inspection 1. Verify the customer's concern is present. If the concern is present, continue to the next step. If the concern is not present, then the vehicle is operating normally. Note: The shock assembly DOES NOT have to be removed from the vehicle to perform the following inspection procedure. 2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair). 3. Visually inspect each of the shock absorbers for external fluid leaks. Refer to the following conditions 1, 2, 3, and 4 for visual inspection. * If conditions 1 or 2 are found, continue to step 4. * If conditions 3 or 4 are found, replace shock absorber. Refer to Shock Absorber Replacement. 4. If equipped with electronic suspension control system, ensure that the system is working properly. Refer to Diagnostic Starting Point-Electronic Suspension Control. 5. Use your hands in order to lift up and push down on each corner of the vehicle 3 times. Remove your hands from the vehicle. If the corner motion exceeds 2 cycles, replace the shock absorber. If the shock absorber does not exceed 2 cycles, NO repair is necessary. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Testing and Inspection > Front Suspension > Page 13102 Suspension Strut / Shock Absorber: Testing and Inspection Rear Suspension Strut and Shock Absorber Inspection (Shock Absorber) Note: The shock absorber assembly DOES NOT have to be removed from the vehicle to perform the following inspection procedure. Note: A light film of oil on the top portion of the lower shock absorber tube is normal. DO NOT replace the shock absorber for this condition. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Testing and Inspection > Front Suspension > Page 13103 Condition 1 Oil or fluid residue only on the bottom or top of the shock absorber and not originating from the shaft seal, is not a shock absorber related problem. DO NOT replace the shock absorber, look for other external leaks. Condition 2 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Testing and Inspection > Front Suspension > Page 13104 Light film/residue on approximately 1/3 (a) or less of the lower shock tube (A) and originating from the shaft seal, is a NORMAL condition. DO NOT replace the shock absorber. Condition 3 Oil drip or trail down the lower shock tube and originating from the shaft seal, is an ABNORMAL condition. Replace the shock absorber. Condition 4 An extreme wet film of oil covering more than 1/3 (b) of the lower shock tube and originating from the shaft seal (B), is an ABNORMAL condition. Replace the shock absorber. Refer to Shock Absorber Replacement (2500, 3500) (See: Service and Repair/Rear Suspension Shock Absorber/Shock Absorber Replacement)Shock Absorber Replacement (1500) (See: Service and Repair/Rear Suspension Shock Absorber/Shock Absorber Replacement ). Inspection 1. Verify the customer's concern is present. If the concern is present, continue to the next step. If the concern is not present, then the vehicle is operating normally. Note: The shock absorber assembly DOES NOT have to be removed from the vehicle to perform the following inspection procedure. 2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair). 3. Visually inspect each of the shock absorbers for external fluid leaks. Refer to the following conditions 1, 2 , 3 , and 4 for visual inspection. * If conditions 1 or 2 are found, continue to step 4. * If conditions 3 or 4 are found, replace shock absorber. Refer to Shock Absorber Replacement (2500, 3500) (See: Service and Repair/Rear Suspension Shock Absorber/Shock Absorber Replacement)Shock Absorber Replacement (1500) (See: Service and Repair/Rear Suspension Shock Absorber/Shock Absorber Replacement). 4. If equipped with electronic suspension control system, ensure that the system is working properly. Refer to Diagnostic Starting Point - Electronic Suspension Control. 5. Use your hands in order to lift up and push down on each corner of the vehicle 3 times. Remove your hands from the vehicle. If the corner motion exceeds 2 cycles, replace the shock absorber. If the shock absorber does not exceed 2 cycles, NO repair is necessary. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Suspension Shock Absorber Suspension Strut / Shock Absorber: Service and Repair Front Suspension Shock Absorber Shock Absorber, Shock Absorber Component, or Spring Replacement Shock Absorber, Shock Absorber Component, or Spring Replacement Special Tools CH-48845 Spring Compressor Removal Procedure Warning Use only the CH-48845 Spring Compressor when servicing suspension components on this vehicle. Other tools may not be strong enough for the springs on this vehicle and you could be injured if you do not use Special Tool CH-48845. Failure to do so could result in serious personal injury. Note: Use only hand tools to perform the following service procedure. 1. Install the front shock absorber assembly in the CH-48845 . Note: For vehicles equipped with electronic suspension control, ensure that the upper retaining bracket of the CH-48845 is adjusted properly so that it DOES NOT damage the front suspension mount. 2. Position the shock absorber (2) in the upper retaining bracket of the CH-48845 (1) so the shock absorber will be centered. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Suspension Shock Absorber > Page 13107 3. Using the CH-48845 (1), compress the front spring (2). 4. Using the appropriate size wrench, hold the shock absorber shaft. Note: DO NOT re-use the shock absorber nut, discard and replace with new ONLY. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Suspension Shock Absorber > Page 13108 5. Using the appropriate tool, remove and discard the shock absorber nut (1). 6. Remove the front lower shock absorber (2) and the front spring lower insulator (1). 7. Remove the front suspension strut mount (1), front spring upper seat (2), front suspension strut bumper (3), front spring upper insulator (4), and the front suspension spring (5) from the spring compressor. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Suspension Shock Absorber > Page 13109 Note: The inboard strut mounting studs are spaced closer together than the outboard stud. The outboard stud should be facing toward the outside (closest to the technician proper alignment. 1. Assemble the front suspension strut mount (1), front spring upper seat (2), front suspension strut bumper (3), front spring upper insulator (4), and the front suspension spring (5) in the spring compressor. 2. Align the spring seat stop (3), the outboard stud (1), and the center of the lower strut mount (4). The notch in the spring seat (2) should be just to the right of the outboard stud. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Suspension Shock Absorber > Page 13110 Note: For vehicles equipped with electronic suspension control, ensure that the upper retaining bracket of the CH-48845 is adjusted properly so that it DOES NOT damage the front suspension mount. 3. Position the shock absorber (2) in the upper retaining bracket of the CH-48845 (1) so the shock absorber will be centered. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Suspension Shock Absorber > Page 13111 4. Using the CH-48845 (1), compress the front spring (2). 5. Using the appropriate size wrench, hold the shock absorber shaft. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Suspension Shock Absorber > Page 13112 6. Install the NEW shock absorber nut (1) and tighten. * For vehicles equipped with electronic suspension, tighten the shock absorber nut to 80 Nm (59 lb ft). * For vehicles equipped with electronic suspension, tighten the electrical connector to 20 Nm (15 lb ft). * For vehicles without electronic suspension, tighten the shock absorber nut to 60 Nm (44 lb ft). 7. Remove the shock absorber assembly from the spring compressor 8. Install the shock absorber in the vehicle. Refer to Shock Absorber and Spring Assembly Replacement (See: Shock Absorber and Spring Assembly Replacement). Shock Absorber Disposal Shock Absorber Disposal Warning Gas charged shock absorbers contain high pressure gas. Do not remove the snap ring from inside the top of the tube. If the snap ring is removed, the contents of the shock absorber will come out with extreme force which may result in personal injury. Warning To prevent personal injury, wear safety glasses when centerpunching and drilling the shock absorber. Use care not to puncture the shock absorber tube with the centerpunch. 1. Make an indentation 10 mm (0.4 in) from the bottom (4) of the tube (3) using a centerpunch. 2. Clamp the shock absorber in a vise horizontally with the shock absorber rod (1) completely extended. 3. Drill a hole in the shock absorber at the centerpunch (4) using a 5 mm (3/16 in) drill bit. Gas or a gas/oil mixture will exhaust when the drill bit penetrates the shock absorber. Use shop towels in order to contain the escaping oil. 4. Make an indentation in the middle (2) of the tube (3) with a centerpunch. 5. Drill a second hole in the shock absorber at the centerpunch (2) using a 5 mm (3/16 in) drill bit. Oil will exhaust when the drill bit penetrates the shock absorber. Use shop towels in order to contain the escaping oil. 6. Remove the shock absorber from the vise. Hold the shock absorber over a drain pan horizontally with the holes down. Move the rod (1) in and out of the tube (3) to completely drain the oil from the shock absorber. Shock Absorber and Spring Assembly Replacement Shock Absorber and Spring Assembly Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Suspension Shock Absorber > Page 13113 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Suspension Shock Absorber > Page 13114 Suspension Strut / Shock Absorber: Service and Repair Rear Suspension Shock Absorber Shock Absorber Replacement Shock Absorber Replacement (2500, 3500) Shock Absorber Disposal Shock Absorber Disposal Warning Gas charged shock absorbers contain high pressure gas. Do not remove the snap ring from inside the top of the tube. If the snap ring is removed, the contents of the shock absorber will come out with extreme force which may result in personal injury. Warning Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Suspension Shock Absorber > Page 13115 To prevent personal injury, wear safety glasses when centerpunching and drilling the shock absorber. Use care not to puncture the shock absorber tube with the centerpunch. 1. Make an indentation 10 mm (0.4 in) from the bottom (4) of the tube (3) using a centerpunch. 2. Clamp the shock absorber in a vise horizontally with the shock absorber rod (1) completely extended. 3. Drill a hole in the shock absorber at the centerpunch (4) using a 5 mm (3/16 in) drill bit. Gas or a gas/oil mixture will exhaust when the drill bit penetrates the shock absorber. Use shop towels in order to contain the escaping oil. 4. Make an indentation in the middle (2) of the tube (3) with a centerpunch. 5. Drill a second hole in the shock absorber at the centerpunch (2) using a 5 mm (3/16 in) drill bit. Oil will exhaust when the drill bit penetrates the shock absorber. Use shop towels in order to contain the escaping oil. 6. Remove the shock absorber from the vise. Hold the shock absorber over a drain pan horizontally with the holes down. Move the rod (1) in and out of the tube (3) to completely drain the oil from the shock absorber. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component Information > Service and Repair > Front Suspension Suspension Travel Bumper: Service and Repair Front Suspension Jounce Bumper Replacement (2500 Series) Removal Procedure Note: The following service procedure is for 2500 series vehicles. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair). 3. Remove the nut from the jounce bumper stud. 4. Remove the jounce bumper. Installation Procedure 1. Install the jounce bumper. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the nut to the jounce bumper stud and tighten to 30 Nm (22 lb ft). 3. Install the tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair). 4. Lower the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component Information > Service and Repair > Front Suspension > Page 13120 Suspension Travel Bumper: Service and Repair Rear Suspension Jounce Bumper Replacement (2500, 3500) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Service and Repair > Torsion Bar and Support Assembly Replacement (Bushing Style) Torsion Bar: Service and Repair Torsion Bar and Support Assembly Replacement (Bushing Style) Torsion Bar and Support Assembly Replacement (Bushing Style) Special Tools J 36202 Torsion Bar Unloading/Loading Tool Removal Procedure Note: When lifting the vehicle to service the torsion bars or related components, DO NOT lift the vehicle by the front suspension. Use the appropriate hoist to lift the vehicle by the frame. Caution: Use care when handling the torsion bars in order to avoid chipping or scratching the coating. Damage to the coating will result in premature failure of the torsion bars. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair). 2. Install the J 36202 to the adjustment arm and the crossmember. 3. Using the J 36202 , increase the tension on the adjustment arm until the load is removed from the adjustment bolt and the adjuster nut. Note: Mark the adjustment bolt and count the number of times that is required to remove the adjustment bolt. 4. Remove the adjustment bolt (3) and the adjust nut (4) from the crossmember (1). 5. Remove the J 36202 , allowing the torsion bar to unload. 6. Remove the adjustment arm (2) by sliding the torsion bar forward. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Service and Repair > Torsion Bar and Support Assembly Replacement (Bushing Style) > Page 13125 7. Remove the torsion bar crossmember bolt (4) from the weld nut (1). 8. Remove the crossmember (2) from the crossmember mount (3). 9. Remove the torsion bar from the crossmember. Note: The left and right torsion bars are different and are not interchangeable. 10. Remove the torsion bars from the vehicle. Installation Procedure 1. Position the torsion bar in the lower control arm. 2. Install the torsion bar in the crossmember (2) on the crossmember mount (3). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the torsion bar crossmember bolt (4) in the weld nut (1) and tighten to 110 Nm (81 lb ft).. 4. Install the adjustment arm (2) in the crossmember (1). 5. Install the adjuster bolt (3) and the adjuster nut (4). 6. Install the torsion bar into the adjustment arm until the torsion bar is fully seated. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Service and Repair > Torsion Bar and Support Assembly Replacement (Bushing Style) > Page 13126 7. Install the J 36202 to the adjustment arm and the crossmember. 8. Using the J 36202 , increase the tension on the adjustment arm to load the torsion bar. 9. Turn the adjuster bolt the same amount of turns as it took to remove it. 10. Remove the J 36202 from the crossmember. 11. Remove the safety stands and lower the vehicle. 12. Measure the Z height. Refer to Trim Height Inspection (See: Testing and Inspection/Component Tests and General Diagnostics/Trim Height Inspection). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Service and Repair > Torsion Bar and Support Assembly Replacement (Bushing Style) > Page 13127 Torsion Bar: Service and Repair Torsion Bar and Support Assembly Replacement (Link Style) Torsion Bar and Support Assembly Replacement (Link Style) Special Tools J 36202 Torsion Bar Unloading/Loading Tool Removal Procedure Note: When lifting the vehicle to service the torsion bars or related components, DO NOT lift the vehicle by the front suspension. Use the appropriate hoist and lift the vehicle by the frame. Caution: Use care when handling the torsion bars in order to avoid chipping or scratching the coating. Damage to the coating will result in premature failure of the torsion bars. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair). 2. Install the J 36202 to the adjustment arm and the support assembly. 3. Using the J 36202 , increase the tension on the adjustment arm until the load is removed from the adjustment bolt and the adjuster nut. Note: Create a reference point for the adjustment bolt to the support. Count the number of times that is required to remove the adjustment bolt. 4. Remove the adjustment bolt (3) and the adjuster nut (4) from the support assembly (1). 5. Remove the J 36202 , allowing the torsion bar to unload. 6. Remove the adjustment arm (2) by sliding the torsion bar forward. 7. Remove the adjustment arm (2) from the support assembly (1). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Service and Repair > Torsion Bar and Support Assembly Replacement (Bushing Style) > Page 13128 8. Remove the upper link mounting bolt (1) and nut (2) from the link (3). 9. Remove the torsion bar support assembly (4). Note: The left and right torsion bars are different and are not interchangeable 10. Remove the torsion bar from the vehicle. Installation Procedure 1. Position the torsion bar in the lower control arm. 2. Install the torsion bar in the support assembly. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the upper link mounting nut (2) and the bolt (1) in the link (3). Tighten the nut to 95 Nm (70 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Service and Repair > Torsion Bar and Support Assembly Replacement (Bushing Style) > Page 13129 4. Install the adjustment arm (2) in the support assembly (1). 5. Install the adjuster bolt (3) and the adjustment nut (4). 6. Slide the torsion bar rearward until the torsion bar is fully seated in the adjustment arm. 7. Install the J 36202 on the adjustment arm and the support assembly. 8. Using the J 36202 , increase the tension on the adjustment arm in order to load the torsion bar. 9. Align the reference marks, turn the adjuster bolt the same amount of turns as it took to remove it. 10. Remove the J 36202 from the support assembly. 11. Remove the safety stand and lower the vehicle. 12. Measure the Z height. Refer to Trim Height Inspection (See: Testing and Inspection/Component Tests and General Diagnostics/Trim Height Inspection). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Service and Repair > Torsion Bar and Support Assembly Replacement (Bushing Style) > Page 13130 Torsion Bar: Service and Repair Torsion Bars Bushing Replacement Torsion Bars Bushing Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications FRONT WHEEL BEARINGS Wheel bearing lubricant meeting requirements of NLGI #2, Category GC or GC-LB (GM Part No. U.S. 1051344, in Canada 993037). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications > Page 13134 Wheel Bearing: Testing and Inspection Wheel Bearings Diagnosis Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Wheel Drive Shaft Nut ......................................................................................................................... .................................................... 240 Nm (177 lb ft) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Service and Repair Vehicle Lifting: Service and Repair Lifting and Jacking the Vehicle Danger: To avoid any vehicle damage, serious personal injury or death, always use the jackstands to support the vehicle when lifting the vehicle with a jack. Danger: To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed and strap the vehicle to the hoist. Caution: Perform the following steps before beginning any vehicle lifting or jacking procedure: * Remove or secure all of the vehicle contents in order to avoid any shifting or any movement that may occur during the vehicle lifting or jacking procedure. * The lifting equipment or the jacking equipment weight rating must meet or exceed the weight of the vehicle and any vehicle contents. * The lifting equipment or the jacking equipment must meet the operational standards of the lifting equipment or jacking equipment manufacturer. * Perform the vehicle lifting or jacking procedure on a clean, hard, dry, level surface. * Perform the vehicle lifting or jacking procedure only at the identified lift points. DO NOT allow the lifting equipment or jacking equipment to contact any other vehicle components. Failure to perform the previous steps could result in damage to the lifting equipment or the jacking equipment, the vehicle, and/or the vehicle contents. For lifting the vehicle, various lift points are recommended. Before you begin any lifting procedure, place the vehicle on a clean, hard, level surface. Verify that all the lifting equipment meets weight standards and is in good working order. Verify that all of the vehicle loads are equally distributed and secure. If you are only supporting the vehicle at the frame side rails, verify that the lifting equipment does not put too much stress on, or weaken, the frame side rails. During hoisting, do NOT damage the fuel tanks, the exhaust system, or the underbody. 1 - Lower Control Arm Contact Points 2 - Front Frame Contact Points 3 - Rear Frame Contact Points 4 - Rear Axle Contact Points Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Service and Repair > Page 13143 5 - Differential Contact Points Frame Contact Hoist Front Hoist Pads Note: The front hoist pads must not contact the rocker panels, the front fenders, or the floor pan. Position the front hoist pads under the front frame between the lower control arm and the frame pad. Rear Hoist Pads Note: The rear hoist pads must not contact the body rocker panels or the floor pan. Position the rear hoist pads under the rear spring, just behind the hanger Suspension Contact Hoist Front Lift Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Service and Repair > Page 13144 Position the front lift under the outer edge of the front suspension lower control arms. Rear Lift Position the rear lift under the axle housing tubes on each side of the differential. Do not damage the stabilizer bar. Jacking When you are lifting a vehicle with a vehicle jack or a floor jack, block the wheels at the opposite end from which you are lifting. Use jack stands to provide additional support. Under the Frame Rails Note: The floor jack pad must not contact rocker panel or the floor pan. Position the floor jack pad under the frame rail pad. Under the Rear Differential Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Service and Repair > Page 13145 Position the floor jack pad under the center of the rear axle differential. Do not damage the establisher bar. Under the Rear Spring Hanger Position the jack under the rear spring hanger. Jack Stands When you support the vehicle with jack stands, place the jack stands under the frame, the front suspension crossmember, or the rear axle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Module > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > Page 13156 Tire Pressure Sensor: Testing and Inspection Tire Pressure Indicator Sensor Learn Special Tools J-46079 Tire Pressure Monitor Diagnostic Tool Learn Mode Description The tire pressure monitor (TPM) system uses the instrument panel cluster (IPC), body control module (BCM), remote control door lock receiver (RCDLR), keyless entry transmitter, 4 radio frequency transmitting pressure sensors, and the serial data circuit to perform the TPM learn mode functions. The sensor learn procedure must be performed after every tire rotation, RCDLR replacement, or sensor replacement. Once the learn mode has been enabled, each of the sensors unique identification codes can be learned into the RCDLR memory. When a sensor ID has been learned, the RCDLR sends a serial data message to the BCM to sound a horn chirp. This verifies the sensor has transmitted its ID and the RCDLR has received and learned it. The RCDLR must learn the sensor IDs in the proper sequence to determine correct sensor location. The first learned ID is assigned to the left front location, the second to right front, the third to right rear and the fourth to left rear. The turn signals will individually illuminate indicating which location is to be learned in the proper sequence. Sensor Functions Using J-46079 Each sensor has an internal low frequency coil. When the J-46079 is used in activate mode, it produces a low frequency transmission that activates the sensor. The sensor responds to a low frequency activation by transmitting in learn mode. When the RCDLR receives a learn mode transmission while in TPM learn mode, it will assign that sensors ID to the location on the vehicle relative to the order in which it was learned. Sensor Functions Using Pressure Increase/Decrease Method Each sensor takes a pressure measurement sample once every 30 seconds while in stationary mode. If the tire pressure increases, or decreases by more than 8.3 kPa (1.2 psi) from the last pressure measurement, another measurement will occur immediately to verify the change in pressure. If a pressure change has indeed occurred, the sensor transmits in Learn mode. When the RCDLR receives a Learn mode transmission while in TPM learn mode, it will assign that sensor's ID to the location on the vehicle relative to the order in which it was learned. Learn Mode Cancellation The learn mode will cancel if the ignition is cycled to OFF or if more than 2 minutes has elapsed for any sensor that has not been learned. If the learn mode is cancelled before the first sensor is learned, the original sensor IDs will be maintained. If the learn mode is canceled after the first sensor is learned, the following will occur: * All stored sensor IDs will be invalidated in the RCDLR memory. * If equipped, the DIC will display dashes instead of tire pressures. * DTC C0775 will be set. These conditions will now require the learn procedure to be repeated for the system to function properly. TPM Learn Procedure Note: If using the scan tool to enable the learn mode, the J-46079 must be used to activate the sensors. When this preferred method is used, any stray sensor signals will not affect the learn procedure. In the event a particular sensor's information is displayed on the special tool upon activation but the horn does not chirp, it may be necessary to rotate the wheel valve stem to a different position due to the sensor signal is being blocked by another component. If using the keyless entry transmitter or DIC buttons to enable the learn mode, the J-46079 or Pressure Increase/Decrease Method may be used. Before proceeding with this method, ensure that no other learn procedure is being performed simultaneously or that tire pressures are not being adjusted on another TPM equipped vehicle within close proximity. Stray signals from other TPM equipped vehicles just driving by can be inadvertently learned. If any random horn chirps are heard from the vehicle while performing the learn procedure, most likely a stray sensor has been learned and the procedure will need to be cancelled and repeated. Under these circumstances, performing the TPM Learn Procedure away from other vehicles would be highly recommended. In the event a particular sensor activation does not cause the horn to chirp, it may be necessary to rotate the wheel valve stem to a different position due to the sensor signal is being blocked by another component. Preferred Scan Tool Learn Enable Method 1. Using a scan tool, initiate the TPM Learn Mode. A double horn chirp will sound indicating the Learn Mode has been enabled. The left front turn signal will also be illuminated. 2. Starting with the left front tire, active the sensor by holding the antenna of the J-46079 aimed upward against the tire sidewall close to the wheel rim at the valve stem location. Press and release the Activate button and wait for a horn chirp. Once the horn chirp has sounded, the sensor information is learned and the turn signal in the next location to be learned will illuminate. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > Page 13157 3. After the horn chirp has sounded and the right front turn signal is illuminated, repeat step 2 for the remaining 3 sensors in the following order: 1. Right front 2. Right rear 3. Left rear 4. When the left rear sensor has been learned and a double horn chirp has sounded, the learn process is complete and the RCDLR exits the learn mode. 5. Ignition OFF, adjust all tires to the recommended pressures. Refer to Vehicle Certification, Tire Placard, Anti-Theft, and Service Parts ID Label ( See: Application and ID/Vehicle Certification, Tire Placard, Anti-Theft and Service Parts ID Label). Alternate Keyless Entry Transmitter or DIC Learn Enable Method 1. Ignition ON, initiate the TPM Learn Mode using one of the following procedures: * On vehicles equipped with keyless entry, simultaneously press the keyless entry transmitters lock and unlock buttons until a double horn chirp sounds indicating the Learn Mode has been enabled. The left front turn signal will also be illuminated. * On vehicles not equipped with keyless entry, press and release the driver information center (DIC) INFO button until the TIRE LEARN message appears on the DIC display. Press and hold the SET/RESET button until a double horn chirp sounds indicating the Learn Mode has been enabled. The left front turn signal will also be illuminated. 2. Starting with the left front tire, learn the tire pressure using one of the following methods: * Hold the antenna of the J-46079 aimed upward against the tire sidewall close to the wheel rim at the valve stem location. Press and release the activate button and wait for a horn chirp. Once the horn chirp has sounded, the sensor information is learned and the turn signal in the next location to be learned will illuminate. Warning Over inflating tires may cause personal injury or damage to the tires and wheels. When increasing tire pressure do not exceed the maximum inflation pressure as noted on the tire sidewall. * Increase/decrease the tire pressure for 8-10 seconds then wait for a horn chirp. The horn chirp may occur before or up to 30 seconds after the 8-10 second pressure increase/decrease time period has been reached. Once the horn chirp has sounded, the sensor information is learned and the turn signal in the next location to be learned will illuminate. 3. After the horn chirp has sounded and the right front turn signal is illuminated, repeat step 2 for the remaining 3 sensors in the following order: 1. Right front 2. Right rear 3. Left rear 4. When the left rear sensor has been learned and a double horn chirp has sounded, the learn process is complete and the RCDLR exits the learn mode. 5. Ignition OFF, adjust all tires to the recommended pressures. Refer to Vehicle Certification, Tire Placard, Anti-Theft, and Service Parts ID Label ( See: Application and ID/Vehicle Certification, Tire Placard, Anti-Theft and Service Parts ID Label). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement (Clamp In Style) Tire Pressure Sensor: Service and Repair Tire Pressure Indicator Sensor Replacement (Clamp In Style) Tire Pressure Indicator Sensor Replacement (Clamp In Style) Removal Procedure 1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Remove the tire/wheel assembly from the vehicle. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). Note: Before the tire is removed from the wheel, note the following items to avoid tire pressure sensor damage upon tire dismounting: * Place the sensors cap and valve on a dry clean surface after removal. The cap is aluminum and the valve is nickel plated to prevent corrosion and are not to be substituted with a cap or valve made of any other material. * When separating the tire bead from the wheel, position the bead breaking fixture 90 degrees from the valve stem. * Position the mounting/dismounting head so the tire iron, or pry bar can be inserted slightly clockwise of the sensor body when prying the tire bead up and over the mounting/dismounting head. * Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the out side of the wheel rim. * Repeat items for inner bead. 3. Remove the tire from the wheel. Refer to Tire Dismounting and Mounting (See: Tires/Service and Repair/Removal and Replacement). Note: If any tire sealant is noted upon tire dismounting, remove all residual liquid sealant from the inside of the tire and wheel surfaces. 4. Remove the tire pressure sensor nut. 5. Remove the tire pressure sensor. Installation Procedure 1. Clean any dirt or debris from the grommet sealing area. 2. Insert the sensor in the wheel hole with the air passage facing away from the wheel. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the sensor nut and position the sensor body parallel to the inside wheel surface while torquing. Tighten the sensor nut to 7 Nm (62 lb in). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement (Clamp In Style) > Page 13160 Note: Before reinstalling the tire on the wheel, note the following items to avoid tire pressure sensor damage upon tire mounting: * Position the mounting/dismounting head 180 degrees from the valve stem. * Position the bead transition area 45 degrees counterclockwise of the valve stem. * Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the inside of the wheel rim. * Repeat items for outer bead. 4. Install the tire on the wheel. Refer to Tire Dismounting and Mounting (See: Tires/Service and Repair/Removal and Replacement). Note: A service replacement tire pressure sensor is shipped in OFF mode. In this mode the sensor unique identification code cannot be learned into the remote control door lock receiver (RCDLR) memory. The sensor must be taken out of OFF mode by spinning the tire/wheel assembly above 32 km/h (20 mph) in order to close the sensors internal roll switch for at least 10 seconds. 5. Install the tire/wheel assembly on the vehicle. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). 6. Lower the vehicle. 7. Learn the tire pressure sensors. Refer to Tire Pressure Indicator Sensor Learn (See: Tire Monitoring System/Service and Repair/Service Manual Tire Pressure Sensor Learn). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement (Clamp In Style) > Page 13161 Tire Pressure Sensor: Service and Repair Tire Pressure Indicator Sensor Replacement (Snap In Style) Tire Pressure Indicator Sensor Replacement (Snap In Style) Removal Procedure 1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Remove the tire/wheel assembly from the vehicle. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). 3. Dismount the tire from the rim. Refer to Tire Dismounting and Mounting (See: Tires/Service and Repair/Removal and Replacement). Note: When servicing the tire pressure sensor always use a new Schrader(R) tire pressure monitor (TPM) and a new TORX screw during installation. 4. Remove the TORX screw (1) from the tire pressure sensor (2) and pull it straight off the tire pressure valve stem (3). Caution: Do not scratch or damage the clear coating on aluminum wheels with the tire changing equipment. Scratching the clear coating could cause the aluminum wheel to corrode and the clear coating to peel from the wheel. 5. Remove the tire pressure valve stem by pulling it through the rim. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement (Clamp In Style) > Page 13162 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Note: * Ensure the flat of the valve, lines up with the flats of the snap in the enclosure. * TPM valves and TORX screws are one-time use only. 1. Assemble the tire pressure sensor (2) to the valve stem and install the new TORX screw (3) and tighten to 1.3 Nm (11.5 lb in). Note: Use and approved tire mounting lubricant. DO NOT use silicon or corrosive base compounds to lubricate the tire bead and the wheel rim. A corrosive type compound can cause tire or rim deterioration. 2. Apply tire soap to the rubber portion of the valve stem (1). 3. Using a tire valve stem mounting tool, pull the valve stem through in a direction parallel to the valve hole on the rim. Note: Snap Fit TPM sensors are still shipped in the OFF mode. However, the TPM no longer needs to be spun to remove it from the OFF mode. The sensor will exit its OFF state when the tire is inflated. The technician can then program the vehicle as normal. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement (Clamp In Style) > Page 13163 4. Mount the tire to the rim. Refer to Tire Dismounting and Mounting (See: Tires/Service and Repair/Removal and Replacement). 5. Install the tire/wheel assembly on the vehicle. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). 6. Lower the vehicle. 7. Learn the tire pressure sensors. Refer to Tire Pressure Indicator Sensor Learn (See: Tire Monitoring System/Service and Repair/Service Manual Tire Pressure Sensor Learn). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips Low Tire Pressure Indicator: Technical Service Bulletins Tire Pressure Monitor - TPM System Message/Service Tips # 09-03-16-002A: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire Pressure Monitor (TPM) System Message, Light and Customer Information - (Apr 27, 2010) Subject: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire Pressure Monitor (TPM) System Message, Light and Customer Information Models: 2006-2011 Cars and Light Duty Trucks (Including Saturn and Saab) 2006-2010 HUMMER H2, H3 ATTENTION The information found in this bulletin is to be used as a dealership service consultant procedures for customers coming into the service lane with an illuminated "low tire light" or comments on a check tire pressure/low tire pressure/add air to tire or service tire monitor system message. Maintaining proper tire pressures is an Owner's Maintenance item and is not covered under warranty. This bulletin is being revised to add model years and update additional bulletin reference information. Please discard Corporate Bulletin Number 09-03-16-002 (Section 03 -- Suspension). Customer Concerns and Confusion with the Tire Pressure Monitoring (TPM) System The following procedure should be used by dealership service consultants when a customer comes into the service drive with a "low tire light" on or comments on a check tire pressure/low tire pressure/add air to tire or service tire monitor system message. The service consultant should perform the following steps: Procedure Turn the key to ON, without starting the engine. ^ If the low tire light comes on and stays on solid with a check tire pressure/low tire pressure/add air to tire message (on vehicles equipped with DIC), advise the customer: - The system is working properly. - Properly adjusting all tire air pressures to the recommended levels and driving the vehicle will turn the light off (refer to the Tire and Loading Information label on the driver side door). - More detailed information can be found in the Owner Manual. - Service is not covered under warranty - this maintenance is the responsibility of the owner. - Give the customer a copy of the "GM Customer TPMS Information". ^ If the Tire Pressure Monitor (TPM) light blinks for one minute then stays on solid with a service tire monitor system message (on vehicles equipped with DIC): - A TPM system problem exists. The vehicle should be written up accordingly and sent to your service department for further DTC diagnosis and service. - If dashes (--) are displayed in only one or two of the tire pressure readouts, it is likely caused by a previous TPM system relearn that was performed incorrectly due to interference from another vehicle's TPM system during the relearn process (refer to the Important statement later in this bulletin regarding TPM relearn with a Tech 2(R)). - If dashes (--) are displayed in all four of the tire pressure readouts, there is a system problem. Follow the appropriate SI service procedures. ^ If a customer indicates the low tire light comes on for a few minutes when the vehicle is started, then goes off after driving a while, advise the customer: - The system is working properly. - Most likely, air pressure in one or more of the tires is low enough to turn the light on when tires are cold. After driving for a while, tires will heat Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 13169 up, allowing tire air pressure to increase above the threshold causing the light to go off. Properly adjusting all tire air pressures to the recommended levels will correct this (Refer to the Tire and Loading Information Label on the driver side door). - More detailed information can be found in the Owner Manual. - Service is not covered under warranty - this maintenance is the responsibility of the owner. - Give the customer a copy of the "GM Customer TPMS Information". For more detailed information, refer to Corporate Bulletin Number 07-03-16-004C and TPMS Training Course 13044.12T2. Tire Pressure Light At key on, without starting the vehicle: Steady Solid Glowing TPM Indicator If the TPM indicator appears as a steady glowing yellow lamp (as above), the system is functioning properly and you should add air to the tires to correct this condition. Blinking TPM Indicator If the TPM indicator appears as a BLINKING yellow lamp for one minute and then stays on solid, diagnostic service is needed. The Effect of Outside Temperature on Tire Pressures Important: As a rule of thumb, tire pressure will change about 7kPa (1 psi) for every 6°C (10°F) decrease in temperature - Tire pressure will drop when it gets colder outside, and rise when it gets warmer. Under certain situations such as extreme outside temperature changes, the system may bring on a solid light with a check tire pressure message. This should be considered normal and the system is working properly. The light will turn off upon adding the proper amount of air to the tires (refer to the Tire & Loading Information label in the driver's door opening). When properly adjusting tire air pressure, the following steps are important to help optimize the system and prolong bringing a tire pressure light on: ^ Use an accurate, high quality tire pressure gauge. ^ Never set the tire pressure below the specified placard value regardless of tire temperature or ambient temperature. ^ Tire pressure should be set to the specified placard pressure at the lowest seasonal temperature the vehicle will encounter during operation. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 13170 ^ When adding proper tire air pressure, it is important to remember fluctuations in outside air temperatures and tire temperatures effect tire air pressures. ^ After you have added the proper tire pressure, if the vehicle has a DIC (after the system has updated), check to see if DIC displays are the same readings as the tire pressure gauge used (adjust as necessary). ^ Only perform a TPM sensor re-learn after a tire rotation or system part replacements and use the Tech 2(R) to initiate the relearn whenever possible to avoid invalid sensor I.D. learns. Important: Always take outside temperature and tire temperature into consideration to properly set tire pressures. Foe example, on colder days (20°F/-7°C), if setting tire pressure when the vehicle has been indoors (60°F/16°C) or the tires are warm from being driven, it will be necessary to compensate for the low outside temperature by adding 21-27 kPa (3-4 psi) more then the placecard pressure. At some later time, when the vehicle has been parked outside for a while, the tires will cool off and the pressures will drop back into the placecard range. Important: Recently, nitrogen gas (for use in inflating tires) has become available to the general customer through some retailers. The use of nitrogen gas to inflate tires is a technology used in automobile racing. Tires inflated with nitrogen gas may exhibit less of a pressure change in response to outside temperature changes. Nitrogen gas inflation is compatible with GM TPM sensors. For additional information, refer to Corporate Service Bulletin 05-03-10-020C. Important: All Models (Except the Pontiac Vibe): Do not perform a TPM relearn at PDI, the system has already been set at the Assembly Plant. Do not perform a TPM relearn after adding air to the tires. The low tire light is similar to the low fuel indicator and adding something (fuel, air) to the vehicle makes that light turn back off again. Note that because of system behavior, some vehicles must be driven a short distance before the sensors recognize the increase in pressure and turns the light off again. Pontiac Vibe Only: Do not use the TPMS reset button to turn off the light. The system will update and light will turn off when all tire pressures have been adjusted followed by short distance drive. Important: All models (except the Pontiac Vibe): Each tire monitor sensor is learned to a specific vehicle corner. When performing a TPM relearn (only after a tire rotation or replacement of a TPM sensor or Module), always use the Tech2(R) to initiate the J 46079 relearned process. Tech 2(R) - initiated relearns lock out other vehicle TPM signals that may be broadcasting in the area. Only signals initiated by the J 46079 tool will be accepted. This method avoids storing false TPM I.D.s and will prevent customers from returning with dashes (--) displayed in tire pressure readouts and/or a flashing tire pressure monitor (TPM) light. Checking the four TPM I.D.s with the Tech 2(R) prior to and following relearn to verify they are the same can prevent invalid I.D. learns. Pontiac Vibe Only: Tire Monitor Sensors are not learned to a specific vehicle corner. Do not perform a TPM Reset after tire rotation. The TPMS Reset button must only be used during pre-delivery inspection by the dealer to initialize the system (after all tire pressures have been adjusted properly) or when a Tire Pressure Monitor System component is replaced. The J 46079 tool does not work on Vibe TPM sensors. A TPMS relearn on Vibe must be preformed with a Tech 2(R) to set the TPMS Module in learn mode. The TPMS sensor IDs are entered through the Tech 2(R). Refer to SI for further Vibe TPMS information. Labor Operation and Repair Order/Warranty System Claim Required Documentation Important: The ONLY time labor operation E0726 or E0722 should be used is to diagnose for a system issue. That should ONLY occur if, at key ON, without starting the engine, the Tire Pressure Monitor (TPM) blinks for one minute and then stays on solid with a Service Tire Monitor System message (on vehicles equipped with a DIC) If that occurs, a TPM system problem exists and the system will have set a DTC. If one of these operastions is used, the following Repair Order and Warranty System documentation are required: ^ Document the customer complaint on the Repair Order. ^ Document the TPMS DTC that has set on the Repair Order. ^ Enter the TPMS DTC in the Warranty System (WINS) in the Failure Code/DTC field on the claim submission (refer to the Claims Processing Manual, Section IV, Warranty claim Data, Page 6, Item G). If the above information is not documented on the Repair Order and Warranty System, the claim may be rejected. If the Warranty Parts Center (WPC) generates a request, this repair order documentation must be sent back. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 13171 Customer TPMS Information Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 13172 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 13173 Frequently Asked Questions Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Module > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Technical Service Bulletins > Page 13182 Tire Pressure Sensor: Testing and Inspection Tire Pressure Indicator Sensor Learn Special Tools J-46079 Tire Pressure Monitor Diagnostic Tool Learn Mode Description The tire pressure monitor (TPM) system uses the instrument panel cluster (IPC), body control module (BCM), remote control door lock receiver (RCDLR), keyless entry transmitter, 4 radio frequency transmitting pressure sensors, and the serial data circuit to perform the TPM learn mode functions. The sensor learn procedure must be performed after every tire rotation, RCDLR replacement, or sensor replacement. Once the learn mode has been enabled, each of the sensors unique identification codes can be learned into the RCDLR memory. When a sensor ID has been learned, the RCDLR sends a serial data message to the BCM to sound a horn chirp. This verifies the sensor has transmitted its ID and the RCDLR has received and learned it. The RCDLR must learn the sensor IDs in the proper sequence to determine correct sensor location. The first learned ID is assigned to the left front location, the second to right front, the third to right rear and the fourth to left rear. The turn signals will individually illuminate indicating which location is to be learned in the proper sequence. Sensor Functions Using J-46079 Each sensor has an internal low frequency coil. When the J-46079 is used in activate mode, it produces a low frequency transmission that activates the sensor. The sensor responds to a low frequency activation by transmitting in learn mode. When the RCDLR receives a learn mode transmission while in TPM learn mode, it will assign that sensors ID to the location on the vehicle relative to the order in which it was learned. Sensor Functions Using Pressure Increase/Decrease Method Each sensor takes a pressure measurement sample once every 30 seconds while in stationary mode. If the tire pressure increases, or decreases by more than 8.3 kPa (1.2 psi) from the last pressure measurement, another measurement will occur immediately to verify the change in pressure. If a pressure change has indeed occurred, the sensor transmits in Learn mode. When the RCDLR receives a Learn mode transmission while in TPM learn mode, it will assign that sensor's ID to the location on the vehicle relative to the order in which it was learned. Learn Mode Cancellation The learn mode will cancel if the ignition is cycled to OFF or if more than 2 minutes has elapsed for any sensor that has not been learned. If the learn mode is cancelled before the first sensor is learned, the original sensor IDs will be maintained. If the learn mode is canceled after the first sensor is learned, the following will occur: * All stored sensor IDs will be invalidated in the RCDLR memory. * If equipped, the DIC will display dashes instead of tire pressures. * DTC C0775 will be set. These conditions will now require the learn procedure to be repeated for the system to function properly. TPM Learn Procedure Note: If using the scan tool to enable the learn mode, the J-46079 must be used to activate the sensors. When this preferred method is used, any stray sensor signals will not affect the learn procedure. In the event a particular sensor's information is displayed on the special tool upon activation but the horn does not chirp, it may be necessary to rotate the wheel valve stem to a different position due to the sensor signal is being blocked by another component. If using the keyless entry transmitter or DIC buttons to enable the learn mode, the J-46079 or Pressure Increase/Decrease Method may be used. Before proceeding with this method, ensure that no other learn procedure is being performed simultaneously or that tire pressures are not being adjusted on another TPM equipped vehicle within close proximity. Stray signals from other TPM equipped vehicles just driving by can be inadvertently learned. If any random horn chirps are heard from the vehicle while performing the learn procedure, most likely a stray sensor has been learned and the procedure will need to be cancelled and repeated. Under these circumstances, performing the TPM Learn Procedure away from other vehicles would be highly recommended. In the event a particular sensor activation does not cause the horn to chirp, it may be necessary to rotate the wheel valve stem to a different position due to the sensor signal is being blocked by another component. Preferred Scan Tool Learn Enable Method 1. Using a scan tool, initiate the TPM Learn Mode. A double horn chirp will sound indicating the Learn Mode has been enabled. The left front turn signal will also be illuminated. 2. Starting with the left front tire, active the sensor by holding the antenna of the J-46079 aimed upward against the tire sidewall close to the wheel rim at the valve stem location. Press and release the Activate button and wait for a horn chirp. Once the horn chirp has sounded, the sensor information is learned and the turn signal in the next location to be learned will illuminate. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Technical Service Bulletins > Page 13183 3. After the horn chirp has sounded and the right front turn signal is illuminated, repeat step 2 for the remaining 3 sensors in the following order: 1. Right front 2. Right rear 3. Left rear 4. When the left rear sensor has been learned and a double horn chirp has sounded, the learn process is complete and the RCDLR exits the learn mode. 5. Ignition OFF, adjust all tires to the recommended pressures. Refer to Vehicle Certification, Tire Placard, Anti-Theft, and Service Parts ID Label ( See: Application and ID/Vehicle Certification, Tire Placard, Anti-Theft and Service Parts ID Label). Alternate Keyless Entry Transmitter or DIC Learn Enable Method 1. Ignition ON, initiate the TPM Learn Mode using one of the following procedures: * On vehicles equipped with keyless entry, simultaneously press the keyless entry transmitters lock and unlock buttons until a double horn chirp sounds indicating the Learn Mode has been enabled. The left front turn signal will also be illuminated. * On vehicles not equipped with keyless entry, press and release the driver information center (DIC) INFO button until the TIRE LEARN message appears on the DIC display. Press and hold the SET/RESET button until a double horn chirp sounds indicating the Learn Mode has been enabled. The left front turn signal will also be illuminated. 2. Starting with the left front tire, learn the tire pressure using one of the following methods: * Hold the antenna of the J-46079 aimed upward against the tire sidewall close to the wheel rim at the valve stem location. Press and release the activate button and wait for a horn chirp. Once the horn chirp has sounded, the sensor information is learned and the turn signal in the next location to be learned will illuminate. Warning Over inflating tires may cause personal injury or damage to the tires and wheels. When increasing tire pressure do not exceed the maximum inflation pressure as noted on the tire sidewall. * Increase/decrease the tire pressure for 8-10 seconds then wait for a horn chirp. The horn chirp may occur before or up to 30 seconds after the 8-10 second pressure increase/decrease time period has been reached. Once the horn chirp has sounded, the sensor information is learned and the turn signal in the next location to be learned will illuminate. 3. After the horn chirp has sounded and the right front turn signal is illuminated, repeat step 2 for the remaining 3 sensors in the following order: 1. Right front 2. Right rear 3. Left rear 4. When the left rear sensor has been learned and a double horn chirp has sounded, the learn process is complete and the RCDLR exits the learn mode. 5. Ignition OFF, adjust all tires to the recommended pressures. Refer to Vehicle Certification, Tire Placard, Anti-Theft, and Service Parts ID Label ( See: Application and ID/Vehicle Certification, Tire Placard, Anti-Theft and Service Parts ID Label). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement (Clamp In Style) Tire Pressure Sensor: Service and Repair Tire Pressure Indicator Sensor Replacement (Clamp In Style) Tire Pressure Indicator Sensor Replacement (Clamp In Style) Removal Procedure 1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Remove the tire/wheel assembly from the vehicle. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). Note: Before the tire is removed from the wheel, note the following items to avoid tire pressure sensor damage upon tire dismounting: * Place the sensors cap and valve on a dry clean surface after removal. The cap is aluminum and the valve is nickel plated to prevent corrosion and are not to be substituted with a cap or valve made of any other material. * When separating the tire bead from the wheel, position the bead breaking fixture 90 degrees from the valve stem. * Position the mounting/dismounting head so the tire iron, or pry bar can be inserted slightly clockwise of the sensor body when prying the tire bead up and over the mounting/dismounting head. * Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the out side of the wheel rim. * Repeat items for inner bead. 3. Remove the tire from the wheel. Refer to Tire Dismounting and Mounting (See: Tires/Service and Repair/Removal and Replacement). Note: If any tire sealant is noted upon tire dismounting, remove all residual liquid sealant from the inside of the tire and wheel surfaces. 4. Remove the tire pressure sensor nut. 5. Remove the tire pressure sensor. Installation Procedure 1. Clean any dirt or debris from the grommet sealing area. 2. Insert the sensor in the wheel hole with the air passage facing away from the wheel. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the sensor nut and position the sensor body parallel to the inside wheel surface while torquing. Tighten the sensor nut to 7 Nm (62 lb in). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement (Clamp In Style) > Page 13186 Note: Before reinstalling the tire on the wheel, note the following items to avoid tire pressure sensor damage upon tire mounting: * Position the mounting/dismounting head 180 degrees from the valve stem. * Position the bead transition area 45 degrees counterclockwise of the valve stem. * Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the inside of the wheel rim. * Repeat items for outer bead. 4. Install the tire on the wheel. Refer to Tire Dismounting and Mounting (See: Tires/Service and Repair/Removal and Replacement). Note: A service replacement tire pressure sensor is shipped in OFF mode. In this mode the sensor unique identification code cannot be learned into the remote control door lock receiver (RCDLR) memory. The sensor must be taken out of OFF mode by spinning the tire/wheel assembly above 32 km/h (20 mph) in order to close the sensors internal roll switch for at least 10 seconds. 5. Install the tire/wheel assembly on the vehicle. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). 6. Lower the vehicle. 7. Learn the tire pressure sensors. Refer to Tire Pressure Indicator Sensor Learn (See: Service and Repair/Service Manual Tire Pressure Sensor Learn). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement (Clamp In Style) > Page 13187 Tire Pressure Sensor: Service and Repair Tire Pressure Indicator Sensor Replacement (Snap In Style) Tire Pressure Indicator Sensor Replacement (Snap In Style) Removal Procedure 1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Remove the tire/wheel assembly from the vehicle. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). 3. Dismount the tire from the rim. Refer to Tire Dismounting and Mounting (See: Tires/Service and Repair/Removal and Replacement). Note: When servicing the tire pressure sensor always use a new Schrader(R) tire pressure monitor (TPM) and a new TORX screw during installation. 4. Remove the TORX screw (1) from the tire pressure sensor (2) and pull it straight off the tire pressure valve stem (3). Caution: Do not scratch or damage the clear coating on aluminum wheels with the tire changing equipment. Scratching the clear coating could cause the aluminum wheel to corrode and the clear coating to peel from the wheel. 5. Remove the tire pressure valve stem by pulling it through the rim. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement (Clamp In Style) > Page 13188 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Note: * Ensure the flat of the valve, lines up with the flats of the snap in the enclosure. * TPM valves and TORX screws are one-time use only. 1. Assemble the tire pressure sensor (2) to the valve stem and install the new TORX screw (3) and tighten to 1.3 Nm (11.5 lb in). Note: Use and approved tire mounting lubricant. DO NOT use silicon or corrosive base compounds to lubricate the tire bead and the wheel rim. A corrosive type compound can cause tire or rim deterioration. 2. Apply tire soap to the rubber portion of the valve stem (1). 3. Using a tire valve stem mounting tool, pull the valve stem through in a direction parallel to the valve hole on the rim. Note: Snap Fit TPM sensors are still shipped in the OFF mode. However, the TPM no longer needs to be spun to remove it from the OFF mode. The sensor will exit its OFF state when the tire is inflated. The technician can then program the vehicle as normal. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement (Clamp In Style) > Page 13189 4. Mount the tire to the rim. Refer to Tire Dismounting and Mounting (See: Tires/Service and Repair/Removal and Replacement). 5. Install the tire/wheel assembly on the vehicle. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). 6. Lower the vehicle. 7. Learn the tire pressure sensors. Refer to Tire Pressure Indicator Sensor Learn (See: Service and Repair/Service Manual Tire Pressure Sensor Learn). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Spare Tire > Component Information > Service and Repair Spare Tire: Service and Repair Spare Wheel Hoist Replacement Tire Hoist Secondary Latch Mechanism Note: If the spare tire hoist has been fully raised without a spare tire in place, the secondary latch mechanism may have become engaged. If this has occurred the hoist will not lower and the following steps will need to be followed: 1. Rotate the hoist shaft counterclockwise until approximately 15 cm (6 in) of cable (1) is exposed. 2. While holding the latch pin (3), fully depress the latch button (2) and release the secondary latch from the hoist assembly. Some side-to-side and/or up-and-down movement may be necessary to disengage the latch mechanism. 3. Continue rotating the hoist shaft counterclockwise in order to lower the hoist the rest of the way. 4. If this does not release the secondary latch, the spare tire hoist will need to be replaced. See the following procedure. Removal Procedure 1. If the vehicle is equipped with a spare tire stowage lock cylinder, open the spare tire lock cover on the bumper and using the ignition key, remove the lock. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Spare Tire > Component Information > Service and Repair > Page 13194 Caution: Use only hand tools to lower and raise the spare tire hoist assembly. Do not use air tools. The use of air tools at high speeds will damage the spare tire hoist assembly. 2. Rotate the hoist shaft counterclockwise in order to lower the spare tire to the ground. Continue to rotate the shaft until the spare tire can be pulled out from under the vehicle and removed. If the spare tire does not lower to the ground, the secondary latch is engaged causing the tire not to lower. 3. If the secondary latch is engaged and the cable end is visible, perform the following procedure: 1. Tighten the cable by rotating the hoist shaft clockwise until you hear 2 clicks or feel it skip twice. You cannot overtighten the cable. 2. Loosen the cable by rotating the hoist shaft counterclockwise 3 or 4 turns. 3. If the spare tire can be lowered, repeat steps 1 and 2 to see if the spare tire can be removed. 4. If the spare tire cannot be lowered, rotate the hoist shaft counterclockwise until approximately 15 cm (6 in) of cable is exposed. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 6. Place a transmission jack, or equivalent, under the spare tire. 7. Position the center of the transmission jack under the secondary latch release button at the center of the spare tire. Arrange the arms of the transmission jack so they will support the tire after it has been released. 8. Raise the jack until the spare tire stops moving upward and is firmly held in place, releasing the secondary latch. 9. Lower the tire. If the spare tire is hanging by the cable, rotate the hoist shaft counterclockwise until the tire is low enough to remove. 4. If the secondary latch is engaged and the cable end is NOT visible, perform the following procedure: 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Place a transmission jack, or equivalent, under the spare tire. 3. Position the center of the transmission jack under the secondary latch release button at the center of the spare tire. Arrange the arms of the transmission jack so they will support the tire after it has been released. 4. Raise the jack until the spare tire stops moving upward and is firmly held in place, releasing the secondary latch. 5. Lower the tire and remove it from the jack. 5. Raise and support the vehicle if it is not already raised. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 6. Depress the tabs, remove the guide shaft from the hoist collar, and slide the shaft toward the bumper. 7. Remove the collar from the hoist. 8. Remove the bolt. 9. Remove the hoist from the bracket. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Spare Tire > Component Information > Service and Repair > Page 13195 10. Remove the spare tire hoist shaft guide from the bumper. Installation Procedure 1. Install the spare tire hoist shaft guide to the bumper. 2. Install the hoist to the crossmember. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the bolt and tighten to 40 Nm (30 lb ft). 4. Install the collar to the hoist. 5. Install the shaft to the hoist. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Spare Tire > Component Information > Service and Repair > Page 13196 6. Install the spare tire to the hoist. Caution: Use only hand tools to lower and raise the spare tire hoist assembly. Do not use air tools. The use of air tools at high speeds will damage the spare tire hoist assembly. 7. Rotate the hoist shaft clockwise until the spare tire is in position and the hoist clicks 2 times or it skips twice. You cannot overtighten the cable. 8. Remove the safety stands. 9. Lower the vehicle. 10. Install the spare tire stowage lock cylinder. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 07-03-10-012D > Apr > 11 > Tires/Wheels - Rattle Noise from Wheel Or Hub Cap Wheels: Customer Interest Tires/Wheels - Rattle Noise from Wheel Or Hub Cap TECHNICAL Bulletin No.: 07-03-10-012D Date: April 12, 2011 Subject: Rattle Noise from Wheel or Hub Cap While Driving, Loose Wheel Nut Caps or Wheel Nut Caps May Not Tighten on Wheel Nuts (Inspect/Replace Wheel Nut Caps As Necessary) Models: 2007-2012 Chevrolet Express, Silverado, Suburban 1500, 2500 and 3500 Series 2007-2012 GMC Savana, Sierra, Yukon XL 1500, 2500 and 3500 Series with 8 Lug Wheel Nut Center Caps (RPOs NX7, NZ7, PY0, PY2, PY9, P03, P25, QB5, QC1, QR5, Q9A) Supercede: This bulletin is being revised to update the model year information. Please discard Corporate Bulletin Number 07-03-10-012C (Section 03 - Suspension). Condition Some customers may comment on a rattle noise from the wheel or hub cap while driving. Other customers may comment on loose wheel nut caps or caps that may not tighten on the wheel nuts. Cause Depending on the generation of the wheel caps, the issue may be overtorqued wheel nut caps or may be caused by the lack of internal threads inside the wheel nut caps. The wheel nut cap (1) is correctly threaded. The wheel nut cap (2) shows the insufficient threads. Correction Important The wheel nut caps are serviced separately from the center wheel hub cap for most hub caps. Refer to the GM electronic parts catalog (EPC) for details. Inspect each wheel nut cap and replace as necessary using the steps below. 1. Remove the wheel hub cap from the vehicle. 2. Place the front of the wheel hub cap down on a protected clean work bench being careful not to scratch or damage the hub cap surface. 3. Inspect all the wheel nut caps, marking any bad wheel nut caps. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 07-03-10-012D > Apr > 11 > Tires/Wheels - Rattle Noise from Wheel Or Hub Cap > Page 13205 Tip The bad wheel nut cap can be removed by placing a drift or punch inside the center of the nut cap and using a hammer to tap the wheel nut cap out of the hub cap. 4. From inside the hub cap, apply direct pressure to one side of the wheel nut cap rim (1). The wheel nut cap will tip down and pop out of the wheel hub cap hole when enough pressure is applied. Repeat this procedure for any additional wheel nut caps that need to be replaced. 5. Flip the hub cap over on the work bench. The emblem side should be up. Tip A 22 mm (7/8 in) socket placed over the wheel nut cap may be used along with a hammer to tap the new wheel nut cap back into the hub cap hole. 6. Install the new wheel nut cap into the existing hub cap hole by applying direct pressure to the front center of the wheel nut cap. 7. Install the wheel hub cap onto the vehicle and tighten the wheel nut caps. 8. Repeat this entire procedure for each additional hub cap. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) Wheels: Customer Interest Wheels/Tires - Tire Radial Force Variation (RFV) INFORMATION Bulletin No.: 00-03-10-006F Date: May 04, 2010 Subject: Information on Tire Radial Force Variation (RFV) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION Supercede: This bulletin is being revised to considerably expand the available information on Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin Number 00-03-10-006E (Section 03 - Suspension). Important - Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires. - Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel assemblies for each vehicle. The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force variation is highway speed shake on smooth roads. Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out of round and tire force variation. These three conditions are not necessarily related. All three conditions must be addressed. Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle, two plane dynamic wheel balancers are readily available and can accurately correct any imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer, and proper balance weights, are all factors required for a quality balance. However, a perfectly balanced tire/wheel assembly can still be "oval shaped" and cause a vibration. Before balancing, perform the following procedures. Tire and Wheel Diagnosis 1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick. 3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and correct as necessary: - Missing balance weights - Bent rim flange - Irregular tire wear - Incomplete bead seating - Tire irregularities (including pressure settings) - Mud/ice build-up in wheel - Stones in the tire tread - Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to diagnosing a smooth road shake condition. 4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a sufficient distance on a known, smooth road surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order (one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high enough in frequency that most humans can start to hear them at highway speeds, but are too high to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment. If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a throbbing), chances are good that the vehicle could have driveline vibration. This type Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 13210 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 13211 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 13212 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels Wheels: Customer Interest Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels TECHNICAL Bulletin No.: 05-03-10-003F Date: April 27, 2010 Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels Supercede: This bulletin is being revised to update the model years and the bulletin reference information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension). Condition Some customers may comment on a low tire pressure condition. Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel. Cause Porosity in the cast aluminum wheel may be the cause. Notice This bulletin specifically addresses issues related to the wheel casting that may result in an air leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat). Correction 1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the tire/wheel assembly in a water bath, or use a spray bottle with soap and water to locate the specific leak location. Important - If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim), the wheel should be replaced. - If two or more leaks are located on one wheel, the wheel should be replaced. 3. If air bubbles are observed, mark the location. - If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks. - If the leak is located on the aluminum wheel area, continue with the next step. 4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose cleaner, such as 3M(R) General Purpose Adhesive Cleaner, P/N 08984, or equivalent. 8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use 88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry. Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging the repair area may result in an air leak. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels > Page 13217 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON Wheels: Customer Interest Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON TECHNICAL Bulletin No.: 08-03-10-006C Date: April 27, 2010 Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat) Models: 2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-03-10-006B (Section 03 - Suspension). Condition Some customers may comment on a tire that slowly loses air pressure over a period of days or weeks. Cause Abrasive elements in the environment may intrude between the tire and wheel at the bead seat. There is always some relative motion between the tire and wheel (when the vehicle is driven) and this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear continues, there may also be intrusion at the tire/wheel interface by corrosive media from the environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be visible until the tire is dismounted from the wheel. Notice This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Correction In most cases, this type of air loss can be corrected by following the procedure below. Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to repair the wheel with the procedure below. Notice The repair is no longer advised or applicable for chromed aluminum wheels. 1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to be around the bead seat of the wheel, dismount the tire to examine the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat Corrosion Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 13222 Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for additional information on possible wheel porosity issues. 3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a rough or uneven surface that is difficult for the tire to maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion 4. If corrosion is found on the wheel bead seat, measure the affected area as shown below. - For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. - For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. 5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the corrosion and any flaking paint. You should remove the corrosion back far enough until you reach material that is stable and firmly bonded to the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired surface. Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend to the visible surfaces on the FACE of the wheel, that wheel must be replaced. Important Remove ONLY the material required to eliminate the corrosion from the bead seating surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as smooth and level as possible. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 13223 Acceptably Prepared (Cleaned-Up) Wheel Surface 6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially available tire sealant such as Patch Brand Bead Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat 7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in SI. Parts Information Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 13224 Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion INFORMATION Bulletin No.: 00-03-10-002F Date: April 21, 2011 Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum Wheels Models: 2012 and Prior GM Cars and Trucks Supercede: This bulletin is being revised to update model years, suggest additional restorative products and add additional corrosion information. Please discard Corporate Bulletin Number 00-03-10-002E (Section 03 - Suspension). Important You may give a copy of this bulletin to the customer. What is Chemical Staining of Chrome Wheels? Figure 1 Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an example). These stains are frequently milky, black, or greenish in appearance. They result from using cleaning solutions that contain acids on chrome wheels. Soap and water is usually sufficient to clean wheels. If the customer insists on using a wheel cleaner they should only use one that specifically states that it is safe for chromed wheels and does not contain anything in the following list. (Dealers should also survey any products they use during prep or normal cleaning of stock units for these chemicals.) - Ammonium Bifluoride (fluoride source for dissolution of chrome) - Hydrofluoric Acid (directly dissolves chrome) - Hydrochloric Acid (directly dissolves chrome) - Sodium Dodecylbenzenesulfonic Acid - Sulfamic Acid - Phosphoric Acid - Hydroxyacetic Acid Notice Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal. Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car warranty. Soap and water applied with a soft brush is usually all that is required to clean the calipers. Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean, clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts, lug nut caps, between the wheel cladding and off the back side of the wheel. Wheels returned to the Warranty Parts Center (WPC) that exhibit damage from wheel cleaners most often have the damage around and under the wheel weight where the cleaner was incompletely flushed away. Notice Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 13230 Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome wheels (or any wheels). If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be avoided. For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and Instructions below. Warranty of Stained Chrome Wheels Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be charged back to the dealership. To assist the customer, refer to Customer Assistance and Instructions below. Pitting or Spotted Appearance of Chrome Wheels Figure 2 A second type or staining or finish disturbance may result from road chemicals, such as calcium chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can also stain chrome wheels. The staining will look like small pitting. This staining will usually be on the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward direction while being splashed by the road chemical. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Warranty of Pitted or Spotted Chrome Wheels Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time. Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish and may cause damage if the wheels are not kept clean. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean if they are operating the vehicle in an area that applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). "Stardust" Corrosion of Chrome Wheels Figure 3 A third type of finish disturbance results from prolonged exposure to brake dust and resultant penetration of brake dust through the chrome. As brakes are applied hot particles of brake material are thrown off and tend to be forced through the leading edge of the wheel spoke windows by airflow. These Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 13231 hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the chrome leaving a pit or small blister in the chrome. Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax #M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may be used. It will clean and shine the chrome and leave behind a wax coating that may help protect the finish. Warranty of Stardust Corroded Chrome Wheels Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be replaced one time. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). Customer Assistance and Instructions GM has looked for ways customers may improve the appearance of wheels damaged by acidic cleaners. The following product and procedure has been found to dramatically improve the appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the following: Notice THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER, EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS EXACTLY. 1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce wheel staining. Flood all areas of the wheel with water to rinse. 2. Dry the wheels completely. Notice Begin with a small section of the wheel and with light pressure buff off polish and examine results. ONLY apply and rub with sufficient force and time to remove enough staining that you are satisfied with the results. Some wheels may be stained to the extent that you may only achieve a 50% improvement while others may be able to be restored to the original lustre. IN ALL CASES, only apply until the results are satisfactory. 3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If continued applications fail to improve the appearance further discontinue use. This procedure will improve the appearance of the wheels and may, with repeated applications, restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above procedure may marginally improve the condition but will not restore the finish or remove the pitting. In this type of staining the wheel finish has actually been removed in spots and no manner of cleaning will restore the finish. †*We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 13232 *This product is currently available from 3M. To obtain information for your local retail location please call 3M at 1-888-364-3577. **This product is currently available from Meguiars (Canada). To obtain information for your local retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com. ^ This product is currently available from Tri-Peek International. To obtain information for your local retail location please call Tri-Peek at 1-877-615-4272 or at www.tripeek.com. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 07-03-10-012D > Apr > 11 > Tires/Wheels Rattle Noise from Wheel Or Hub Cap Wheels: All Technical Service Bulletins Tires/Wheels - Rattle Noise from Wheel Or Hub Cap TECHNICAL Bulletin No.: 07-03-10-012D Date: April 12, 2011 Subject: Rattle Noise from Wheel or Hub Cap While Driving, Loose Wheel Nut Caps or Wheel Nut Caps May Not Tighten on Wheel Nuts (Inspect/Replace Wheel Nut Caps As Necessary) Models: 2007-2012 Chevrolet Express, Silverado, Suburban 1500, 2500 and 3500 Series 2007-2012 GMC Savana, Sierra, Yukon XL 1500, 2500 and 3500 Series with 8 Lug Wheel Nut Center Caps (RPOs NX7, NZ7, PY0, PY2, PY9, P03, P25, QB5, QC1, QR5, Q9A) Supercede: This bulletin is being revised to update the model year information. Please discard Corporate Bulletin Number 07-03-10-012C (Section 03 - Suspension). Condition Some customers may comment on a rattle noise from the wheel or hub cap while driving. Other customers may comment on loose wheel nut caps or caps that may not tighten on the wheel nuts. Cause Depending on the generation of the wheel caps, the issue may be overtorqued wheel nut caps or may be caused by the lack of internal threads inside the wheel nut caps. The wheel nut cap (1) is correctly threaded. The wheel nut cap (2) shows the insufficient threads. Correction Important The wheel nut caps are serviced separately from the center wheel hub cap for most hub caps. Refer to the GM electronic parts catalog (EPC) for details. Inspect each wheel nut cap and replace as necessary using the steps below. 1. Remove the wheel hub cap from the vehicle. 2. Place the front of the wheel hub cap down on a protected clean work bench being careful not to scratch or damage the hub cap surface. 3. Inspect all the wheel nut caps, marking any bad wheel nut caps. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 07-03-10-012D > Apr > 11 > Tires/Wheels Rattle Noise from Wheel Or Hub Cap > Page 13237 Tip The bad wheel nut cap can be removed by placing a drift or punch inside the center of the nut cap and using a hammer to tap the wheel nut cap out of the hub cap. 4. From inside the hub cap, apply direct pressure to one side of the wheel nut cap rim (1). The wheel nut cap will tip down and pop out of the wheel hub cap hole when enough pressure is applied. Repeat this procedure for any additional wheel nut caps that need to be replaced. 5. Flip the hub cap over on the work bench. The emblem side should be up. Tip A 22 mm (7/8 in) socket placed over the wheel nut cap may be used along with a hammer to tap the new wheel nut cap back into the hub cap hole. 6. Install the new wheel nut cap into the existing hub cap hole by applying direct pressure to the front center of the wheel nut cap. 7. Install the wheel hub cap onto the vehicle and tighten the wheel nut caps. 8. Repeat this entire procedure for each additional hub cap. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires Refinishing Aluminum Wheels Wheels: All Technical Service Bulletins Wheels/Tires - Refinishing Aluminum Wheels INFORMATION Bulletin No.: 99-08-51-007E Date: March 17, 2011 Subject: Refinishing Aluminum Wheels Models: 2012 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 99-08-51-007D (Section 08 - Body and Accessories). This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic refinishing of the wheel's coatings, using recommended procedures, is allowed. Evaluating Damage In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion, scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been refinished by an outside company must be returned to the same vehicle. The Dealer must record the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. Aluminum Wheel Refinishing Recommendations - Chrome-plated aluminum wheels Re-plating these wheels is not recommended. - Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. - Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel. - Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them. In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel should be resurfaced by using a sanding process rather than a machining process. This allows the least amount of material to be removed. Important Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using any of the painting options, it is recommended that all four wheels be refinished in order to maintain color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures and product recommendations. Refinisher's Responsibility - Outside Company Important Some outside companies are offering wheel refinishing services. Such refinished wheels will be permanently marked by the refinisher and are warranted by the refinisher. Any process that re-machines or otherwise re-manufactures the wheel should not be used. A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to assure that the same wheel is returned. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Re-machining of the wheel is not allowed. Paint and/or clear coat must not be present on the following surfaces: the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires Refinishing Aluminum Wheels > Page 13242 longer. Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions Wheels: All Technical Service Bulletins Wheels - Changing Procedures/Precautions INFORMATION Bulletin No.: 06-03-10-010A Date: June 09, 2010 Subject: Information on Proper Wheel Changing Procedures and Cautions Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER Models 2005-2009 Saab 9-7X 2005-2009 Saturn Vehicles Attention: Complete wheel changing instructions for each vehicle line can be found under Tire and Wheel Removal and Installation in Service Information (SI). This bulletin is intended to quickly review and reinforce simple but vital procedures to reduce the possibility of achieving low torque during wheel installation. Always refer to SI for wheel lug nut torque specifications and complete jacking instructions for safe wheel changing. Supercede: This bulletin is being revised to include the 2011 model year and update the available special tool list. Please discard Corporate Bulletin Number 06-03-10-010 (Section 03 Suspension). Frequency of Wheel Changes - Marketplace Driven Just a few years ago, the increasing longevity of tires along with greater resistance to punctures had greatly reduced the number of times wheels were removed to basically required tire rotation intervals. Today with the booming business in accessory wheels/special application tires (such as winter tires), consumers are having tire/wheel assemblies removed - replaced - or installed more than ever. With this increased activity, it opens up more of a chance for error on the part of the technician. This bulletin will review a few of the common concerns and mistakes to make yourself aware of. Proper Servicing Starts With the Right Tools The following tools have been made available to assist in proper wheel and tire removal and installation. - J 41013 Rotor Resurfacing Kit (or equivalent) - J 42450-A Wheel Hub Resurfacing Kit (or equivalent) Corroded Surfaces One area of concern is corrosion on the mating surfaces of the wheel to the hub on the vehicle. Excessive corrosion, dirt, rust or debris built up on these surfaces can mimic a properly tightened wheel in the service stall. Once the vehicle is driven, the debris may loosen, grind up or be washed away from water splash. This action may result in clearance at the mating surface of the wheel and an under-torqued condition. Caution Before installing a wheel, remove any buildup on the wheel mounting surface and brake drum or brake disc mounting surface. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This may cause a wheel to come off when the vehicle is moving, possibly resulting in a loss of control or personal injury. Whenever you remove the tire/wheel assemblies, you must inspect the mating surfaces. If corrosion is found, you should remove the debris with a die grinder equipped with a fine sanding pad, wire brush or cleaning disc. Just remove enough material to assure a clean, smooth mating surface. The J 41013 (or equivalent) can be used to clean the following surfaces: - The hub mounting surface - The brake rotor mounting surface - The wheel mounting surface Use the J 42450-A (or equivalent) to clean around the base of the studs and the hub. Lubricants, Grease and Fluids Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 13247 Some customers may use penetrating oils, grease or other lubricants on wheel studs to aid in removal or installation. Always use a suitable cleaner/solvent to remove these lubricants prior to installing the wheel and tire assemblies. Lubricants left on the wheel studs may cause improper readings of wheel nut torque. Always install wheels to clean, dry wheel studs ONLY. Notice Lubricants left on the wheel studs or vertical mounting surfaces between the wheel and the rotor or drum may cause the wheel to work itself loose after the vehicle is driven. Always install wheels to clean, dry wheel studs and surfaces ONLY. Beginning with 2011 model year vehicles, put a light coating of grease, GM P/N 1051344 (in Canada, P/N 9930370), on the inner surface of the wheel pilot hole to prevent wheel seizure to the axle or bearing hub. Wheel Stud and Lug Nut Damage Always inspect the wheel studs and lug nuts for signs of damage from crossthreading or abuse. You should never have to force wheel nuts down the stud. Lug nuts that are damaged may not retain properly, yet give the impression of fully tightening. Always inspect and replace any component suspected of damage. Tip Always start wheel nuts by hand! Be certain that all wheel nut threads have been engaged BEFORE tightening the nut. Important If the vehicle has directional tread tires, verify the directional arrow on the outboard side of the tire is pointing in the direction of forward rotation. Wheel Nut Tightening and Torque Improper wheel nut tightening can lead to brake pulsation and rotor damage. In order to avoid additional brake repairs, evenly tighten the wheel nuts to the proper torque specification as shown for each vehicle in SI. Always observe the proper wheel nut tightening sequence as shown below in order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off center resulting in vibration. The Most Important Service You Provide While the above information is well known, and wheel removal so common, technicians run the risk of becoming complacent on this very important Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 13248 service operation. A simple distraction or time constraint that rushes the job may result in personal injury if the greatest of care is not exercised. Make it a habit to double check your work and to always side with caution when installing wheels. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) Wheels: All Technical Service Bulletins Wheels/Tires - Tire Radial Force Variation (RFV) INFORMATION Bulletin No.: 00-03-10-006F Date: May 04, 2010 Subject: Information on Tire Radial Force Variation (RFV) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION Supercede: This bulletin is being revised to considerably expand the available information on Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin Number 00-03-10-006E (Section 03 - Suspension). Important - Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires. - Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel assemblies for each vehicle. The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force variation is highway speed shake on smooth roads. Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out of round and tire force variation. These three conditions are not necessarily related. All three conditions must be addressed. Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle, two plane dynamic wheel balancers are readily available and can accurately correct any imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer, and proper balance weights, are all factors required for a quality balance. However, a perfectly balanced tire/wheel assembly can still be "oval shaped" and cause a vibration. Before balancing, perform the following procedures. Tire and Wheel Diagnosis 1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick. 3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and correct as necessary: - Missing balance weights - Bent rim flange - Irregular tire wear - Incomplete bead seating - Tire irregularities (including pressure settings) - Mud/ice build-up in wheel - Stones in the tire tread - Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to diagnosing a smooth road shake condition. 4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a sufficient distance on a known, smooth road surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order (one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high enough in frequency that most humans can start to hear them at highway speeds, but are too high to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment. If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a throbbing), chances are good that the vehicle could have driveline vibration. This type Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 13253 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 13254 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 13255 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels Wheels: All Technical Service Bulletins Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels TECHNICAL Bulletin No.: 05-03-10-003F Date: April 27, 2010 Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels Supercede: This bulletin is being revised to update the model years and the bulletin reference information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension). Condition Some customers may comment on a low tire pressure condition. Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel. Cause Porosity in the cast aluminum wheel may be the cause. Notice This bulletin specifically addresses issues related to the wheel casting that may result in an air leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat). Correction 1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the tire/wheel assembly in a water bath, or use a spray bottle with soap and water to locate the specific leak location. Important - If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim), the wheel should be replaced. - If two or more leaks are located on one wheel, the wheel should be replaced. 3. If air bubbles are observed, mark the location. - If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks. - If the leak is located on the aluminum wheel area, continue with the next step. 4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose cleaner, such as 3M(R) General Purpose Adhesive Cleaner, P/N 08984, or equivalent. 8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use 88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry. Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging the repair area may result in an air leak. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels > Page 13260 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON Wheels: All Technical Service Bulletins Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON TECHNICAL Bulletin No.: 08-03-10-006C Date: April 27, 2010 Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat) Models: 2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-03-10-006B (Section 03 - Suspension). Condition Some customers may comment on a tire that slowly loses air pressure over a period of days or weeks. Cause Abrasive elements in the environment may intrude between the tire and wheel at the bead seat. There is always some relative motion between the tire and wheel (when the vehicle is driven) and this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear continues, there may also be intrusion at the tire/wheel interface by corrosive media from the environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be visible until the tire is dismounted from the wheel. Notice This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Correction In most cases, this type of air loss can be corrected by following the procedure below. Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to repair the wheel with the procedure below. Notice The repair is no longer advised or applicable for chromed aluminum wheels. 1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to be around the bead seat of the wheel, dismount the tire to examine the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat Corrosion Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 13265 Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for additional information on possible wheel porosity issues. 3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a rough or uneven surface that is difficult for the tire to maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion 4. If corrosion is found on the wheel bead seat, measure the affected area as shown below. - For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. - For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. 5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the corrosion and any flaking paint. You should remove the corrosion back far enough until you reach material that is stable and firmly bonded to the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired surface. Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend to the visible surfaces on the FACE of the wheel, that wheel must be replaced. Important Remove ONLY the material required to eliminate the corrosion from the bead seating surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as smooth and level as possible. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 13266 Acceptably Prepared (Cleaned-Up) Wheel Surface 6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially available tire sealant such as Patch Brand Bead Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat 7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in SI. Parts Information Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 13267 Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion INFORMATION Bulletin No.: 00-03-10-002F Date: April 21, 2011 Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum Wheels Models: 2012 and Prior GM Cars and Trucks Supercede: This bulletin is being revised to update model years, suggest additional restorative products and add additional corrosion information. Please discard Corporate Bulletin Number 00-03-10-002E (Section 03 - Suspension). Important You may give a copy of this bulletin to the customer. What is Chemical Staining of Chrome Wheels? Figure 1 Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an example). These stains are frequently milky, black, or greenish in appearance. They result from using cleaning solutions that contain acids on chrome wheels. Soap and water is usually sufficient to clean wheels. If the customer insists on using a wheel cleaner they should only use one that specifically states that it is safe for chromed wheels and does not contain anything in the following list. (Dealers should also survey any products they use during prep or normal cleaning of stock units for these chemicals.) - Ammonium Bifluoride (fluoride source for dissolution of chrome) - Hydrofluoric Acid (directly dissolves chrome) - Hydrochloric Acid (directly dissolves chrome) - Sodium Dodecylbenzenesulfonic Acid - Sulfamic Acid - Phosphoric Acid - Hydroxyacetic Acid Notice Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal. Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car warranty. Soap and water applied with a soft brush is usually all that is required to clean the calipers. Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean, clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts, lug nut caps, between the wheel cladding and off the back side of the wheel. Wheels returned to the Warranty Parts Center (WPC) that exhibit damage from wheel cleaners most often have the damage around and under the wheel weight where the cleaner was incompletely flushed away. Notice Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 13273 Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome wheels (or any wheels). If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be avoided. For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and Instructions below. Warranty of Stained Chrome Wheels Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be charged back to the dealership. To assist the customer, refer to Customer Assistance and Instructions below. Pitting or Spotted Appearance of Chrome Wheels Figure 2 A second type or staining or finish disturbance may result from road chemicals, such as calcium chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can also stain chrome wheels. The staining will look like small pitting. This staining will usually be on the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward direction while being splashed by the road chemical. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Warranty of Pitted or Spotted Chrome Wheels Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time. Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish and may cause damage if the wheels are not kept clean. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean if they are operating the vehicle in an area that applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). "Stardust" Corrosion of Chrome Wheels Figure 3 A third type of finish disturbance results from prolonged exposure to brake dust and resultant penetration of brake dust through the chrome. As brakes are applied hot particles of brake material are thrown off and tend to be forced through the leading edge of the wheel spoke windows by airflow. These Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 13274 hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the chrome leaving a pit or small blister in the chrome. Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax #M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may be used. It will clean and shine the chrome and leave behind a wax coating that may help protect the finish. Warranty of Stardust Corroded Chrome Wheels Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be replaced one time. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). Customer Assistance and Instructions GM has looked for ways customers may improve the appearance of wheels damaged by acidic cleaners. The following product and procedure has been found to dramatically improve the appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the following: Notice THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER, EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS EXACTLY. 1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce wheel staining. Flood all areas of the wheel with water to rinse. 2. Dry the wheels completely. Notice Begin with a small section of the wheel and with light pressure buff off polish and examine results. ONLY apply and rub with sufficient force and time to remove enough staining that you are satisfied with the results. Some wheels may be stained to the extent that you may only achieve a 50% improvement while others may be able to be restored to the original lustre. IN ALL CASES, only apply until the results are satisfactory. 3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If continued applications fail to improve the appearance further discontinue use. This procedure will improve the appearance of the wheels and may, with repeated applications, restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above procedure may marginally improve the condition but will not restore the finish or remove the pitting. In this type of staining the wheel finish has actually been removed in spots and no manner of cleaning will restore the finish. †*We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 13275 *This product is currently available from 3M. To obtain information for your local retail location please call 3M at 1-888-364-3577. **This product is currently available from Meguiars (Canada). To obtain information for your local retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com. ^ This product is currently available from Tri-Peek International. To obtain information for your local retail location please call Tri-Peek at 1-877-615-4272 or at www.tripeek.com. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires Refinishing Aluminum Wheels Wheels: All Technical Service Bulletins Wheels/Tires - Refinishing Aluminum Wheels INFORMATION Bulletin No.: 99-08-51-007E Date: March 17, 2011 Subject: Refinishing Aluminum Wheels Models: 2012 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 99-08-51-007D (Section 08 - Body and Accessories). This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic refinishing of the wheel's coatings, using recommended procedures, is allowed. Evaluating Damage In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion, scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been refinished by an outside company must be returned to the same vehicle. The Dealer must record the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. Aluminum Wheel Refinishing Recommendations - Chrome-plated aluminum wheels Re-plating these wheels is not recommended. - Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. - Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel. - Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them. In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel should be resurfaced by using a sanding process rather than a machining process. This allows the least amount of material to be removed. Important Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using any of the painting options, it is recommended that all four wheels be refinished in order to maintain color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures and product recommendations. Refinisher's Responsibility - Outside Company Important Some outside companies are offering wheel refinishing services. Such refinished wheels will be permanently marked by the refinisher and are warranted by the refinisher. Any process that re-machines or otherwise re-manufactures the wheel should not be used. A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to assure that the same wheel is returned. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Re-machining of the wheel is not allowed. Paint and/or clear coat must not be present on the following surfaces: the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires Refinishing Aluminum Wheels > Page 13280 longer. Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions Wheels: All Technical Service Bulletins Wheels - Changing Procedures/Precautions INFORMATION Bulletin No.: 06-03-10-010A Date: June 09, 2010 Subject: Information on Proper Wheel Changing Procedures and Cautions Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER Models 2005-2009 Saab 9-7X 2005-2009 Saturn Vehicles Attention: Complete wheel changing instructions for each vehicle line can be found under Tire and Wheel Removal and Installation in Service Information (SI). This bulletin is intended to quickly review and reinforce simple but vital procedures to reduce the possibility of achieving low torque during wheel installation. Always refer to SI for wheel lug nut torque specifications and complete jacking instructions for safe wheel changing. Supercede: This bulletin is being revised to include the 2011 model year and update the available special tool list. Please discard Corporate Bulletin Number 06-03-10-010 (Section 03 Suspension). Frequency of Wheel Changes - Marketplace Driven Just a few years ago, the increasing longevity of tires along with greater resistance to punctures had greatly reduced the number of times wheels were removed to basically required tire rotation intervals. Today with the booming business in accessory wheels/special application tires (such as winter tires), consumers are having tire/wheel assemblies removed - replaced - or installed more than ever. With this increased activity, it opens up more of a chance for error on the part of the technician. This bulletin will review a few of the common concerns and mistakes to make yourself aware of. Proper Servicing Starts With the Right Tools The following tools have been made available to assist in proper wheel and tire removal and installation. - J 41013 Rotor Resurfacing Kit (or equivalent) - J 42450-A Wheel Hub Resurfacing Kit (or equivalent) Corroded Surfaces One area of concern is corrosion on the mating surfaces of the wheel to the hub on the vehicle. Excessive corrosion, dirt, rust or debris built up on these surfaces can mimic a properly tightened wheel in the service stall. Once the vehicle is driven, the debris may loosen, grind up or be washed away from water splash. This action may result in clearance at the mating surface of the wheel and an under-torqued condition. Caution Before installing a wheel, remove any buildup on the wheel mounting surface and brake drum or brake disc mounting surface. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This may cause a wheel to come off when the vehicle is moving, possibly resulting in a loss of control or personal injury. Whenever you remove the tire/wheel assemblies, you must inspect the mating surfaces. If corrosion is found, you should remove the debris with a die grinder equipped with a fine sanding pad, wire brush or cleaning disc. Just remove enough material to assure a clean, smooth mating surface. The J 41013 (or equivalent) can be used to clean the following surfaces: - The hub mounting surface - The brake rotor mounting surface - The wheel mounting surface Use the J 42450-A (or equivalent) to clean around the base of the studs and the hub. Lubricants, Grease and Fluids Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 13285 Some customers may use penetrating oils, grease or other lubricants on wheel studs to aid in removal or installation. Always use a suitable cleaner/solvent to remove these lubricants prior to installing the wheel and tire assemblies. Lubricants left on the wheel studs may cause improper readings of wheel nut torque. Always install wheels to clean, dry wheel studs ONLY. Notice Lubricants left on the wheel studs or vertical mounting surfaces between the wheel and the rotor or drum may cause the wheel to work itself loose after the vehicle is driven. Always install wheels to clean, dry wheel studs and surfaces ONLY. Beginning with 2011 model year vehicles, put a light coating of grease, GM P/N 1051344 (in Canada, P/N 9930370), on the inner surface of the wheel pilot hole to prevent wheel seizure to the axle or bearing hub. Wheel Stud and Lug Nut Damage Always inspect the wheel studs and lug nuts for signs of damage from crossthreading or abuse. You should never have to force wheel nuts down the stud. Lug nuts that are damaged may not retain properly, yet give the impression of fully tightening. Always inspect and replace any component suspected of damage. Tip Always start wheel nuts by hand! Be certain that all wheel nut threads have been engaged BEFORE tightening the nut. Important If the vehicle has directional tread tires, verify the directional arrow on the outboard side of the tire is pointing in the direction of forward rotation. Wheel Nut Tightening and Torque Improper wheel nut tightening can lead to brake pulsation and rotor damage. In order to avoid additional brake repairs, evenly tighten the wheel nuts to the proper torque specification as shown for each vehicle in SI. Always observe the proper wheel nut tightening sequence as shown below in order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off center resulting in vibration. The Most Important Service You Provide While the above information is well known, and wheel removal so common, technicians run the risk of becoming complacent on this very important Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 13286 service operation. A simple distraction or time constraint that rushes the job may result in personal injury if the greatest of care is not exercised. Make it a habit to double check your work and to always side with caution when installing wheels. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Description and Operation > Replacement Wheels Description Wheels: Description and Operation Replacement Wheels Description Replacement Wheels Description Replace the wheel if any of the following conditions exist: * The wheel exhibits excessive runout. * The wheel is bent. * The wheel is cracked. * The wheel is severely rusted. * The wheel is severely corroded. Note: Air leaks caused by porosity on aluminum wheels are repairable. * The wheel leaks air. Warning If you are replacing the wheel(s), the wheel stud(s), the wheel nut(s) or the wheel bolt(s), install only new GM original equipment parts. Installation of used parts or non-GM original equipment parts may cause the wheel to loosen, loss of tire air pressure, poor vehicle handling and loss of vehicle control resulting in personal injury. Caution: The use of non-GM original equipment wheels may cause: * Damage to the wheel bearing, the wheel fasteners and the wheel * Tire damage caused by the modified clearance to the adjacent vehicle components * Adverse vehicle steering stability caused by the modified scrub radius * Damage to the vehicle caused by the modified ground clearance * Speedometer and odometer inaccuracy Replace the wheel, the wheel studs and the wheel/nuts, or the wheel bolts if applicable, if any of the following conditions exist: * The wheel has elongated bolt holes. * The wheel/nuts, or bolts if applicable, loosen repeatedly. Steel wheel identification is stamped into the wheel near the valve stem. Aluminum wheel identification is cast into the inboard side of the wheel. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Description and Operation > Replacement Wheels Description > Page 13289 Wheels: Description and Operation Steel Wheel Repair Description Steel Wheel Repair Description Caution: Do not heat wheels in an attempt to soften them for straightening or repair damage from striking curbs, etc. Do not weld wheels. The alloy used in these wheels is heat-treated and uncontrolled heating from welding affects the properties of the material. Caution: The use of tubes in tubeless tires is not a recommended repair due to the fact that speed ratings are greatly reduced. You can repair porosity in aluminum wheels. If leaks are found in a steel wheel, replace the wheel with a wheel of original equipment quality. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Description and Operation > Page 13290 Wheels: Service and Repair Aluminum Wheel Refinishing Aluminum Wheel Refinishing Guidelines Warning To avoid personal injury when exposed to plastic media blast, hand and/or lathe sanding dust, primer, color coat, and clearcoat, you must work in a properly ventilated area, wearing an approved respirator, eye protection, earplugs and protective gloves and clothing. Evaluating Damage Note: * Inspect the wheel for corrosion, scrapes, gouges, etc. Damage MUST NOT be deeper than what can be sanded or polished off. * Inspect the wheel for cracks. If cracks are found, discard the wheel. * ALL wheels with bent rim flanges must not be repaired or refinished. * The re-machining and the re-clear coating of aluminum wheels is not recommended in the dealer environment due to concerns of repair durability. * Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Aluminum Wheel Refinishing General Recommendations/Options * Painted aluminum wheels use a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. (See option number 1). * If the clearcoat is damaged, it is possible to refinish with clearcoat only, however, the required refinishing process cannot be performed in the dealer environment. Refer to Refinishers Responsibility (Repair option number 2). * Re-plating of chrome-plated aluminum wheels is not recommended. Repair Option Number 1 Material Required/Information Resources * The Paint Manufacturer's Color Book * Refer to the latest GM Approved Refinish Materials Booklet (GM 4901 MD-2005) for specific products for aluminum refinishing. * To access the booklet, go to www.gmgoodwrench.com. Click on GM Collision Parts. Click on GM Technical Repair Information, select Paint Shop. * A Color Compatibility chart is also at this site defining what colors are used on what models. Note: Chemical strippers are not recommended. * Refer to specific Paint Manufacturers for refinish procedures and process pertaining to "Aluminum Refinishing". The procedure requires the wheel surface to be plastic media blasted to remove old paint or clearcoat. General Color Selection * If the wheels being painted were previously clearcoated aluminum, and a painted aluminum look is desired, using Corsican Silver WAEQ9283 for a fine "aluminum-like" look, or Sparkle Silver WA9967 for a very bright look. Body color is another option to the customer that may also be used. * Some specific colors may be recommended on certain models. * If painting wheels that were previously clearcoated aluminum, it is recommended that all 4 wheels and their center caps be refinished to maintain color uniformity. General Refinishing Procedures - Removal 1. Remove the wheels from the vehicle. The tires may remain mounted on the wheels. 2. Remove the balance weights and mark their locations on the tire. 3. Remove excess grease, etc. from the wheels with wax and grease remover. 4. Have the wheels plastic media blasted to remove the clearcoat. Note: MASK OFF ALL MOUNTING SURFACES, whenever a wheel is refinished. The mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. 5. Clean and mask and paint the wheels. General Refinishing Procedures - Installation 1. Unmask the wheels. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Description and Operation > Page 13291 2. Clean all wheel mounting surface of any corrosion, overspray, or dirt. Note: When re-balancing a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. 3. Install NEW coated balance weights at marked locations. Note: Use a torque stick on an impact wrench, or a torque wrench to consistently and uniformly fasten the wheel to the specified torque for the vehicle. The star pattern must be followed. 4. Install wheels on vehicle. Repair Option Number 2 - Outside Companies * Some outside companies are offering wheel refinishing services. One such company, Transwheel Corporation (800-892-3733), provides this service with GM guidelines. Other companies may also exist. * Any process that re-machines or otherwise remanufactures the wheel should not be used. * The wheel ID must be recorded and follow the wheel throughout the process to assure that the same wheel is returned. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is longer. * Paint and/or clearcoat must not be present on the following surfaces, the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. * A refinishers responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications FRONT WHEEL BEARINGS Wheel bearing lubricant meeting requirements of NLGI #2, Category GC or GC-LB (GM Part No. U.S. 1051344, in Canada 993037). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 13295 Wheel Bearing: Testing and Inspection Wheel Bearings Diagnosis Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Wheel Drive Shaft Nut ......................................................................................................................... .................................................... 240 Nm (177 lb ft) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Customer Interest for Wheel Fastener: > 07-03-10-012D > Apr > 11 > Tires/Wheels - Rattle Noise from Wheel Or Hub Cap Wheel Fastener: Customer Interest Tires/Wheels - Rattle Noise from Wheel Or Hub Cap TECHNICAL Bulletin No.: 07-03-10-012D Date: April 12, 2011 Subject: Rattle Noise from Wheel or Hub Cap While Driving, Loose Wheel Nut Caps or Wheel Nut Caps May Not Tighten on Wheel Nuts (Inspect/Replace Wheel Nut Caps As Necessary) Models: 2007-2012 Chevrolet Express, Silverado, Suburban 1500, 2500 and 3500 Series 2007-2012 GMC Savana, Sierra, Yukon XL 1500, 2500 and 3500 Series with 8 Lug Wheel Nut Center Caps (RPOs NX7, NZ7, PY0, PY2, PY9, P03, P25, QB5, QC1, QR5, Q9A) Supercede: This bulletin is being revised to update the model year information. Please discard Corporate Bulletin Number 07-03-10-012C (Section 03 - Suspension). Condition Some customers may comment on a rattle noise from the wheel or hub cap while driving. Other customers may comment on loose wheel nut caps or caps that may not tighten on the wheel nuts. Cause Depending on the generation of the wheel caps, the issue may be overtorqued wheel nut caps or may be caused by the lack of internal threads inside the wheel nut caps. The wheel nut cap (1) is correctly threaded. The wheel nut cap (2) shows the insufficient threads. Correction Important The wheel nut caps are serviced separately from the center wheel hub cap for most hub caps. Refer to the GM electronic parts catalog (EPC) for details. Inspect each wheel nut cap and replace as necessary using the steps below. 1. Remove the wheel hub cap from the vehicle. 2. Place the front of the wheel hub cap down on a protected clean work bench being careful not to scratch or damage the hub cap surface. 3. Inspect all the wheel nut caps, marking any bad wheel nut caps. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Customer Interest for Wheel Fastener: > 07-03-10-012D > Apr > 11 > Tires/Wheels - Rattle Noise from Wheel Or Hub Cap > Page 13308 Tip The bad wheel nut cap can be removed by placing a drift or punch inside the center of the nut cap and using a hammer to tap the wheel nut cap out of the hub cap. 4. From inside the hub cap, apply direct pressure to one side of the wheel nut cap rim (1). The wheel nut cap will tip down and pop out of the wheel hub cap hole when enough pressure is applied. Repeat this procedure for any additional wheel nut caps that need to be replaced. 5. Flip the hub cap over on the work bench. The emblem side should be up. Tip A 22 mm (7/8 in) socket placed over the wheel nut cap may be used along with a hammer to tap the new wheel nut cap back into the hub cap hole. 6. Install the new wheel nut cap into the existing hub cap hole by applying direct pressure to the front center of the wheel nut cap. 7. Install the wheel hub cap onto the vehicle and tighten the wheel nut caps. 8. Repeat this entire procedure for each additional hub cap. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 07-03-10-012D > Apr > 11 > Tires/Wheels - Rattle Noise from Wheel Or Hub Cap Wheel Fastener: All Technical Service Bulletins Tires/Wheels - Rattle Noise from Wheel Or Hub Cap TECHNICAL Bulletin No.: 07-03-10-012D Date: April 12, 2011 Subject: Rattle Noise from Wheel or Hub Cap While Driving, Loose Wheel Nut Caps or Wheel Nut Caps May Not Tighten on Wheel Nuts (Inspect/Replace Wheel Nut Caps As Necessary) Models: 2007-2012 Chevrolet Express, Silverado, Suburban 1500, 2500 and 3500 Series 2007-2012 GMC Savana, Sierra, Yukon XL 1500, 2500 and 3500 Series with 8 Lug Wheel Nut Center Caps (RPOs NX7, NZ7, PY0, PY2, PY9, P03, P25, QB5, QC1, QR5, Q9A) Supercede: This bulletin is being revised to update the model year information. Please discard Corporate Bulletin Number 07-03-10-012C (Section 03 - Suspension). Condition Some customers may comment on a rattle noise from the wheel or hub cap while driving. Other customers may comment on loose wheel nut caps or caps that may not tighten on the wheel nuts. Cause Depending on the generation of the wheel caps, the issue may be overtorqued wheel nut caps or may be caused by the lack of internal threads inside the wheel nut caps. The wheel nut cap (1) is correctly threaded. The wheel nut cap (2) shows the insufficient threads. Correction Important The wheel nut caps are serviced separately from the center wheel hub cap for most hub caps. Refer to the GM electronic parts catalog (EPC) for details. Inspect each wheel nut cap and replace as necessary using the steps below. 1. Remove the wheel hub cap from the vehicle. 2. Place the front of the wheel hub cap down on a protected clean work bench being careful not to scratch or damage the hub cap surface. 3. Inspect all the wheel nut caps, marking any bad wheel nut caps. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 07-03-10-012D > Apr > 11 > Tires/Wheels - Rattle Noise from Wheel Or Hub Cap > Page 13314 Tip The bad wheel nut cap can be removed by placing a drift or punch inside the center of the nut cap and using a hammer to tap the wheel nut cap out of the hub cap. 4. From inside the hub cap, apply direct pressure to one side of the wheel nut cap rim (1). The wheel nut cap will tip down and pop out of the wheel hub cap hole when enough pressure is applied. Repeat this procedure for any additional wheel nut caps that need to be replaced. 5. Flip the hub cap over on the work bench. The emblem side should be up. Tip A 22 mm (7/8 in) socket placed over the wheel nut cap may be used along with a hammer to tap the new wheel nut cap back into the hub cap hole. 6. Install the new wheel nut cap into the existing hub cap hole by applying direct pressure to the front center of the wheel nut cap. 7. Install the wheel hub cap onto the vehicle and tighten the wheel nut caps. 8. Repeat this entire procedure for each additional hub cap. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Page 13315 Wheel Fastener: Specifications Wheel Nuts .......................................................................................................................................... ..................................................... 190 Nm (140 lb ft) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Page 13316 Wheel Fastener: Description and Operation Metric Wheel Nuts and Bolts Description Metric wheel/nuts and bolts are identified in the following way: * The wheel/nut has the word Metric stamped on the face. * The letter M is stamped on the end of the wheel bolt. The thread sizes of metric wheel/nuts and the bolts are indicated by the following example: M12 x 1.5. * M = Metric * 12 = Diameter in millimeters * 1.5 = Millimeters gap per thread Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Suspension Wheel Fastener: Service and Repair Front Suspension Wheel Stud Replacement Tools Required J 43631 Ball Joint Remover Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). 3. Remove the brake rotor. Refer to Front Brake Rotor Replacement (JD9, JF3, JF7, JG4) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Front Brake Rotor Replacement (JD9, JF3, JF7, JG4))Front Brake Rotor Replacement (JH6, JH7) ( See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Front Brake Rotor Replacement (JH6, JH7)). 4. Use the J 43631 to press the stud from the wheel bearing/hub. Installation Procedure 1. Install a new stud. Use washers and a wheel nut and pull the new stud into the hub. 2. Install the brake rotor. Refer to Front Brake Rotor Replacement (JD9, JF3, JF7, JG4) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Front Brake Rotor Replacement (JD9, JF3, JF7, JG4))Front Brake Rotor Replacement (JH6, JH7) ( See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Front Brake Rotor Replacement (JH6, JH7)). 3. Install the tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). 4. Lower the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Suspension > Page 13319 Wheel Fastener: Service and Repair Rear Suspension Wheel Stud Replacement Special Tools J 43631 - Ball Joint Remover For equivalent regional tools, refer to Special Tools (See: Suspension/Tools and Equipment/Rear Suspension) Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). 3. Remove the rear brake drum, if equipped. Refer to Brake Drum Replacement (See: Brakes and Traction Control/Drum Brake System/Brake Drum/Service and Repair/Removal and Replacement). 4. Remove the rear brake rotor, if equipped. Refer to Rear Brake Rotor Replacement (JD9) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JD9))Rear Brake Rotor Replacement (JH6) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JH6))Rear Brake Rotor Replacement (JH7) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JH7)). 5. Using the J 43631 - remover , remove wheel stud from the rear axle shaft. 6. For those vehicles equipped with RPO codes JH6 or JH7, remove the rear axle hub assembly. Refer to Rear Axle Hub, Bearing, Cup, and/or Seal Replacement (See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Bearing/Service and Repair/Rear Axle Hub, Bearing, Cup, and/or Seal Replacement). Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Suspension > Page 13320 1. Position the wheel stud in the rear axle shaft. 2. Using washers and a wheel nut, tighten the wheel nut until the wheel stud is firmly seated in the rear axle shaft. 3. Remove the wheel nut and the washers. 4. Install the rear axle hub assembly, if removed. Refer to Rear Axle Hub, Bearing, Cup, and/or Seal Replacement (See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Bearing/Service and Repair/Rear Axle Hub, Bearing, Cup, and/or Seal Replacement). 5. Install the brake rotor. Refer to Rear Brake Rotor Replacement (JD9) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JD9))Rear Brake Rotor Replacement (JH6) (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JH6))Rear Brake Rotor Replacement (JH7) ( See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Rear Brake Rotor Replacement (JH7)). 6. Install the rear brake drum. Refer to Brake Drum Replacement (See: Brakes and Traction Control/Drum Brake System/Brake Drum/Service and Repair/Removal and Replacement). 7. Install the tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). 8. Remove the supports and lower the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams Air Door Actuator / Motor: Diagrams Component Connector End Views Air Temperature Actuator - Left (CJ2) Air Temperature Actuator - Right (CJ2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Page 13326 Air Temperature Actuator (C67 or C42) Recirculation Actuator (C67 or CJ2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Page 13327 Mode Actuator (C67, C42 or CJ2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > HVAC - Automatic Air Door Actuator / Motor: Service and Repair HVAC - Automatic Air Inlet Valve Actuator Replacement Air Inlet Valve Actuator Replacement Mode Valve Actuator Replacement Mode Valve Actuator Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > HVAC - Automatic > Page 13330 Temperature Valve Actuator Replacement - Right Side Temperature Valve Actuator Replacement - Right Side Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > HVAC - Automatic > Page 13331 Temperature Valve Actuator Replacement - Left Side Temperature Valve Actuator Replacement - Left Side Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > HVAC - Automatic > Page 13332 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > HVAC - Automatic > Page 13333 Air Door Actuator / Motor: Service and Repair HVAC - Manual Air Inlet Valve Actuator Replacement Air Inlet Valve Actuator Replacement Mode Valve Actuator Replacement Mode Valve Actuator Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > HVAC - Automatic > Page 13334 Temperature Valve Actuator Replacement Temperature Valve Actuator Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > HVAC - Automatic > Page 13335 Temperature Valve Actuator Replacement - Left Side Temperature Valve Actuator Replacement - Left Side Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > HVAC - Automatic > Page 13336 Temperature Valve Actuator Replacement - Right Side Temperature Valve Actuator Replacement - Right Side Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Distributor Duct Replacement Air Duct: Service and Repair Air Distributor Duct Replacement Air Distributor Duct Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Distributor Duct Replacement > Page 13341 Air Duct: Service and Repair Floor Air Outlet Duct Replacement - Left Side Floor Air Outlet Duct Replacement - Left Side Removal Procedure 1. Remove the push pin from the left floor air outlet duct (3). 2. Remove the left floor duct (3) from the right floor air outlet duct (2). Installation Procedure 1. Install the left floor air outlet duct (3) to the right floor air outlet duct (2). 2. Install the push pin to the left floor air outlet duct (3). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Distributor Duct Replacement > Page 13342 Air Duct: Service and Repair Floor Air Outlet Duct Replacement - Right Side Floor Air Outlet Duct Replacement - Right Side Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air Distributor Duct Replacement > Page 13343 Air Duct: Service and Repair Air Inlet Assembly Replacement Air Inlet Assembly Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Side Window Air Outlet Replacement Air Register: Service and Repair Side Window Air Outlet Replacement Side Window Air Outlet Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Side Window Air Outlet Replacement > Page 13348 Air Register: Service and Repair Instrument Panel Outer Air Outlet Replacement - Left Side (without RPO SLT) Instrument Panel Outer Air Outlet Replacement - Left Side (without RPO SLT) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Side Window Air Outlet Replacement > Page 13349 Air Register: Service and Repair Instrument Panel Outer Air Outlet Replacement - Left Side (with RPO SLT) Instrument Panel Outer Air Outlet Replacement - Left Side (with RPO SLT) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Side Window Air Outlet Replacement > Page 13350 Air Register: Service and Repair Instrument Panel Center Air Outlet Replacement (without RPO SLT) Instrument Panel Center Air Outlet Replacement (without RPO SLT) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Side Window Air Outlet Replacement > Page 13351 Air Register: Service and Repair Side Window Air Outlet Replacement Side Window Air Outlet Replacement Instrument Panel Outer Air Outlet Replacement - Left Side (without RPO SLT) Instrument Panel Outer Air Outlet Replacement - Left Side (without RPO SLT) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Side Window Air Outlet Replacement > Page 13352 Instrument Panel Outer Air Outlet Replacement - Left Side (with RPO SLT) Instrument Panel Outer Air Outlet Replacement - Left Side (with RPO SLT) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Side Window Air Outlet Replacement > Page 13353 Instrument Panel Center Air Outlet Replacement (without RPO SLT) Instrument Panel Center Air Outlet Replacement (without RPO SLT) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Side Window Air Outlet Replacement > Page 13354 Instrument Panel Center Air Outlet Replacement (With RPO SLT) Instrument Panel Center Air Outlet Replacement (With RPO SLT) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Side Window Air Outlet Replacement > Page 13355 Instrument Panel Outer Air Outlet Replacement - Right Side (Without RPO SLT) Instrument Panel Outer Air Outlet Replacement - Right Side (Without RPO SLT) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Side Window Air Outlet Replacement > Page 13356 Instrument Panel Outer Air Outlet Replacement - Right Side (With RPO SLT) Instrument Panel Outer Air Outlet Replacement - Right Side (With RPO SLT) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Side Window Air Outlet Replacement > Page 13357 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams Ambient Temperature Sensor / Switch HVAC: Diagrams Component Connector End Views Ambient Air Temperature Sensor (CJ2 or C67) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Page 13361 Ambient Temperature Sensor / Switch HVAC: Service and Repair Ambient Air Temperature Sensor Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions Blower Motor: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Schematic Symbols Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13366 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13367 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13368 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13369 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13370 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13371 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13372 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13373 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13374 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13375 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13376 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13377 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13378 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13379 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13380 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13381 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13382 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13383 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13384 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13385 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13386 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13387 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13388 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13389 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13390 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13391 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13392 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13393 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13394 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13395 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13396 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13397 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13398 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13399 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13400 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13401 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13402 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13403 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13404 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13405 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13406 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13407 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13408 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13409 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13410 Blower Motor: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed with Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13411 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13412 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Connector Test Adapters) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13413 Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Test Lamp) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Fused Jumper Wires) * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage Drop) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Frequency) * Testing Ground and Low Reference Circuits (See: Testing and Inspection/Component Tests and General Diagnostics/Testing Ground and Low Reference Circuits) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fuses) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Circuit Breakers) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fusible Links) Troubleshooting with a Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Testing for a Short to Voltage Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13414 Testing for a Short to Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure tests for a short to voltage in a circuit. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the Digital Multimeter (DMM) to the V (DC) position. 4. Connect the positive lead of the DMM to one end of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. Turn ON the ignition and operate all accessories. 7. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Special Tools J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure). Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents). Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13415 The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the frequency of a signal. Note: Connecting the Digital Multimeter (DMM) to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Set to Hz on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13416 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the Digital Multimeter (DMM). 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the difference in voltage potential between 2 points. 1. Set the Digital Multimeter (DMM) to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13417 Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Backprobe Note: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13418 (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for Continuity Testing for Continuity Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures verify good continuity in a circuit. With a Digital Multimeter (DMM) 1. Set the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Select the MIN MAX function on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13419 Testing for Electrical Intermittents Testing for Electrical Intermittents Special Tools J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. Note: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions). 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13420 visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing for Terminal Fretting Some intermittent conditions can be caused by wire terminal fretting corrosion. Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can pile up enough at the electrical contact spots that the electrical resistance across the connection increases. Movement between the contacting surfaces as small as 10 to 100 microns can cause fretting. To put this in perspective, a sheet of paper is about 100 microns thick, so fretting motion is small and hard to see. Vibration and thermal expansion/contraction are the main sources that create fretting motion. Since vehicles vibrate and can experience large temperature swings, they are a good source for fretting motion. Tin, copper, nickel, and iron surfaces are all susceptible to fretting corrosion. Fretting corrosion can be difficult to see but it looks like small, dark smudges on the terminals contact surface. To correct a fretting condition disconnect the suspect connector and add Nyogel lubricant 760G (dielectric grease) to both sides of the connector terminals. Then reconnect the connector and wipe away any excess lubricant. This will correct the additional terminal contact resistance due to the terminal fretting corrosion. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13421 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics). * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Ground Distribution Schematics). Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Checking Aftermarket Accessories). * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13422 Note: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures test for a short to ground in a circuit. With a Digital Multimeter (DMM) 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohms position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Danger: High voltage circuits should only be tested using a digital multimeter (DMM) and test leads with at least a CAT III rating, such as the J 39200-A Digital Multimeter. Failure to follow the procedures exactly as written may result in serious injury or death. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Digital Multimeter (DMM) Basic Requirements Service information is validated using digital multimeters that meet or exceed the following requirements. Using a multimeter that does not meet these basic requirements may give inaccurate readings which could lead to an incorrect diagnosis. Display and Settings 1. Four digits displayed 2. Voltage, amperage, resistance, frequency, diode test settings, and min-max function 3. Display positive and negative values Voltage 1. Have at least 10 M ohm input impedance Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13423 2. Test a DC voltage range of 0.1-1000 V. 3. Test an AC voltage range of 0.1-1000 V. Amperage 1. Test a DC amperage range of 0.1µA-10 A. 2. Test an AC amperage range of 0.1µA-10 A. Resistance Test a resistance range of 0.1 ohm-40 Mohm and displays infinite for a value greater than 40 M ohm (O.L. (Over-load)) Frequency Test for a frequency range of 0.5 HZ-199 K HZ Diode Test 1. Apply at least 1 mA when performing the diode bias test 2. Display the break over voltage drop (0-3 V) of a forward biased diode 3. Display infinite (O.L. (Over-load)) when a diode is reverse biased Min-Max Readings 1. Can update at a 1 ms sample rate 2. Saves and displays minimum and maximum values Note: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Probe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors). * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the EL-38125-580 GM Approved Terminal Release Tool Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the EL-38125-580 GM Approved Terminal Release Tool Kit , ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the EL-38125-580 GM Approved Terminal Release Tool Kit label on the inside of the EL-38125-580 GM Approved Terminal Release Tool Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13424 Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/EPC Connectors AFL/EPC Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13425 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 3. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13426 View showing depressing of the lever lock release tab. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13427 6. Release the rear lower half of the wiredress cover. 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13428 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13429 Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Bosch Connectors (ECM) Bosch Connectors (ECM) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13430 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. 2. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13431 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-bladed tool to release the locking tabs and remove the dress cover. 4. The terminal positive assurance (TPA) is located in the front of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13432 5. Use a small flat-blade tool to remove TPA from the connector. 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13433 Note: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13434 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13435 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Terminal Replacement Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13436 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13437 5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Position Assurance Locks) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Terminal Position Assurance Locks) * AFL/EPC Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/AFL/EPC Connectors) * Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (BSK))Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (0.64))Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (2.8 JPT))Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (ECM)) * Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Weather Pack))Delphi Connectors (Push To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Push to Seat))Delphi Connectors Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13438 (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Pull to Seat))Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro-Pack 100W))Delphi Connectors (Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro .64))Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (12-Way)) * FCI Connectors (Lever Lock) (See: General Electrical Diagnostic Procedures/Connector Repairs/FCI Connectors (Lever Lock)) * JST Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/JST Connectors) * Kostal Connectors (Glow Plug Control Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Glow Plug Control Module))Kostal Connectors (Transmission) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Transmission)) * Molex Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Molex Connectors) * Sumitomo Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Sumitomo Connectors) * Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (CM 42-Way))Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Sensor))Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (0.25 Cap))Tyco/AMP Connectors (43-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (43-Way))Tyco/AMP Connectors (Door Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Door Module))Tyco/AMP Connectors (102-Way Inline) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (102-Way Inline))Tyco/AMP Connectors (Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Seat))Tyco/AMP Connectors (SIR) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (SIR)) * Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (2-Way))Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (16-Way)) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13439 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13440 * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13441 * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13442 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13443 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13444 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Push to Seat) Delphi Connectors (Push To Seat) Special Tools J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13445 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs). 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Terminated Lead Repair 1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice sleeves depending on the gauge size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Delphi Connectors (Pull to Seat) Delphi Connectors (Pull To Seat) Special Tools Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13446 J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Note: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13447 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. View of a typical Micro 64 connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13448 Depress the lock and pull the lever over and past the lock. View of the connector when released from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13449 View of another type of Micro 64 connector. Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13450 View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13451 Note: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13452 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13453 Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Note: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13454 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13455 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13456 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13457 1. Cut the wire as close to the terminal as possible. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13458 Terminal Replacement Procedure After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Special Tools J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Note: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals). 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12-Way) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13459 Delphi Connectors (12-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13460 4. Release the lower wire dress cover locking tab. 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13461 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13462 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors (Lever Lock) FCI Connectors (Lever Lock) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13463 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. The release tab is located on the top of the wiredress cover. 3. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13464 6. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13465 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13466 1. While depressing the lock, remove the connector from the component. 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13467 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. 4. View of the TPA when removed from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13468 5. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Glow Plug Control Module) Kostal Connectors (Glow Plug Control Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13469 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13470 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13471 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. Note: The front TPA cannot be removed from the connector. Only move it to the preset position. 6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm). 7. Use a small flat-blade tool to completely remove the rear TPA from the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13472 8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Transmission) Kostal Connectors (Transmission) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13473 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13474 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Terminal Replacement Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13475 After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13476 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13477 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13478 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13479 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13480 3. To assemble the connector, reverse the connector disassembly procedure. Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13481 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13482 7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13483 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13484 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13485 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13486 Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13487 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13488 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13489 6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (102-Way Inline) Tyco/AMP Connectors (102-Way Inline) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13490 View of a typical connector in the assembled position. 1. Pull the locking lever to the 90 degree position from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13491 2. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal. 3. Slide the male connector body out away from the guide plates. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13492 Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 4. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. 5. Using terminal release tool J 38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13493 6. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 7. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13494 8. The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool J-38125-11A or equivalent to release the locking tab and slide the connector off the female body. 9. Move the locking lever 180 degrees from the connected position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13495 10. With the locking lever in the 180 degree position the guide plates can be removed from the connector body. Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 11. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13496 12. Using terminal release tool J 38125-216, lift the terminal plate past the terminals and out of the connector body cavity. 13. Terminal plate will bind slightly on each corner. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13497 14. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 15. Using terminal release tool J 38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13498 16. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 17. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13499 18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever. 19. Slide the male connector body back inward toward the guide plates. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13500 20. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly. 21. Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Seat) Tyco/AMP Connectors (Seat) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13501 Removal Procedure 1. Grasp the locking slide lever and pull outward from the end of the connector. 2. As the slide lever is pulled out the mating connector is lifted from the seated position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13502 Note: TPA is keyed and can only be inserted in one direction. 3. Using terminal release tool J 38125-11A or equivalent, push the TPA tabs into the connector body. 4. Pull the TPA from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13503 5. Using terminal release tool J 38125-11A or equivalent, release the connector wire dress cover locking tab. 6. With the lock tab released, lift the connector wire dress cover from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13504 7. Using terminal release tool J 38125-212, press the prongs into the holes each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 8. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13505 9. Using terminal release tool J 38125-556, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (SIR) Tyco/AMP Connectors (SIR) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13506 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13507 3. Using terminal tool J-38125-11A or equivalent, release the wire dress cover locking tabs. 4. Pivot connector wire dress cover while removing from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13508 5. Using terminal tool J-38125-11A or equivalent, remove the TPA by lifting straight off the connector body. 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals Repairing Connector Terminals Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13509 Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gauge size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13510 2. Disconnect the connector from the component. 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13511 4. Relieve the tension on the nose piece retainers by inserting J 38125-12A into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. 5. Once the nose piece retainers are relaxed, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13512 6. On the opposite side of the nose piece, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13513 8. Insert the J 38125-553 tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13514 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. If the TPA is removed, be sure to reinstall it before reconnecting the connector. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13515 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Special Tools Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13516 J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Note: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13517 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13518 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13519 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13520 1. While depressing the lock, pull the two connector halves apart. Note: The TPA is fragile and may break if not done carefully. 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. 3. View of the male half of the connector with female terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13521 4. View of the female half of the connector with male terminals. 5. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. View of the female half of the connector with male terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13522 7. View of the male half of the connector with female terminals. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13523 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are a one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine if the element in the fuse is broken (2). If not broken (1), also check for continuity using a Digital Multimeter (DMM) or a continuity tester. If the element is broken or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a Digital Multimeter (DMM) at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gauge size. Repairing a Fusible Link Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13524 Flat Wire Repairs The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Special Tools J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool * J 38125-5 Ultra Torch Special Tool The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Note: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation). GMLAN Connector Terminal Repair Note: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) for the appropriate connector repair procedure. GMLAN Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13525 Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13526 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Special Tools J-38125 Terminal Repair Kit Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13527 repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs High Temperature Wiring Repairs Special Tools J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gauge size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13528 splice. Note: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13529 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13530 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the wire insulation has been chafed, or broken, enough to show the conductive portion of the wire, and the wire is not damaged, determine the length of insulation that needs to be repaired. If the repair is less than 280 mm (11 in), cut the wire within the damaged area. Then slide the appropriate heat shrink tubing (listed below) over the wire, and repair the wire by splicing the wires together. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Once the wire is spliced together slide heat shrink tubing over the damaged area and apply heat to seal the repaired wire. If the wire is damaged, or the damaged area is larger than 280 mm (11 in), then replace the damaged wire by splicing in a new section of wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13531 SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Special Tools J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13532 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13533 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13534 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Special Tools J-38125 Terminal Repair Kit Note: Use only DuraSeal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use DuraSeal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use DuraSeal splice sleeves where there are special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13535 * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13536 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13537 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the instructions for Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Staggering the splices by 65 mm (2.5 in) is recommended. Note: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product AL-36FR to replace the damaged mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Flat Wire Repairs) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/GMLAN Wiring Repairs) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Heated Oxygen Sensor Wiring Repairs) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves) * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Twisted or Shielded Cable) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Inline Harness Diodes) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/SIR/SRS Wiring Repairs) US English/Metric Conversion US English/Metric Conversion Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13538 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13539 Testing Ground and Low Reference Circuits Testing Ground and Low Reference Circuits Because a test lamp can light with up to 200 ohm in a ground or low reference circuit they are not recommended to be used for this type of test. A low impedance test lamp can light and indicate the circuit is good when there is as much as 20-30 ohm present, while a high impedance test lamp can light with up to 200 ohm present in the circuit. This is why the Digital Multi-Meter (DMM) is used when validating a ground or low reference circuit continuity. When using the DMM there are many vehicle conditions that can affect the ground and low reference continuity testing. If these conditions are not met, a ground or low reference circuit test can fail on a good circuit. This may cause longer diagnosis time and incorrect component replacement. Any current flow through a ground or low reference circuit, while being tested, will skew the DMM continuity reading, or display a reading higher than when there is no current flowing. Performing a ground or low reference circuit continuity test, in reference to the vehicles battery negative terminal, will have the highest risk of failing a good ground or low reference circuit test than any other ground reference point. The best ground test points would be a control module housing (if the control modules housing is metal and grounded), door jamb striker (if attached to metal), under dash metal frame work, engine block, or body ground studs (other than where the negative battery cable is attached). A typical DMM ground or low reference circuit continuity reading can be as high as 100 ohm with the ignition ON, and drop to 15-25 ohm after the ignition is turned OFF. The reading will drop below 10 ohm after 30-40 seconds, then below 5 ohm after 60 seconds. Once the vehicle completely goes to sleep (generally 3-10 minutes) the reading will drop below 0.3 ohm. The following list of conditions may need to be met to ensure a valid continuity reading on a ground or low reference circuit: * Ignition OFF * Key out of the ignition switch (when not equipped with keyless entry and remote start) * Retained Accessory Power (RAP) OFF (open and close the driver door after ignition OFF) * Battery charger set at a 2 A or less charge rate * Scan tool not communicating with any vehicle control module (in some cases it may need to be disconnected from the DLC) * All entry doors closed * Headlamps OFF (auto headlamps disabled) * Any delay lighting OFF * HVAC after blow OFF * Any accessory that can work when the ignition is OFF * Wait up to 60 seconds (after all other listed conditions are met) Activating the DOOR LOCK function with a key fob can greatly reduce the time to achieve a valid ground or low reference continuity test result. Terminal Removal Terminal Removal Special Tools * EL-38125-580 - Terminal Release Tool Kit * EL-35616 - Connector Test Adapter Kit For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repair procedures. 1. Find the appropriate connector end view within the connector end view section. The connector end view has the following information: Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13540 * Diagnostic probe tool * Terminal release tool * Terminal/terminated lead part numbers Note: Not using the proper test kit probe may cause damage to the terminal(s) that are probed. 2. Determine if a terminal is damaged. * Locate the diagnostic probe tool from the connector end view. The connector end view describes the color and part number to help the technician find and use the correct tool. * Connect the probe tool to the Digital Multimeter. * Insert the probe tool into the cavity and follow the procedures from the Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter). 3. Disconnect the connector body to perform the repair. 4. Use the following procedure to remove the terminal from the connector body. Note: Several procedures for specific connector bodies are called out in the Wiring Repairs section. * The terminal position assurance (TPA) and connector position assurance (CPA) should be removed before releasing the terminal for the connector body. * Look at the connector end view to locate the cavity of the damaged terminal and find the proper terminal release tool from the terminal release tool kit. Note: Using the incorrect terminal release tool can damage the connector body. * Insert the terminal release tool into the cavity. Note: Some terminals have a lever that must be disengaged before the terminal can be released. 5. Gently pull the wire out of the back of the connector. 6. Repair the terminal by following the Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) procedure. 7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminated Lead Repair Terminated Lead Repair Special Tools * J-38125-8 - Splice Sleeve Crimp Tool Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13541 * J-38125-5 - Ultra Torch For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) procedures. Terminated leads are terminals that are crimped onto wires. The terminated lead can be used throughout the vehicle since it is designed for temperatures up to 150°C. The length of the wire is 450 mm. The DuraSeal splice sleeve has the following 2 critical features: * A special heat shrink tubing that environmentally seals the splice. The shrink tubing contains a sealing adhesive inside the shrink tubing. * A cross hatched (knurled) core crimp that provides the necessary contact integrity for sensitive low energy circuits. 1. Use the connector end view to identify the correct terminated lead. 2. The terminated lead package should include a DuraSeal splice sleeve. If not, use the chart to identify the correct part. 3. Open the harness by removing any tape: Use a sewing seam ripper, or a comparable tool, to cut open the harness, to avoid wire insulation damage. 4. Depending on how many terminals need repairs, cut the terminal and wire back at least 40 mm. Try to keep the harness wire length the same. If more than one terminated lead is required, stagger the lengths by 40 mm. This helps reduce the bundle size of the wire harness. 5. Use the EL-38125-10 - tool in order to position the DuraSeal splice sleeve in the proper color nest of the splice sleeve crimp tool. The crimp tool has four nests, one for each color. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13542 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the J-38125-5 - ultra torch , apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 13543 Blower Motor: Connector Views Component Connector End Views Blower Motor Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Page 13544 Blower Motor: Service and Repair Blower Motor Replacement Removal Procedure 1. If equipped, remove the sound insulator panel. Refer to Instrument Panel Insulator Replacement (With RPO SLT) (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Insulator Replacement (With RPO SLT))Instrument Panel Insulator Replacement (Without RPO SLT) (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Insulator Replacement (Without RPO SLT)). 2. Remove the blower motor insulating cover screws. 3. Disconnect the electrical connector from the blower motor. 4. Remove the blower motor insulating cover. 5. Pull the retaining tab down while turning the blower motor counterclockwise in order to disengage the blower motor from the heater/ventilation module. 6. Remove the blower motor. Installation Procedure 1. Install the blower motor. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Page 13545 2. Install the blower motor to the heater/ventilation module. Turn the blower assembly clockwise until the retaining tab locks into place. 3. Install the blower motor insulating cover. 4. Connect the electrical connector to the blower motor. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Install the blower motor insulating cover screws and tighten to 1.6 Nm (14 lb in). 6. If equipped, install the sound insulator panel. Refer to Instrument Panel Insulator Replacement (With RPO SLT) (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Insulator Replacement (With RPO SLT))Instrument Panel Insulator Replacement (Without RPO SLT) (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Insulator Replacement (Without RPO SLT)). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information > Service and Repair Cabin Temperature Sensor / Switch: Service and Repair Inside Air Temperature Sensor Replacement Removal Procedure 1. Remove the left windshield garnish molding. Refer to Windshield Pillar Garnish Molding Replacement (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Windshield Pillar Garnish Molding Replacement). 2. Remove the left center pillar assist handle. Refer to Roof Rail Rear Assist Handle Replacement (See: Body and Frame/Interior Moulding / Trim/Passenger Assist Handle/Service and Repair/Roof Rail Rear Assist Handle Replacement). 3. Remove the center pillar garnish molding. Refer to Center Pillar Upper Garnish Molding Replacement (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Center Pillar Upper Garnish Molding Replacement). 4. Remove the left sunshade. Refer to Sunshade Replacement (See: Body and Frame/Interior Moulding / Trim/Sun Visor/Service and Repair). 5. Gently pull down the headliner. 6. Disconnect the electrical connector from the inside air temperature sensor. 7. Partially remove the inside air temperature sensor from the headliner. 8. Remove the sensor grille from the inside air temperature sensor. 9. Remove the inside air temperature sensor from the headliner. Installation Procedure 1. Install the new sensor grille to the headliner. 2. Install the inside air temperature sensor to the headliner and sensor grille. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information > Service and Repair > Page 13549 3. Connect the electrical connector to the inside air temperature sensor. 4. Install the left sunshade. Refer to Sunshade Replacement (See: Body and Frame/Interior Moulding / Trim/Sun Visor/Service and Repair). 5. Install the left center pillar garnish molding. Refer to Center Pillar Upper Garnish Molding Replacement (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Center Pillar Upper Garnish Molding Replacement). 6. Install the left center assist handle. Refer to Roof Rail Rear Assist Handle Replacement (See: Body and Frame/Interior Moulding / Trim/Passenger Assist Handle/Service and Repair/Roof Rail Rear Assist Handle Replacement). 7. Install the left windshield garnish molding. Refer to Windshield Pillar Garnish Molding Replacement (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Windshield Pillar Garnish Molding Replacement). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Cabin Ventilation Grille > Component Information > Service and Repair Cabin Ventilation Grille: Service and Repair Pressure Relief Valve Replacement Removal Procedure 1. Remove the rear window lower garnish molding. Refer to Rear Window Lower Garnish Molding Replacement (Ext Cab/Crew Cab w/A48) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Rear Window Lower Garnish Molding Replacement (Ext Cab/Crew Cab w/A48))Rear Window Lower Garnish Molding Replacement (Ext Cab/Crew Cab w/o A48) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Rear Window Lower Garnish Molding Replacement (Ext Cab/Crew Cab w/o A48))Rear Window Lower Garnish Molding Replacement (Regular Cab) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Rear Window Lower Garnish Molding Replacement (Regular Cab)) 2. Remove the body lock pillar trim. Refer to Body Lock Pillar Trim Replacement (Crew Cab) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Body Lock Pillar Trim Replacement (Crew Cab))Body Lock Pillar Trim Replacement (Extended Cab) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Body Lock Pillar Trim Replacement (Extended Cab))Body Lock Pillar Trim Replacement (Regular Cab) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Body Lock Pillar Trim Replacement (Regular Cab)) 3. Pull back carpeting on the rear wall of the cab exposing the pressure relief valve. 4. Press on the retaining tab on the top downward to release the valve from the cab back panel. 5. Remove the pressure relief valve from the vehicle. Installation Procedure 1. Align the pressure relief valve into the opening of the rear cab. 2. Press the pressure relief valve into the cab back panel until the locking tabs are fully seated. 3. Realign carpeting on the rear wall of the cab to lay flat. 4. Install the body lock pillar trim. Refer to Body Lock Pillar Trim Replacement (Crew Cab) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Body Lock Pillar Trim Replacement (Crew Cab))Body Lock Pillar Trim Replacement (Extended Cab) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Body Lock Pillar Trim Replacement (Extended Cab))Body Lock Pillar Trim Replacement (Regular Cab) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Body Lock Pillar Trim Replacement (Regular Cab)) 5. Install the rear window lower garnish molding. Refer to Rear Window Lower Garnish Molding Replacement (Ext Cab/Crew Cab w/A48) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Rear Window Lower Garnish Molding Replacement (Ext Cab/Crew Cab w/A48))Rear Window Lower Garnish Molding Replacement (Ext Cab/Crew Cab w/o A48) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Rear Window Lower Garnish Molding Replacement (Ext Cab/Crew Cab w/o A48))Rear Window Lower Garnish Molding Replacement (Regular Cab) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Rear Window Lower Garnish Molding Replacement (Regular Cab)) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications Compressor Clutch: Specifications Pulley To Drive Plate Air Gap .............................................................................................................................................. 0.35-0.65 mm (0.014-0.026 in) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 13557 Compressor Clutch: Diagrams Component Connector End Views A/C Compressor Clutch (C67) A/C Compressor Clutch (CJ2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 13558 Compressor Clutch: Adjustments Air Conditioning Clutch Drive Plate Adjustment 1. Install the clutch plate assembly. Note: Ensure the drive plate does not drag against the pulley when the pulley is rotated. 2. Measure the air gap between the pulley and the drive plate. Adjust the shims to achieve a 0.35-0.65 mm (0.014-0.026 in) air gap. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the clutch plate retaining bolt and tighten to 18 Nm (13 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Hub > Component Information > Service and Repair Compressor Clutch Hub: Service and Repair Compressor Clutch Plate/Hub Assembly Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Hub > Component Information > Service and Repair > Page 13562 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations Compressor Clutch Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 13566 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 13567 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 13568 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 13569 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 13570 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 13571 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 13572 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Service and Repair Condenser HVAC: Service and Repair Air Conditioning Condenser Replacement (LMM Diesel) Special Tools J 39400-A Halogen Leak Detector Removal Procedure 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging (Non-HP2) (See: Refrigerant/Service and Repair)Refrigerant Recovery and Recharging (HP2) (See: Service and Repair). 2. Remove tie bar. Refer to Front End Upper Tie Bar Replacement (See: Body and Frame/Radiator Support/Service and Repair/Front End Upper Tie Bar Replacement). 3. Remove the hood stop bracket. Refer to Hood Stop Bracket Replacement (See: Body and Frame/Doors, Hood and Trunk/Hood/Hood Stop/Service and Repair/Hood Stop Bracket Replacement). 4. Remove radiator support bolts (1). Access the bolts from the rear of the upper radiator support. 5. Remove radiator support. 6. Remove the compressor discharge hose assembly bolt from the condenser. 7. Disconnect the compressor discharge hose assembly from the condenser. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Service and Repair > Page 13576 8. Remove the evaporator tube nut from the condenser. 9. Disconnect the evaporator tube from the condenser. 10. Remove the insulator retainer bolts and the upper insulator retainers. 11. Remove the condenser from the vehicle. Installation Procedure Note: If replacing the condenser, add the refrigerant oil to the condenser. Refer to Refrigerant Recovery and Recharging (Non-HP2) (See: Refrigerant/Service and Repair)Refrigerant Recovery and Recharging (HP2) (See: Service and Repair) for system capacity information. 1. Install the condenser to the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the upper insulator retainers and the insulator retainer bolts. Tighten the bolts to 2.4 Nm (21 lb in). 3. Connect the evaporator tube to the condenser using new sealing washers. Refer to Air Conditioning System Seal Replacement (See: Coupler HVAC/A/C Coupler O-ring/Service and Repair/Air Conditioning System Seal Replacement). 4. Install the evaporator tube nut to the condenser. Tighten the nut to 16 Nm (12 lb ft). 5. Connect the compressor discharge hose to the condenser using new sealing washers. Refer to Air Conditioning System Seal Replacement (See: Coupler HVAC/A/C Coupler O-ring/Service and Repair/Air Conditioning System Seal Replacement). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Service and Repair > Page 13577 6. Install the compressor discharge hose nut to the condenser. Tighten the nut to 16 Nm (12 lb ft). 7. Install tie bar. Refer to Front End Upper Tie Bar Replacement (See: Body and Frame/Radiator Support/Service and Repair/Front End Upper Tie Bar Replacement). 8. Install the hood stop bracket. Refer to Hood Stop Bracket Replacement (See: Body and Frame/Doors, Hood and Trunk/Hood/Hood Stop/Service and Repair/Hood Stop Bracket Replacement). 9. Install the radiator support. Access the bolts (1) from the rear of the upper radiator support. Refer to Radiator Support Replacement (See: Body and Frame/Radiator Support/Service and Repair/Radiator Support Replacement). Tighten the nut to 16 Nm (12 lb ft). 10. Install radiator support bracket bolts (1). 11. Evacuate and recharge the system. Refer to Refrigerant Recovery and Recharging (Non-HP2) (See: Refrigerant/Service and Repair)Refrigerant Recovery and Recharging (HP2) (See: Service and Repair). 12. Leak test the fittings of the component using the J 39400-A . Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > Customer Interest for Control Module HVAC: > 11-01-38-001 > Feb > 11 > A/C - Excessive Cabin Moisture/Reduced Window Clearing Control Module HVAC: Customer Interest A/C - Excessive Cabin Moisture/Reduced Window Clearing TECHNICAL Bulletin No.: 11-01-38-001 Date: February 28, 2011 Subject: Excessive Cabin Moisture / Reduced Window Clearing (Reprogram HVAC System Control Module) Models: 2010-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2010-2011 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL All with RPO CJ3 or C67 (Manual Air Conditioning) Condition In rare cases, some customers may comment on excessive cabin moisture or difficulty keeping the windows clear in low ambient temperatures. Cause This concern may be caused by the recirculation door being in the recirculation position while the mode is set to a floor through defrost position. Correction Important DO NOT replace the HVAC control module for this concern. Revised software has been developed to address this condition. Technicians are to reprogram the HVAC Control Module using the Service Programming System (SPS) with the latest software currently available in TIS2WEB. When using a Tech 2(R) or a Multiple Diagnostic Interface (MDI) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > Customer Interest for Control Module HVAC: > 10-01-38-001 > Mar > 10 > A/C - Reduced Windshield Clearing/Defrost Control Module HVAC: Customer Interest A/C - Reduced Windshield Clearing/Defrost TECHNICAL Bulletin No.: 10-01-38-001 Date: March 02, 2010 Subject: Reduced Windshield Clearing\Defrost at Low Ambient Temperatures (Reprogram HVAC Control Module) Models: 2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2010 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon XL Denali All Equipped with HVAC System RPOs C42, C67 or CJ3 All Built Prior to February 17, 2010 Condition In rare cases, some customers may comment that the HVAC system has reduced defrost or added difficulty keeping the windshield clear in low ambient temperatures. Cause This condition may be caused by the airflow calibrations which can contribute to the above condition. Calibration changes at the start of the 2010 model year may not meet some customers' expectations. Testing has confirmed that defrost levels will meet requirements. Correction Important DO NOT replace the HVAC Control Module for this concern. Reprogram the HVAC Control Module with the latest software calibration. Important Select the correct calibration files for the appropriate vehicle configuration (body style) and RPO codes. A revised calibration has been developed to address this condition. Technicians are to reprogram the HVAC Control Module using the Service Programming System (SPS) with the latest calibrations available on TIS2WEB. Refer to HVAC System Control Module Programming and Setup in SI. When using a Tech 2(R) or a Multiple Diagnostic Interface (MDI) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 11-01-38-001 > Feb > 11 > A/C Excessive Cabin Moisture/Reduced Window Clearing Control Module HVAC: All Technical Service Bulletins A/C - Excessive Cabin Moisture/Reduced Window Clearing TECHNICAL Bulletin No.: 11-01-38-001 Date: February 28, 2011 Subject: Excessive Cabin Moisture / Reduced Window Clearing (Reprogram HVAC System Control Module) Models: 2010-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2010-2011 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL All with RPO CJ3 or C67 (Manual Air Conditioning) Condition In rare cases, some customers may comment on excessive cabin moisture or difficulty keeping the windows clear in low ambient temperatures. Cause This concern may be caused by the recirculation door being in the recirculation position while the mode is set to a floor through defrost position. Correction Important DO NOT replace the HVAC control module for this concern. Revised software has been developed to address this condition. Technicians are to reprogram the HVAC Control Module using the Service Programming System (SPS) with the latest software currently available in TIS2WEB. When using a Tech 2(R) or a Multiple Diagnostic Interface (MDI) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 10-01-38-001 > Mar > 10 > A/C Reduced Windshield Clearing/Defrost Control Module HVAC: All Technical Service Bulletins A/C - Reduced Windshield Clearing/Defrost TECHNICAL Bulletin No.: 10-01-38-001 Date: March 02, 2010 Subject: Reduced Windshield Clearing\Defrost at Low Ambient Temperatures (Reprogram HVAC Control Module) Models: 2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2010 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon XL Denali All Equipped with HVAC System RPOs C42, C67 or CJ3 All Built Prior to February 17, 2010 Condition In rare cases, some customers may comment that the HVAC system has reduced defrost or added difficulty keeping the windshield clear in low ambient temperatures. Cause This condition may be caused by the airflow calibrations which can contribute to the above condition. Calibration changes at the start of the 2010 model year may not meet some customers' expectations. Testing has confirmed that defrost levels will meet requirements. Correction Important DO NOT replace the HVAC Control Module for this concern. Reprogram the HVAC Control Module with the latest software calibration. Important Select the correct calibration files for the appropriate vehicle configuration (body style) and RPO codes. A revised calibration has been developed to address this condition. Technicians are to reprogram the HVAC Control Module using the Service Programming System (SPS) with the latest calibrations available on TIS2WEB. Refer to HVAC System Control Module Programming and Setup in SI. When using a Tech 2(R) or a Multiple Diagnostic Interface (MDI) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > Page 13599 Control Module HVAC: Diagrams Component Connector End Views HVAC Control Module X1 (CJ2) HVAC Control Module X2 (C67, C42 or MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > Page 13600 HVAC Control Module X2 (CJ2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > Page 13601 HVAC Control Module X3 (C67, C42, CJ2 or MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > Page 13602 Blower Motor Control Module X1 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > Page 13603 Blower Motor Control Module X2 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > Page 13604 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Service and Repair > HVAC - Automatic Control Module HVAC: Service and Repair HVAC - Automatic HVAC Control Module Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Service and Repair > HVAC - Automatic > Page 13607 Control Module HVAC: Service and Repair HVAC - Manual HVAC Control Module Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Service and Repair > HVAC - Automatic > Page 13608 Control Module HVAC: Service and Repair Blower Motor Control Module Replacement Blower Motor Control Module Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > A/C Coupler O-ring > Component Information > Service and Repair > Air Conditioning System Seal Replacement A/C Coupler O-ring: Service and Repair Air Conditioning System Seal Replacement Air Conditioning System Seal Replacement Removal Procedure 1. Remove the seal washer from the A/C refrigerant component. Important: Cap or tape the open A/C refrigerant components immediately to prevent system contamination. 2. Inspect the seal washer for signs of damage to help determine the root cause of the failure. 3. Inspect the A/C refrigerant components for damage or burrs. Repair if necessary. Important: DO NOT reuse sealing washer. 4. Discard the sealing washer. Installation Procedure Important: Flat washer type seals do not require lubrication. 1. Inspect the new seal washer for any signs of cracks, cuts, or damage. Do not use a damaged seal washer. 2. Remove the cap or tape from the A/C refrigerant components. 3. Using a lint-free clean, dry cloth, clean the sealing surfaces of the A/C refrigerant components. 4. Carefully install the new seal washer onto the A/C refrigerant component. The washer must completely bottom against the surface of the fitting. Important: After tightening the A/C components, there should be a slight sealing washer gap of approximately 1.2 mm (3/64 in) between the A/C line and the A/C component. 5. Assemble the remaining A/C refrigerant components. Refer to the appropriate repair procedure. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > A/C Coupler O-ring > Component Information > Service and Repair > Air Conditioning System Seal Replacement > Page 13614 A/C Coupler O-ring: Service and Repair Air Conditioning O-Ring Seal Replacement Air Conditioning O-Ring Seal Replacement Removal Procedure 1. Disassemble the A/C refrigerant components. Refer to the appropriate repair procedure * For compression style fittings use a back up wrench on the fitting (2) and loosen the fitting nut (1). * For banjo style fittings remove the bolt retaining the banjo type fitting. 2. Remove the O-ring seal from the A/C refrigerant component. 3. Inspect the O-ring seal for signs of damage to help determine the root cause of the failure. 4. Inspect the A/C refrigerant components for damage or burrs. Repair if necessary. Important: Cap or tape the open A/C refrigerant components immediately to prevent system contamination. 5. Cap or tape the A/C refrigerant components. 6. Discard the O-ring seal. Installation Procedure 1. Inspect the new O-ring seal for any sign or cracks, cuts, or damage. Replace if necessary. 2. Remove the cap or tape from the A/C refrigerant components. 3. Using a lint-free clean, dry cloth, carefully clean the sealing surfaces of the A/C refrigerant components. Important: DO NOT allow any of the mineral base 525 viscosity refrigerant oil on the new O-ring seal to enter the refrigerant system. 4. Lightly coat the new O-ring seal with mineral base 525 viscosity refrigerant oil. Important: DO NOT reuse O-ring seals. 5. Carefully slide the new O-ring seal onto the A/C refrigerant component. 6. The O-ring seal must be fully seated. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > A/C Coupler O-ring > Component Information > Service and Repair > Air Conditioning System Seal Replacement > Page 13615 7. Assemble the A/C components. Refer to the appropriate repair procedure. * For compression style fittings use a back up wrench on the fitting (2) and tighten the fitting nut (1) to specification. * For banjo style fittings install the bolt retaining the banjo type fitting and tighten to specification. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Service and Repair > Duct Air Temperature Sensor Replacement - Lower Left Side Discharge Air Temperature Sensor / Switch: Service and Repair Duct Air Temperature Sensor Replacement - Lower Left Side Duct Air Temperature Sensor Replacement - Lower Left Side Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Service and Repair > Duct Air Temperature Sensor Replacement - Lower Left Side > Page 13620 Discharge Air Temperature Sensor / Switch: Service and Repair Duct Air Temperature Sensor Replacement - Lower Right Side Duct Air Temperature Sensor Replacement - Lower Right Side Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Service and Repair > Duct Air Temperature Sensor Replacement - Lower Left Side > Page 13621 Discharge Air Temperature Sensor / Switch: Service and Repair Duct Air Temperature Sensor Replacement - Upper Left Side Duct Air Temperature Sensor Replacement - Upper Left Side Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Service and Repair > Duct Air Temperature Sensor Replacement - Lower Left Side > Page 13622 Discharge Air Temperature Sensor / Switch: Service and Repair Duct Air Temperature Sensor Replacement - Upper Right Side Duct Air Temperature Sensor Replacement - Upper Right Side Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From (HVAC) System Evaporator Core: Customer Interest A/C - Musty Odors Emitted From (HVAC) System TECHNICAL Bulletin No.: 99-01-39-004C Date: June 12, 2009 Subject: Air Conditioning Odor (Install Evaporator Core Dryer Kit and Apply Cooling Coil Coating) Models: 1993-2010 GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 All Equipped with Air Conditioning Supercede: This bulletin is being revised to add the 2009 and 2010 model years. Please discard Corporate Bulletin Number 99-01-39-004B (Section 01 - HVAC). Condition Some customers may comment about musty odors emitted from the Heating, Ventilation and Air Conditioning (HVAC) system at vehicle start-up in hot, humid conditions. Cause This condition may be caused by condensate build-up on the evaporator core, which does not evaporate by itself in high humidity conditions. The odor may be the result of microbial growth on the evaporator core. When the blower motor fan is turned on, the microbial growth may release an unpleasant musty odor into the passenger compartment. There are several other possible sources of a musty odor in a vehicle. A common source is a water leak into the interior of the vehicle or foreign material in the HVAC air distribution system. Follow the procedures in SI for identifying and correcting water leaks and air inlet inspection. The procedure contained in this bulletin is only applicable if the odor source has been determined to be microbial growth on the evaporator core inside the HVAC module. Correction Many vehicles currently incorporate an afterblow function within the HVAC control module software. The afterblow feature, when enabled, employs the HVAC blower fan to dry the evaporator after vehicle shut down and this function will inhibit microbial growth. Technicians are to confirm that the customer concern is evaporator core odor and that the vehicle has the imbedded afterblow feature, as defined in the SI document for that specific vehicle model, model year and specific HVAC option. Refer to SI for enabling the afterblow function. Vehicles being delivered in areas prone to high humidity conditions may benefit from having the afterblow enabled calibration installed prior to any customer comment. Important If the vehicle is not factory equipped with the imbedded afterblow enable feature, it may be added with the Electronic Evaporator Dryer Module Kit (P/N 12497910 or AC Delco 15-5876). Important When installing the Electronic Evaporator Dryer Module, you MUST use the included electrical splice connectors to ensure a proper splice. Complete detailed installation instructions and self testing procedures are supplied with the kit. If necessary, the Electronic Evaporator Dryer Module may be installed underhood if it is protected from extreme heat and water splash areas. To immediately remove the evaporator core odor on all suspect vehicles, it is necessary to eliminate the microbial growth and prevent its re-occurrence. To accomplish this, perform the following procedure: Vehicle and Applicator Tool Preparation 1. The evaporator core must be dry. This may be accomplished by disabling the compressor and running the blower fan on the recirc heat setting for an extended period of time. Note Compressor engagement will cause the evaporator core to remain wet and will prevent full adherence of the Coiling Coil Coating to the evaporator core surfaces. 2. Verify that the air conditioning drain hose is not clogged and place a drain pan beneath the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From (HVAC) System > Page 13631 3. Place a protective cover over the carpet below the evaporator core. 4. Remove the cabin air filter, if equipped, and cover the opening prior to applying the Cooling Coil Coating, as the product may clog the filter. If the cabin air filter appears to have little or no remaining life, suggest a replacement to your customer. 5. If the HVAC module has a blower motor cooling tube, be careful NOT TO SPRAY THE COOLING COIL COATING INTO THE BLOWER MOTOR COOLING TUBE. 6. Attach the Flexible Applicator Pressure Spray Tool (J-43810-20A) to a compressed air line operating at 586 kPa (85 psi) to 793 kPa (115 psi). 7. Shake the bottle of Cooling Coil Coating well. Screw the bottle onto the cap on the applicator tool's pick-up tube. Note The pick-up tube is designed for 120 ml (4 oz) and 240 ml (8 oz) bottles and should coil slightly in the bottom of a 120 ml (4 oz) bottle. 8. Use one of the following three methods to apply the Cooling Coil Coating. Important If the Pressure Applicator Spray Tool (J-43810-20A) is not available, the Cooling Coil Coating is also available in an aerosol can (P/N 12377951 (in Canada, 10953503)). Application Through Blower Motor Control Module Opening - Remove the blower motor control module (blower motor resistor). Refer to the applicable procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor blower motor control module (blower motor resistor) opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor blower motor control module (blower motor control module). Application Through Blower Motor Opening - Remove the blower motor. Refer to the applicable blower motor removal procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor. Application Through a Hole in the HVAC Module - If neither of the two previous application methods are available, it may be necessary to drill a hole in the HVAC module. - Locate an area of the HVAC module between the blower motor and the evaporator core. Drill a 10 mm (3/8 in) hole in the HVAC module. Use caution to keep the drill clear of the evaporator core and the blower motor fan. - With the air distribution vents closed and the blower motor fan speed on HIGH, insert the applicator tool into the hole and spray the Cooling Coil Coating into the airstream toward the evaporator core. - Use a GM approved RTV sealant to plug the hole in the HVAC module. 9. After the Cooling Coil Coating application is complete, start and run the vehicle for approximately 10 minutes, with the compressor disabled, HVAC mode set to Recirculate/Max, heat set to full warm, blower motor fan speed on high, and one window open approximately 12 mm (1/2 in). This cures the Cooling Coil Coating onto the evaporator core surface. 10. While the engine is running, rinse the applicator tool with warm water to prolong the life of the tool. Be sure to spray warm water through the nozzle to rinse out any residual Cooling Coil Coating still in the capillary pick up tube, otherwise it will dry and clog the applicator tool. Also remove the small green valve from the bottle cap and rinse it thoroughly while rolling it between two fingers and then reinstall it. If this valve is clogged , the Cooling Coil Coating will not flow through the applicator tool. 11. Shut off the engine and enable the compressor again. 12. Verify proper HVAC system operation. 13. Remove the protective cover from inside the vehicle. 14. Remove the drain pan from underneath the vehicle. 15. Reinstall the cabin air filter if necessary. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From (HVAC) System > Page 13632 Parts Information Important The Cooling Coil Coating listed below is the only GM approved product for use under warranty as an evaporator core disinfectant and for the long term control of evaporator core microbial growth. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From (HVAC) System Evaporator Core: All Technical Service Bulletins A/C - Musty Odors Emitted From (HVAC) System TECHNICAL Bulletin No.: 99-01-39-004C Date: June 12, 2009 Subject: Air Conditioning Odor (Install Evaporator Core Dryer Kit and Apply Cooling Coil Coating) Models: 1993-2010 GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 All Equipped with Air Conditioning Supercede: This bulletin is being revised to add the 2009 and 2010 model years. Please discard Corporate Bulletin Number 99-01-39-004B (Section 01 - HVAC). Condition Some customers may comment about musty odors emitted from the Heating, Ventilation and Air Conditioning (HVAC) system at vehicle start-up in hot, humid conditions. Cause This condition may be caused by condensate build-up on the evaporator core, which does not evaporate by itself in high humidity conditions. The odor may be the result of microbial growth on the evaporator core. When the blower motor fan is turned on, the microbial growth may release an unpleasant musty odor into the passenger compartment. There are several other possible sources of a musty odor in a vehicle. A common source is a water leak into the interior of the vehicle or foreign material in the HVAC air distribution system. Follow the procedures in SI for identifying and correcting water leaks and air inlet inspection. The procedure contained in this bulletin is only applicable if the odor source has been determined to be microbial growth on the evaporator core inside the HVAC module. Correction Many vehicles currently incorporate an afterblow function within the HVAC control module software. The afterblow feature, when enabled, employs the HVAC blower fan to dry the evaporator after vehicle shut down and this function will inhibit microbial growth. Technicians are to confirm that the customer concern is evaporator core odor and that the vehicle has the imbedded afterblow feature, as defined in the SI document for that specific vehicle model, model year and specific HVAC option. Refer to SI for enabling the afterblow function. Vehicles being delivered in areas prone to high humidity conditions may benefit from having the afterblow enabled calibration installed prior to any customer comment. Important If the vehicle is not factory equipped with the imbedded afterblow enable feature, it may be added with the Electronic Evaporator Dryer Module Kit (P/N 12497910 or AC Delco 15-5876). Important When installing the Electronic Evaporator Dryer Module, you MUST use the included electrical splice connectors to ensure a proper splice. Complete detailed installation instructions and self testing procedures are supplied with the kit. If necessary, the Electronic Evaporator Dryer Module may be installed underhood if it is protected from extreme heat and water splash areas. To immediately remove the evaporator core odor on all suspect vehicles, it is necessary to eliminate the microbial growth and prevent its re-occurrence. To accomplish this, perform the following procedure: Vehicle and Applicator Tool Preparation 1. The evaporator core must be dry. This may be accomplished by disabling the compressor and running the blower fan on the recirc heat setting for an extended period of time. Note Compressor engagement will cause the evaporator core to remain wet and will prevent full adherence of the Coiling Coil Coating to the evaporator core surfaces. 2. Verify that the air conditioning drain hose is not clogged and place a drain pan beneath the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From (HVAC) System > Page 13638 3. Place a protective cover over the carpet below the evaporator core. 4. Remove the cabin air filter, if equipped, and cover the opening prior to applying the Cooling Coil Coating, as the product may clog the filter. If the cabin air filter appears to have little or no remaining life, suggest a replacement to your customer. 5. If the HVAC module has a blower motor cooling tube, be careful NOT TO SPRAY THE COOLING COIL COATING INTO THE BLOWER MOTOR COOLING TUBE. 6. Attach the Flexible Applicator Pressure Spray Tool (J-43810-20A) to a compressed air line operating at 586 kPa (85 psi) to 793 kPa (115 psi). 7. Shake the bottle of Cooling Coil Coating well. Screw the bottle onto the cap on the applicator tool's pick-up tube. Note The pick-up tube is designed for 120 ml (4 oz) and 240 ml (8 oz) bottles and should coil slightly in the bottom of a 120 ml (4 oz) bottle. 8. Use one of the following three methods to apply the Cooling Coil Coating. Important If the Pressure Applicator Spray Tool (J-43810-20A) is not available, the Cooling Coil Coating is also available in an aerosol can (P/N 12377951 (in Canada, 10953503)). Application Through Blower Motor Control Module Opening - Remove the blower motor control module (blower motor resistor). Refer to the applicable procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor blower motor control module (blower motor resistor) opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor blower motor control module (blower motor control module). Application Through Blower Motor Opening - Remove the blower motor. Refer to the applicable blower motor removal procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor. Application Through a Hole in the HVAC Module - If neither of the two previous application methods are available, it may be necessary to drill a hole in the HVAC module. - Locate an area of the HVAC module between the blower motor and the evaporator core. Drill a 10 mm (3/8 in) hole in the HVAC module. Use caution to keep the drill clear of the evaporator core and the blower motor fan. - With the air distribution vents closed and the blower motor fan speed on HIGH, insert the applicator tool into the hole and spray the Cooling Coil Coating into the airstream toward the evaporator core. - Use a GM approved RTV sealant to plug the hole in the HVAC module. 9. After the Cooling Coil Coating application is complete, start and run the vehicle for approximately 10 minutes, with the compressor disabled, HVAC mode set to Recirculate/Max, heat set to full warm, blower motor fan speed on high, and one window open approximately 12 mm (1/2 in). This cures the Cooling Coil Coating onto the evaporator core surface. 10. While the engine is running, rinse the applicator tool with warm water to prolong the life of the tool. Be sure to spray warm water through the nozzle to rinse out any residual Cooling Coil Coating still in the capillary pick up tube, otherwise it will dry and clog the applicator tool. Also remove the small green valve from the bottle cap and rinse it thoroughly while rolling it between two fingers and then reinstall it. If this valve is clogged , the Cooling Coil Coating will not flow through the applicator tool. 11. Shut off the engine and enable the compressor again. 12. Verify proper HVAC system operation. 13. Remove the protective cover from inside the vehicle. 14. Remove the drain pan from underneath the vehicle. 15. Reinstall the cabin air filter if necessary. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From (HVAC) System > Page 13639 Parts Information Important The Cooling Coil Coating listed below is the only GM approved product for use under warranty as an evaporator core disinfectant and for the long term control of evaporator core microbial growth. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporator Core: > 05-06-01-018B > Feb > 11 > Diesel Engine - Drive Belt Chirp/Squeal at Cold Idle Drive Belt: All Technical Service Bulletins Diesel Engine - Drive Belt Chirp/Squeal at Cold Idle TECHNICAL Bulletin No.: 05-06-01-018B Date: February 09, 2011 Subject: Accessory Drive Belt Chirp, Squeal or Squeak Type Noise at Cold Idle (Replace A/C Compressor/Power Steering Pump Mounting Bracket or Enlarge Bracket Bolt Holes) Models: 2004-2010 Chevrolet Silverado 2006-2010 Chevrolet Express 2004-2010 GMC Sierra 2006-2010 GMC Savana Equipped with 6.6L Duramax(R) Diesel Engine (VINs D, 2 - RPOs LBZ, LLY, LMM) Supercede: This bulletin is being revised to add model years and RPOs. Please discard Corporate Bulletin Number 05-06-01-018A (Section 06 - Engine/Propulsion System). Condition Important It should be noted that a chirp type noise on engine shutdown is normal for a diesel engine due to higher engine compression and the rapid stopping of the crankshaft. No repairs should be attempted for this condition. Some customers may comment on an accessory drive belt chirp, squeal, or squeak type noise at idle, especially on a cold start. The noise may be reduced or go away after the engine warms up. Cause Some 2004/2005 Silverado or Sierra trucks, with a 6.6L LLY engine produced before June, 2004, may have an A/C compressor/power steering pump mounting bracket and power steering rear mounting bracket that are machined slightly out of specification, causing a misaligned power steering pump. If the power steering pump is misaligned, it will force the accessory drive belt to run farther inboard on the fan pulley. When the belt leaves the fan pulley, the belt will not align properly to the crankshaft pulley grooves and create a chirp or squeak type noise at the point of interference. Vehicles built after June 2004 will already have the new A/C compressor/power steering pump mounting bracket installed, but still may exhibit belt noise caused by the power steering pump rear mounting bracket. Correction Vehicles built prior to June 2004, replace the A/C compressor/power steering pump mounting bracket. Vehicles built after June 2004, enlarge the rear power steering pump bracket bolt holes. 1. Follow the published service information (SI) diagnostics for drive belt chirping. The diagnostic chart for the drive belt chirping will ask to inspect for a misaligned accessory drive pulley. Important Remove the top section of the radiator shroud and TCM/cover to gain access to check alignment and measure the power steering pulley on the power steering pump shaft. 2. Verify that the power steering pulley is properly pressed onto the power steering pump shaft. Refer to SI for the power steering pulley replacement. If the pulley needs to be realigned on the power steering pump shaft, follow the published SI procedures for the power steering pulley replacement. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporator Core: > 05-06-01-018B > Feb > 11 > Diesel Engine - Drive Belt Chirp/Squeal at Cold Idle > Page 13645 3. If the noise was not fully eliminated by the procedure in step 2, the power steering pulley may be adjusted with an allowable maximum variance of 1.0 mm (0.039 in) to the front from the flush position on the shaft to assist in eliminating any remaining belt noise. Refer to graphic illustration number 1 and number 2. Ensure that the power steering pump pulley illustration number 1 is flush against the power steering pump shaft illustration number 2, with an allowable variance of 1.0 mm (0.039 in). 4. If the noise was not fully eliminated by the procedure in step 3, and there are no other concerns found, follow the published SI diagnostics for drive belt chirping. Then, if the vehicle was built prior to June 2004 go to step 5. If the vehicle was built after June 2004, go to step 6. 5. Vehicles Built Prior to June 2004: 1. Replace the A/C compressor/power steering pump mounting bracket with P/N 97362175. Refer to graphic illustration number 1. Follow the published SI procedures for the Air Conditioning (A/C) Compressor and Power Steering Pump Mounting Bracket Replacement. 2. With the new A/C compressor/power steering pump mounting bracket installed, reposition the power steering pump to gain access to drill larger holes into the rear mounting bracket using a 14 mm (1/2") drill bit. Drilling the bolt holes larger will ensure proper alignment of the bracket when installing the bolts. Refer to graphic illustration number 2. 3. Install the power steering pump to the A/C compressor/power steering pump bracket. Refer to graphic illustration numbers 4, 2, and 1. Important Power steering pump front mounting bolts must always be tightened first to ensure correct pulley alignment. 4. Refer to graphic illustration number 4 and tighten the front power steering pump mounting bolts. Tighten Tighten the bolts to 50 Nm (37 lb ft). 5. Refer to graphic illustration number 2 and tighten the rear power steering bracket bolts. Tighten Tighten the bolts to 50 Nm (37 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporator Core: > 05-06-01-018B > Feb > 11 > Diesel Engine - Drive Belt Chirp/Squeal at Cold Idle > Page 13646 6. Vehicles Built After June 2004: 1. Remove the front and rear power steering bracket bolts from the A/C compressor/power steering pump bracket. Refer to graphic illustration numbers 4, 2, and 1. 2. Reposition the power steering pump to gain access to drill larger holes into the rear mounting bracket using a 14 mm (1/2 in) drill bit. Drilling the bolt holes larger will ensure proper alignment of the bracket when installing the bolts. Refer to graphic illustration number 2. 3. Install the power steering pump to A/C compressor/power steering pump bracket. Refer to graphic illustration numbers 4, 2, and 1. Important Power steering pump front mounting bolts must always be tightened first to ensure correct pulley alignment. 4. Refer to graphic illustration number 4 and tighten the front power steering pump mounting bolts. Tighten Tighten the bolts to 50 Nm (37 lb ft). 5. Refer to graphic illustration number 2 and tighten the rear bracket bolts. Tighten Tighten the bolts to 50 Nm (37 lb ft). Dual Generator System New belts are not available for dual generator systems. If a belt chirp noise is occurring on a dual generator system, please complete a Field Product Report (FPR). The instructions for completing a FPR can be found in Service Bulletin Number 02-00-89-002G. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporator Core: > 05-06-01-018B > Feb > 11 > Diesel Engine - Drive Belt Chirp/Squeal at Cold Idle > Page 13647 Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporator Core: > 08-06-01-008A > Jul > 09 > Engine - Drive Belt Misalignment Diagnostics Drive Belt: All Technical Service Bulletins Engine - Drive Belt Misalignment Diagnostics INFORMATION Bulletin No.: 08-06-01-008A Date: July 27, 2009 Subject: Diagnosing Accessory Drive Belt / Serpentine Belt Noise and Availability and Use of Kent-Moore EN-49228 Laser Alignment Tool - Drive Belt Models: 2010 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add a model year and update the Tool Information. Please discard Corporate Bulletin Number 08-06-01-008 (Section 06 - Engine). Background Several aftermarket companies offer laser alignment tools for accessory drive systems that can be very helpful in eliminating drive belt noise as a result of misaligned pulleys. Typically pricing ranges from $160 - $200. EN-49228 Laser Alignment Tool - Drive Belt The GM Tool program has now made available a competitive, simple to use and time-saving laser tool to assist in achieving precise alignment of the drive belt pulleys. This optional tool removes the guesswork from proper pulley alignment and may serve to reduce comebacks from: - Drive Belt Noise - Accelerated Drive Belt Wear - Drive Belt Slippage Instructions The instructions below are specific only to the truck Gen IV V-8 family of engines. These instructions are only for illustrative purposes to show how the tool may be used. Universal instructions are included in the box with the Laser Alignment Tool - Drive Belt. Caution - Do not look directly into the beam projected from the laser. - Use caution when shining the laser on highly polished or reflective surfaces. Laser safety glasses help reduce laser beam glare in many circumstances. - Always use laser safety glasses when using the laser. Laser safety glasses are not designed to protect eyes from direct laser exposure. 1. Observe and mark the serpentine belt orientation. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporator Core: > 08-06-01-008A > Jul > 09 > Engine - Drive Belt Misalignment Diagnostics > Page 13652 2. Remove the serpentine belt from the accessory drive system. 3. Install the tool onto the power steering pulley. Position the legs of the tool into the outer grooves of the pulley, farthest from the front of the engine. 4. Install the retaining cord around the pulley and to the legs of the tool. 5. Put on the laser safety glasses provided with the tool. 6. Depress the switch on the rear of the tool to activate the light beam. 7. Rotate the power steering pulley as required to project the light beam onto the crankshaft balancer pulley grooves. 8. Inspect for proper power steering pulley alignment. - If the laser beam projects onto the second rib or raised area (1), the pulleys are aligned properly. - If the laser beam projects more than one-quarter rib 0.9 mm (0.035 in) mis-alignment, adjust the position of the power steering pulley as required. - Refer to SI for Power Steering Pulley Removal and Installation procedures. 9. Install the serpentine belt to the accessory drive system in the original orientation. 10. Operate the vehicle and verify that the belt noise concern is no longer present. Tool Information Please visit the GM service tool website for pricing information or to place your order for this tool. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporator Core: > 08-06-01-008A > Jul > 09 > Engine - Drive Belt Misalignment Diagnostics > Page 13653 Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporator Core: > 05-06-01-018B > Feb > 11 > Diesel Engine - Drive Belt Chirp/Squeal at Cold Idle > Page 13659 3. If the noise was not fully eliminated by the procedure in step 2, the power steering pulley may be adjusted with an allowable maximum variance of 1.0 mm (0.039 in) to the front from the flush position on the shaft to assist in eliminating any remaining belt noise. Refer to graphic illustration number 1 and number 2. Ensure that the power steering pump pulley illustration number 1 is flush against the power steering pump shaft illustration number 2, with an allowable variance of 1.0 mm (0.039 in). 4. If the noise was not fully eliminated by the procedure in step 3, and there are no other concerns found, follow the published SI diagnostics for drive belt chirping. Then, if the vehicle was built prior to June 2004 go to step 5. If the vehicle was built after June 2004, go to step 6. 5. Vehicles Built Prior to June 2004: 1. Replace the A/C compressor/power steering pump mounting bracket with P/N 97362175. Refer to graphic illustration number 1. Follow the published SI procedures for the Air Conditioning (A/C) Compressor and Power Steering Pump Mounting Bracket Replacement. 2. With the new A/C compressor/power steering pump mounting bracket installed, reposition the power steering pump to gain access to drill larger holes into the rear mounting bracket using a 14 mm (1/2") drill bit. Drilling the bolt holes larger will ensure proper alignment of the bracket when installing the bolts. Refer to graphic illustration number 2. 3. Install the power steering pump to the A/C compressor/power steering pump bracket. Refer to graphic illustration numbers 4, 2, and 1. Important Power steering pump front mounting bolts must always be tightened first to ensure correct pulley alignment. 4. Refer to graphic illustration number 4 and tighten the front power steering pump mounting bolts. Tighten Tighten the bolts to 50 Nm (37 lb ft). 5. Refer to graphic illustration number 2 and tighten the rear power steering bracket bolts. Tighten Tighten the bolts to 50 Nm (37 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporator Core: > 05-06-01-018B > Feb > 11 > Diesel Engine - Drive Belt Chirp/Squeal at Cold Idle > Page 13660 6. Vehicles Built After June 2004: 1. Remove the front and rear power steering bracket bolts from the A/C compressor/power steering pump bracket. Refer to graphic illustration numbers 4, 2, and 1. 2. Reposition the power steering pump to gain access to drill larger holes into the rear mounting bracket using a 14 mm (1/2 in) drill bit. Drilling the bolt holes larger will ensure proper alignment of the bracket when installing the bolts. Refer to graphic illustration number 2. 3. Install the power steering pump to A/C compressor/power steering pump bracket. Refer to graphic illustration numbers 4, 2, and 1. Important Power steering pump front mounting bolts must always be tightened first to ensure correct pulley alignment. 4. Refer to graphic illustration number 4 and tighten the front power steering pump mounting bolts. Tighten Tighten the bolts to 50 Nm (37 lb ft). 5. Refer to graphic illustration number 2 and tighten the rear bracket bolts. Tighten Tighten the bolts to 50 Nm (37 lb ft). Dual Generator System New belts are not available for dual generator systems. If a belt chirp noise is occurring on a dual generator system, please complete a Field Product Report (FPR). The instructions for completing a FPR can be found in Service Bulletin Number 02-00-89-002G. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporator Core: > 05-06-01-018B > Feb > 11 > Diesel Engine - Drive Belt Chirp/Squeal at Cold Idle > Page 13661 Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporator Core: > 08-06-01-008A > Jul > 09 > Engine - Drive Belt Misalignment Diagnostics > Page 13666 2. Remove the serpentine belt from the accessory drive system. 3. Install the tool onto the power steering pulley. Position the legs of the tool into the outer grooves of the pulley, farthest from the front of the engine. 4. Install the retaining cord around the pulley and to the legs of the tool. 5. Put on the laser safety glasses provided with the tool. 6. Depress the switch on the rear of the tool to activate the light beam. 7. Rotate the power steering pulley as required to project the light beam onto the crankshaft balancer pulley grooves. 8. Inspect for proper power steering pulley alignment. - If the laser beam projects onto the second rib or raised area (1), the pulleys are aligned properly. - If the laser beam projects more than one-quarter rib 0.9 mm (0.035 in) mis-alignment, adjust the position of the power steering pulley as required. - Refer to SI for Power Steering Pulley Removal and Installation procedures. 9. Install the serpentine belt to the accessory drive system in the original orientation. 10. Operate the vehicle and verify that the belt noise concern is no longer present. Tool Information Please visit the GM service tool website for pricing information or to place your order for this tool. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporator Core: > 08-06-01-008A > Jul > 09 > Engine - Drive Belt Misalignment Diagnostics > Page 13667 Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Page 13668 Evaporator Core: Service and Repair Air Conditioning Evaporator Core Replacement (Without HP2) Removal Procedure 1. Remove the HVAC module. Refer to Air Conditioning and Heater Module Assembly Removal and Installation (See: Housing Assembly HVAC/Service and Repair). 2. If equipped remove the heat stakes (1) from the HVAC module (2) with a screw driver and a hammer. 3. Disconnect all wiring connections from blower motor, blower motor control module and sensors. Also, remove all wiring from retainers before removal. 4. If equipped remove the screws from the HVAC module assembly. 5. Remove the evaporator cowl gasket from the evaporator. 6. Separate the upper HVAC module assembly (2) from the lower HVAC module assembly (1) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Page 13669 7. Remove the evaporator core (1) from the upper HVAC module assembly (2). 8. Remove the air conditioning evaporator air temperature sensor. Refer to Air Conditioning Refrigerant Temperature Sensor Replacement (See: Refrigerant Temperature Sensor/Service and Repair/HVAC - Automatic) Installation Procedure Note: If replacing the evaporator core, add the refrigerant oil to the evaporator core. Refer to Refrigerant System Specifications (Non-HP2) ( See: Refrigerant Oil/Specifications). 1. Install the evaporator core (1) to the HVAC module assembly (2). 2. Install the upper HVAC module assembly (2) from the lower HVAC module assembly (1) 3. Install the evaporator cowl gasket to the evaporator. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the screws to the HVAC module assembly. Tighten the screws to 2 Nm (18 lb in). 5. Install the HVAC module assembly. Refer to Air Conditioning and Heater Module Assembly Removal and Installation (See: Housing Assembly HVAC/Service and Repair). 6. Install the air conditioning evaporator air temperature sensor. Refer to Air Conditioning Refrigerant Temperature Sensor Replacement (See: Refrigerant Temperature Sensor/Service and Repair/HVAC - Automatic) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Diagrams Evaporator Temperature Sensor / Switch: Diagrams Component Connector End Views Air Temperature Sensor - Inside (CJ2) Air Temperature Sensor - Lower Left (CJ2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Page 13673 Air Temperature Sensor - Lower Right (CJ2) Air Temperature Sensor - Upper Left (CJ2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Page 13674 Air Temperature Sensor - Upper Right (CJ2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Page 13675 Evaporator Temperature Sensor (except HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Service and Repair Expansion Block/Orifice Tube: Service and Repair Expansion (Orifice) Tube Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Heater Core Cover Replacement Heater Core: Service and Repair Heater Core Cover Replacement Heater Core Cover Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Heater Core Cover Replacement > Page 13683 Heater Core: Service and Repair Heater Core Replacement Heater Core Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Heater Inlet Hose Replacement (Non-HP2) Heater Hose: Service and Repair Heater Inlet Hose Replacement (Non-HP2) Heater Inlet Hose Replacement (Non-HP2) Removal Procedure 1. Drain the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair). 2. Remove the air intake tube. 3. Remove the heater and surge tank hoses from the mounting clip. 4. Squeeze the plastic retainer release tabs. Quick Connect Fittings 5. Pull the connection apart. 6. Remove the inlet heater hose from the water pump. 7. Remove the inlet heater hose. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Heater Inlet Hose Replacement (Non-HP2) > Page 13688 Installation Procedure 1. Install the inlet heater hose. 2. Install the inlet heater hose to the water pump. 3. Connect the heater hose to the heater core. Important: Firmly push the quick connect onto the heater core pipe until you hear an audible click. 4. Install the heater and surge tank hoses to the mounting clip. 5. Install the air intake tube. 6. Fill the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Heater Inlet Hose Replacement (Non-HP2) > Page 13689 Heater Hose: Service and Repair Heater Outlet Hose Replacement (Non-HP2) Heater Outlet Hose Replacement (Non-HP2) Removal Procedure 1. Drain the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair). 2. Remove the air intake tube. 3. Remove the heater and surge tank hoses from the mounting clip. 4. Squeeze the plastic retainer release tabs. Quick Connect Fittings 5. Pull the connection apart. 6. Remove the outlet heater hose from the water pump. 7. Reposition the outlet heater hose clamp at the surge tank. 8. Remove the outlet heater hose from the surge tank. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Heater Inlet Hose Replacement (Non-HP2) > Page 13690 9. Remove the outlet heater hose. Installation Procedure 1. Install the outlet heater hose. 2. Install the outlet heater hose to the water pump. 3. Install the outlet heater hose to the surge tank. 4. Install the outlet heater hose clamp to the surge tank. 5. Connect the heater and surge tank hoses to the heater core. Important: Firmly push the quick connect onto the heater core hose until you hear an audible click. 6. Pull the heater outlet hose to ensure the connection. 7. Install the heater and surge tank hoses to the mounting clip. 8. Install the air intake tube. 9. Fill the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Discharge Hose Replacement Hose/Line HVAC: Service and Repair Discharge Hose Replacement Discharge Hose Replacement (LMM) Special Tools J 39400-A Halogen Leak Detector Removal Procedure 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging (Non-HP2) (See: Refrigerant/Service and Repair)Refrigerant Recovery and Recharging (HP2) (See: Service and Repair). 2. Remove the discharge hose mounting bolt (2) from the A/C compressor. Discard the bolt. 3. Remove the discharge hose (5) from the A/C compressor. 4. Remove the upper radiator air baffle. Refer to Radiator Air Upper Baffle and Deflector Replacement (See: Engine, Cooling and Exhaust/Cooling System/Radiator/Service and Repair/Removal and Replacement/Radiator Air Upper Baffle and Deflector Replacement). 5. Remove the discharge hose nut from the condenser. Discard the nut. 6. Remove the discharge hose from the condenser. 7. Disconnect the A/C recirculation switch from the discharge hose. 8. Remove the discharge hose from the vehicle. 9. Discard all of the used sealing washers. Cap the system openings. Installation Procedure 1. Install the discharge hose to the vehicle. 2. Connect the A/C recirculation switch to the discharge hose. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Discharge Hose Replacement > Page 13695 3. Install the discharge hose to the condenser using new sealing washers. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the NEW discharge hose nut to the condenser. Tighten the nut to 16 Nm (12 lb ft). 5. Install the upper radiator air baffle. Refer to Radiator Air Upper Baffle and Deflector Replacement (See: Engine, Cooling and Exhaust/Cooling System/Radiator/Service and Repair/Removal and Replacement/Radiator Air Upper Baffle and Deflector Replacement). 6. Install the discharge hose (5) to the compressor using new sealing washers. 7. Install the NEW discharge hose mounting bolt (2) to the A/C compressor. Tighten the bolt to 16 Nm (12 lb ft). 8. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging (Non-HP2) (See: Refrigerant/Service and Repair )Refrigerant Recovery and Recharging (HP2) (See: Service and Repair). 9. Leak test the fittings of the component using the J 39400-A . Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Discharge Hose Replacement > Page 13696 Hose/Line HVAC: Service and Repair Suction Hose Replacement Suction Hose Replacement (LMM) Special Tools J 39400-A Halogen Leak Detector Removal Procedure 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging (Non-HP2) (See: Refrigerant/Service and Repair)Refrigerant Recovery and Recharging (HP2) (See: Service and Repair). 2. Remove the suction hose mounting bolt (3) from the A/C compressor. Discard the bolt. 3. Remove the suction hose (1) from the compressor. 4. Remove the suction hose nut from the accumulator. Discard the nut. 5. Remove the suction hose from the accumulator. 6. Remove the suction hose from the vehicle. 7. Discard all of the used sealing washers. Cap the system openings. Installation Procedure 1. Install the suction hose to the vehicle using new sealing washers. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Discharge Hose Replacement > Page 13697 2. Install the suction hose to the accumulator. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the NEW suction hose nut to the accumulator. Tighten the nut to 16 Nm (12 lb ft). 4. Install the suction hose to the compressor (1). 5. Install the NEW suction hose mounting bolt (3). Tighten the bolt to 16 Nm (12 lb ft). 6. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging (Non-HP2) (See: Refrigerant/Service and Repair )Refrigerant Recovery and Recharging (HP2) (See: Service and Repair). 7. Leak test the fittings of the component using the J 39400-A . Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Discharge Hose Replacement > Page 13698 Hose/Line HVAC: Service and Repair Air Conditioning Evaporator Tube Replacement (Non-HP2) Air Conditioning Evaporator Tube Replacement (Non-HP2) Special Tools J 39400-A Halogen Leak Detector Removal Procedure 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging (Non-HP2) (See: Refrigerant/Service and Repair)Refrigerant Recovery and Recharging (HP2) (See: Service and Repair). 2. Remove the upper radiator air baffle and deflector. Refer to Radiator Air Upper Baffle and Deflector Replacement (See: Engine, Cooling and Exhaust/Cooling System/Radiator/Service and Repair/Removal and Replacement/Radiator Air Upper Baffle and Deflector Replacement). 3. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair). 4. Remove the surge tank hold down nut and bolt and position aside. Note: Do not open cooling system. 5. Remove the evaporator tube nut from the evaporator. 6. Disconnect the evaporator tube from the evaporator. 7. Remove the evaporator tube nut from the auxiliary A/C tube, if equipped. 8. Disconnect the evaporator tube from the auxiliary A/C tube, if equipped. 9. Remove the evaporator tube nut from the condenser. 10. Disconnect the evaporator tube from the condenser. 11. Remove the evaporator tube from the vehicle. 12. Discard all of the used sealing washers. Cap all of the open connections. Installation Procedure 1. Connect the evaporator tube to the condenser using new sealing washers. Refer to Air Conditioning System Seal Replacement (See: Coupler HVAC/A/C Coupler O-ring/Service and Repair/Air Conditioning System Seal Replacement). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Discharge Hose Replacement > Page 13699 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the evaporator tube nut to the condenser and tighten to 16 Nm (12 lb ft). 3. Connect the evaporator tube to the auxiliary A/C tube using new sealing washers, if equipped. Refer to Air Conditioning System Seal Replacement (See: Coupler HVAC/A/C Coupler O-ring/Service and Repair/Air Conditioning System Seal Replacement). 4. Install the evaporator tube nut to the auxiliary A/C tube, if equipped, and tighten to 16 Nm (12 lb ft). 5. Install the evaporator tube to the evaporator. 6. Install the evaporator tube nut to the evaporator and tighten to 16 Nm (12 lb ft). 7. Install the surge tank hold down nut and bolt and position aside. 8. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair). 9. Install the upper radiator air baffle and deflector. Refer to Radiator Air Upper Baffle and Deflector Replacement (See: Engine, Cooling and Exhaust/Cooling System/Radiator/Service and Repair/Removal and Replacement/Radiator Air Upper Baffle and Deflector Replacement). 10. Evacuate and recharge the system. Refer to Refrigerant Recovery and Recharging (Non-HP2) (See: Refrigerant/Service and Repair)Refrigerant Recovery and Recharging (HP2) (See: Service and Repair). 11. Leak test the fittings of the components using the J 39400-A . Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair Housing Assembly HVAC: Service and Repair Air Conditioning and Heater Module Assembly Removal and Installation Special Tools J 43181 Heater Line QC Release Tool Removal Procedure 1. Drain the engine coolant. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair). 2. Using the J 43181 disconnect the inlet heater hose from the heater core. 1. Install the J 43181 to the heater core pipe. 2. Close the tool around the heater core pipe. 3. Firmly pull the tool into the quick connect end of the heater hose. 4. Firmly grasp the heater hose. Pull the heater hose forward in order to disengage the inlet hose from the heater core. 3. Using the J 43181 disconnect the surge tank outlet hose from the heater core. 1. Install the J 43181 to the heater core pipe. 2. Close the tool around the heater core pipe. 3. Firmly pull the tool into the quick connect end of the heater hose. 4. Firmly grasp the heater hose. Pull the heater hose forward in order to disengage the surge tank outlet hose from the heater core. 4. Remove the upper intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair). 5. Remove the battery. Refer to Battery Replacement (See: Starting and Charging/Battery/Service and Repair/Removal and Replacement/Battery Replacement). 6. Remove the accumulator. Refer to Air Conditioning Accumulator Replacement (Non-HP2) (). 7. Remove the instrument panel to the service position. Refer to Instrument Panel Service Positioning (with SLT) (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Service Positioning (with SLT))Instrument Panel Service Positioning (without SLT) (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Service Positioning (without SLT)). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Page 13703 8. Remove the nuts (2) from the HVAC module (3). 9. Remove the bolts (1) from the HVAC module (3). 10. Remove the HVAC module (3). Installation Procedure 1. If replacing the HVAC module, transfer the components from the old HVAC module as necessary. 2. Install the HVAC module (3). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the nuts (2) to the HVAC module (3). Tighten the nuts to 9 Nm (80 lb in). 4. Install the bolts (1) to the HVAC module (3). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Page 13704 Tighten the bolts to 4 Nm (35 lb in). 5. Connect the electrical harness and the ground connections. 6. Install the HVAC module drain hose. 7. Install the instrument panel. Refer to Instrument Panel Service Positioning (with SLT) (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Service Positioning (with SLT))Instrument Panel Service Positioning (without SLT) (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Service Positioning (without SLT)). 8. Install the upper intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair). 9. Install the battery. Refer to Battery Replacement (See: Starting and Charging/Battery/Service and Repair/Removal and Replacement/Battery Replacement). 10. Install the accumulator. Refer to Air Conditioning Accumulator Replacement (Non-HP2) (). 11. Install the surge tank outlet hose to the heater core. Firmly push the quick connect onto the heater core pipe until you hear an audible click. 12. Install the inlet heater hose to the heater core. Firmly push the quick connect onto the heater core pipe until you hear an audible click. 13. Fill the engine coolant. Refer to Cooling System Draining and Filling (Vac-N-Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair)Cooling System Draining and Filling (Static Fill) (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications Refrigerant System Specifications (Non-HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 13709 Refrigerant: Fluid Type Specifications Refrigerant System Specifications (Non-HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Page 13710 Refrigerant: Service and Repair Refrigerant Recovery and Recharging (Non-HP2) Special Tools * J 43600 - ACR 2000 Air Conditioning Service Center * J 45037 - A/C Oil Injector For equivalent regional tools, refer to Special Tools (See: Tools and Equipment/Heating, Ventilation, and Air Conditioning). Warning To prevent personal injury, avoid breathing A/C Refrigerant and lubricant vapor or mist. Work in a well ventilated area. To remove refrigerant from the A/C System, use service equipment designed for recovery that is certified to meet the requirements of the appropriate SAE Standards. If an accidental system discharge occurs, ventilate the work area before continuing service. Additional health and safety information may be obtained from the refrigerant, refrigerant recovery, and lubricant manufacturers. Warning For personal protection, goggles and lint-free gloves should be worn and a clean cloth wrapped around fittings, valves, and connections when doing work that includes opening the refrigerant system. If refrigerant comes in contact with any part of the body severe frostbite and personal injury can result. The exposed area should be flushed immediately with cold water and prompt medical help should be obtained. Caution: You must replace the desiccant if the A/C refrigerant system has been open to atmosphere for more than four hours, or if the A/C refrigerant oil has been contaminated. Failure to replace the desiccant will result in damage to the A/C refrigerant system. Caution: R-134a is the only approved refrigerant for use in this vehicle. The use of any other refrigerant may result in poor system performance or component failure. Caution: To avoid system damage use only R-134a dedicated tools when servicing the A/C system. Caution: Use only Polyalkylene Glycol Synthetic Refrigerant Oil (PAG) for internal circulation through the R-134a A/C system and only 525 viscosity mineral oil on fitting threads and O-rings. If lubricants other than those specified are used, compressor failure and/or fitting seizure may result. Caution: R-12 refrigerant and R-134a refrigerant must never be mixed, even in the smallest of amounts, as they are incompatible with each other. If the refrigerants are mixed, compressor failure is likely to occur. Refer to the manufacturer instructions included with the service equipment before servicing. The J 43600 - service center is a complete air conditioning service center for R-134a. The ACR 2000 recovers, recycles, evacuates and recharges A/C refrigerant quickly, accurately and automatically. The unit has a display screen that contains the function controls and displays prompts that will lead the technician through the recover, recycle, evacuate and recharge operations. R-134a is recovered into and charged out of an internal storage vessel. The ACR 2000 automatically replenishes this vessel from an external source tank in order to maintain a constant 5.45-6.82 kg (12-15 lbs) of A/C refrigerant. The ACR 2000 has a built in A/C refrigerant identifier that will test for contamination, prior to recovery and will notify the technician if there are foreign gases present in the A/C system. If foreign gases are present, the ACR 2000 will not recover the refrigerant from the A/C system. The ACR 2000 also features automatic air purge, single pass recycling and an automatic oil drain. Refer to the J 43600 - service center ACR 2000 manual for operation and setup instruction. Always recharge the A/C System with the proper amount of R-134a. Refer to Refrigerant System Specifications (Non-HP2) (See: Refrigerant Oil/Specifications) for the correct amount. A/C Refrigerant System Oil Charge Replenishing If oil was removed from the A/C system during the recovery process or due to component replacement, the oil must be replenished. Oil can be injected into a charged system using J 45037 - injector. For the proper quantities of oil to add to the A/C refrigerant system, refer to Refrigerant System Specifications (Non-HP2) (See: Refrigerant Oil/Specifications). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications Refrigerant System Specifications (Non-HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 13715 Refrigerant Oil: Fluid Type Specifications Refrigerant System Specifications (Non-HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams Refrigerant Pressure Sensor / Switch: Diagrams Component Connector End Views A/C Refrigerant Pressure Sensor (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Air Conditioning Cycling Switch Replacement (Non-HP2) Refrigerant Pressure Sensor / Switch: Service and Repair Air Conditioning Cycling Switch Replacement (Non-HP2) Air Conditioning Cycling Switch Replacement (Non-HP2) Removal Procedure 1. Disconnect the electrical connector from the A/C low pressure switch. 2. Remove the A/C low pressure switch from the accumulator. 3. Remove the O-ring and discard. Installation Procedure 1. Install the new O-ring seal to the switch. Refer to Air Conditioning O-Ring Seal Replacement (See: Coupler HVAC/A/C Coupler O-ring/Service and Repair/Air Conditioning O-Ring Seal Replacement). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the A/C low pressure switch to the accumulator and tighten to 6 Nm (53 lb in). 3. Connect the electrical connector to the A/C low pressure switch. 4. Leak test the fittings of the components using the J 39400-A . Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Air Conditioning Cycling Switch Replacement (Non-HP2) > Page 13721 Refrigerant Pressure Sensor / Switch: Service and Repair Air Conditioning (A/C) Refrigerant Pressure Sensor Replacement (Non-HP2) Air Conditioning (A/C) Refrigerant Pressure Sensor Replacement (Non-HP2) Special Tools J 39400-A Halogen Leak Detector Removal Procedure 1. Disconnect the electrical connector from the A/C refrigerant pressure sensor. 2. Remove the A/C refrigerant pressure sensor (1) from the condenser tube. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Air Conditioning Cycling Switch Replacement (Non-HP2) > Page 13722 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the A/C refrigerant pressure sensor (1). Tighten the switch to 6 Nm (53 lb in). 2. Connect the electrical connector to the A/C refrigerant pressure sensor. 3. Leak test the fittings of the components using the J 39400-A . 4. Lower the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Temperature Sensor > Component Information > Service and Repair > HVAC - Automatic Refrigerant Temperature Sensor: Service and Repair HVAC - Automatic Air Conditioning Refrigerant Temperature Sensor Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Temperature Sensor > Component Information > Service and Repair > HVAC - Automatic > Page 13727 Refrigerant Temperature Sensor: Service and Repair HVAC - Manual Air Conditioning Refrigerant Temperature Sensor Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Compressor Clutch Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 13732 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 13733 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 13734 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 13735 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 13736 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 13737 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 13738 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 11-01-38-001 > Feb > 11 > A/C - Excessive Cabin Moisture/Reduced Window Clearing Control Module HVAC: All Technical Service Bulletins A/C - Excessive Cabin Moisture/Reduced Window Clearing TECHNICAL Bulletin No.: 11-01-38-001 Date: February 28, 2011 Subject: Excessive Cabin Moisture / Reduced Window Clearing (Reprogram HVAC System Control Module) Models: 2010-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2010-2011 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL All with RPO CJ3 or C67 (Manual Air Conditioning) Condition In rare cases, some customers may comment on excessive cabin moisture or difficulty keeping the windows clear in low ambient temperatures. Cause This concern may be caused by the recirculation door being in the recirculation position while the mode is set to a floor through defrost position. Correction Important DO NOT replace the HVAC control module for this concern. Revised software has been developed to address this condition. Technicians are to reprogram the HVAC Control Module using the Service Programming System (SPS) with the latest software currently available in TIS2WEB. When using a Tech 2(R) or a Multiple Diagnostic Interface (MDI) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 10-01-38-001 > Mar > 10 > A/C - Reduced Windshield Clearing/Defrost Control Module HVAC: All Technical Service Bulletins A/C - Reduced Windshield Clearing/Defrost TECHNICAL Bulletin No.: 10-01-38-001 Date: March 02, 2010 Subject: Reduced Windshield Clearing\Defrost at Low Ambient Temperatures (Reprogram HVAC Control Module) Models: 2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2010 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon XL Denali All Equipped with HVAC System RPOs C42, C67 or CJ3 All Built Prior to February 17, 2010 Condition In rare cases, some customers may comment that the HVAC system has reduced defrost or added difficulty keeping the windshield clear in low ambient temperatures. Cause This condition may be caused by the airflow calibrations which can contribute to the above condition. Calibration changes at the start of the 2010 model year may not meet some customers' expectations. Testing has confirmed that defrost levels will meet requirements. Correction Important DO NOT replace the HVAC Control Module for this concern. Reprogram the HVAC Control Module with the latest software calibration. Important Select the correct calibration files for the appropriate vehicle configuration (body style) and RPO codes. A revised calibration has been developed to address this condition. Technicians are to reprogram the HVAC Control Module using the Service Programming System (SPS) with the latest calibrations available on TIS2WEB. Refer to HVAC System Control Module Programming and Setup in SI. When using a Tech 2(R) or a Multiple Diagnostic Interface (MDI) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Customer Interest for Control Module HVAC: > 11-01-38-001 > Feb > 11 > A/C - Excessive Cabin Moisture/Reduced Window Clearing Control Module HVAC: Customer Interest A/C - Excessive Cabin Moisture/Reduced Window Clearing TECHNICAL Bulletin No.: 11-01-38-001 Date: February 28, 2011 Subject: Excessive Cabin Moisture / Reduced Window Clearing (Reprogram HVAC System Control Module) Models: 2010-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2010-2011 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL All with RPO CJ3 or C67 (Manual Air Conditioning) Condition In rare cases, some customers may comment on excessive cabin moisture or difficulty keeping the windows clear in low ambient temperatures. Cause This concern may be caused by the recirculation door being in the recirculation position while the mode is set to a floor through defrost position. Correction Important DO NOT replace the HVAC control module for this concern. Revised software has been developed to address this condition. Technicians are to reprogram the HVAC Control Module using the Service Programming System (SPS) with the latest software currently available in TIS2WEB. When using a Tech 2(R) or a Multiple Diagnostic Interface (MDI) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Customer Interest for Control Module HVAC: > 10-01-38-001 > Mar > 10 > A/C - Reduced Windshield Clearing/Defrost Control Module HVAC: Customer Interest A/C - Reduced Windshield Clearing/Defrost TECHNICAL Bulletin No.: 10-01-38-001 Date: March 02, 2010 Subject: Reduced Windshield Clearing\Defrost at Low Ambient Temperatures (Reprogram HVAC Control Module) Models: 2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2010 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon XL Denali All Equipped with HVAC System RPOs C42, C67 or CJ3 All Built Prior to February 17, 2010 Condition In rare cases, some customers may comment that the HVAC system has reduced defrost or added difficulty keeping the windshield clear in low ambient temperatures. Cause This condition may be caused by the airflow calibrations which can contribute to the above condition. Calibration changes at the start of the 2010 model year may not meet some customers' expectations. Testing has confirmed that defrost levels will meet requirements. Correction Important DO NOT replace the HVAC Control Module for this concern. Reprogram the HVAC Control Module with the latest software calibration. Important Select the correct calibration files for the appropriate vehicle configuration (body style) and RPO codes. A revised calibration has been developed to address this condition. Technicians are to reprogram the HVAC Control Module using the Service Programming System (SPS) with the latest calibrations available on TIS2WEB. Refer to HVAC System Control Module Programming and Setup in SI. When using a Tech 2(R) or a Multiple Diagnostic Interface (MDI) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Page 13760 Control Module HVAC: Diagrams Component Connector End Views HVAC Control Module X1 (CJ2) HVAC Control Module X2 (C67, C42 or MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Page 13761 HVAC Control Module X2 (CJ2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Page 13762 HVAC Control Module X3 (C67, C42, CJ2 or MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Page 13763 Blower Motor Control Module X1 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Page 13764 Blower Motor Control Module X2 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Page 13765 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Service and Repair > HVAC - Automatic Control Module HVAC: Service and Repair HVAC - Automatic HVAC Control Module Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Service and Repair > HVAC - Automatic > Page 13768 Control Module HVAC: Service and Repair HVAC - Manual HVAC Control Module Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Service and Repair > HVAC - Automatic > Page 13769 Control Module HVAC: Service and Repair Blower Motor Control Module Replacement Blower Motor Control Module Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams Ambient Temperature Sensor / Switch HVAC: Diagrams Component Connector End Views Ambient Air Temperature Sensor (CJ2 or C67) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Diagrams > Page 13774 Ambient Temperature Sensor / Switch HVAC: Service and Repair Ambient Air Temperature Sensor Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Service and Repair Cabin Temperature Sensor / Switch: Service and Repair Inside Air Temperature Sensor Replacement Removal Procedure 1. Remove the left windshield garnish molding. Refer to Windshield Pillar Garnish Molding Replacement (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Windshield Pillar Garnish Molding Replacement). 2. Remove the left center pillar assist handle. Refer to Roof Rail Rear Assist Handle Replacement (See: Body and Frame/Interior Moulding / Trim/Passenger Assist Handle/Service and Repair/Roof Rail Rear Assist Handle Replacement). 3. Remove the center pillar garnish molding. Refer to Center Pillar Upper Garnish Molding Replacement (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Center Pillar Upper Garnish Molding Replacement). 4. Remove the left sunshade. Refer to Sunshade Replacement (See: Body and Frame/Interior Moulding / Trim/Sun Visor/Service and Repair). 5. Gently pull down the headliner. 6. Disconnect the electrical connector from the inside air temperature sensor. 7. Partially remove the inside air temperature sensor from the headliner. 8. Remove the sensor grille from the inside air temperature sensor. 9. Remove the inside air temperature sensor from the headliner. Installation Procedure 1. Install the new sensor grille to the headliner. 2. Install the inside air temperature sensor to the headliner and sensor grille. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch > Component Information > Service and Repair > Page 13778 3. Connect the electrical connector to the inside air temperature sensor. 4. Install the left sunshade. Refer to Sunshade Replacement (See: Body and Frame/Interior Moulding / Trim/Sun Visor/Service and Repair). 5. Install the left center pillar garnish molding. Refer to Center Pillar Upper Garnish Molding Replacement (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Center Pillar Upper Garnish Molding Replacement). 6. Install the left center assist handle. Refer to Roof Rail Rear Assist Handle Replacement (See: Body and Frame/Interior Moulding / Trim/Passenger Assist Handle/Service and Repair/Roof Rail Rear Assist Handle Replacement). 7. Install the left windshield garnish molding. Refer to Windshield Pillar Garnish Molding Replacement (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Windshield Pillar Garnish Molding Replacement). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Service and Repair > Duct Air Temperature Sensor Replacement Lower Left Side Discharge Air Temperature Sensor / Switch: Service and Repair Duct Air Temperature Sensor Replacement - Lower Left Side Duct Air Temperature Sensor Replacement - Lower Left Side Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Service and Repair > Duct Air Temperature Sensor Replacement Lower Left Side > Page 13783 Discharge Air Temperature Sensor / Switch: Service and Repair Duct Air Temperature Sensor Replacement - Lower Right Side Duct Air Temperature Sensor Replacement - Lower Right Side Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Service and Repair > Duct Air Temperature Sensor Replacement Lower Left Side > Page 13784 Discharge Air Temperature Sensor / Switch: Service and Repair Duct Air Temperature Sensor Replacement - Upper Left Side Duct Air Temperature Sensor Replacement - Upper Left Side Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Discharge Air Temperature Sensor / Switch, HVAC > Component Information > Service and Repair > Duct Air Temperature Sensor Replacement Lower Left Side > Page 13785 Discharge Air Temperature Sensor / Switch: Service and Repair Duct Air Temperature Sensor Replacement - Upper Right Side Duct Air Temperature Sensor Replacement - Upper Right Side Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Diagrams Evaporator Temperature Sensor / Switch: Diagrams Component Connector End Views Air Temperature Sensor - Inside (CJ2) Air Temperature Sensor - Lower Left (CJ2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Page 13789 Air Temperature Sensor - Lower Right (CJ2) Air Temperature Sensor - Upper Left (CJ2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Page 13790 Air Temperature Sensor - Upper Right (CJ2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Diagrams > Page 13791 Evaporator Temperature Sensor (except HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams Refrigerant Pressure Sensor / Switch: Diagrams Component Connector End Views A/C Refrigerant Pressure Sensor (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Air Conditioning Cycling Switch Replacement (Non-HP2) Refrigerant Pressure Sensor / Switch: Service and Repair Air Conditioning Cycling Switch Replacement (Non-HP2) Air Conditioning Cycling Switch Replacement (Non-HP2) Removal Procedure 1. Disconnect the electrical connector from the A/C low pressure switch. 2. Remove the A/C low pressure switch from the accumulator. 3. Remove the O-ring and discard. Installation Procedure 1. Install the new O-ring seal to the switch. Refer to Air Conditioning O-Ring Seal Replacement (See: Coupler HVAC/A/C Coupler O-ring/Service and Repair/Air Conditioning O-Ring Seal Replacement). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the A/C low pressure switch to the accumulator and tighten to 6 Nm (53 lb in). 3. Connect the electrical connector to the A/C low pressure switch. 4. Leak test the fittings of the components using the J 39400-A . Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Air Conditioning Cycling Switch Replacement (Non-HP2) > Page 13797 Refrigerant Pressure Sensor / Switch: Service and Repair Air Conditioning (A/C) Refrigerant Pressure Sensor Replacement (Non-HP2) Air Conditioning (A/C) Refrigerant Pressure Sensor Replacement (Non-HP2) Special Tools J 39400-A Halogen Leak Detector Removal Procedure 1. Disconnect the electrical connector from the A/C refrigerant pressure sensor. 2. Remove the A/C refrigerant pressure sensor (1) from the condenser tube. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Air Conditioning Cycling Switch Replacement (Non-HP2) > Page 13798 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the A/C refrigerant pressure sensor (1). Tighten the switch to 6 Nm (53 lb in). 2. Connect the electrical connector to the A/C refrigerant pressure sensor. 3. Leak test the fittings of the components using the J 39400-A . 4. Lower the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Temperature Sensor > Component Information > Service and Repair > HVAC - Automatic Refrigerant Temperature Sensor: Service and Repair HVAC - Automatic Air Conditioning Refrigerant Temperature Sensor Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Temperature Sensor > Component Information > Service and Repair > HVAC - Automatic > Page 13803 Refrigerant Temperature Sensor: Service and Repair HVAC - Manual Air Conditioning Refrigerant Temperature Sensor Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Diagrams Solar Sensor: Diagrams Component Connector End Views Ambient Light Sensor (C67, C42 or MEX) Ambient Light/Sunload Sensor (CJ2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Diagrams > Page 13807 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Diagrams > Page 13808 Solar Sensor: Service and Repair Sun Load Temperature Sensor Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Diagrams Solar Sensor: Diagrams Component Connector End Views Ambient Light Sensor (C67, C42 or MEX) Ambient Light/Sunload Sensor (CJ2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Diagrams > Page 13812 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Diagrams > Page 13813 Solar Sensor: Service and Repair Sun Load Temperature Sensor Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair > Seat Belts Repairs and Inspections Required After a Collision: Service and Repair Seat Belts Repairs and Inspections Required After a Collision Warning Restraint systems can be damaged in a collision. To help avoid injury and ensure that all parts in need of replacement are replaced: * Replace any seat belt system that was in use during the collision serious enough to deploy any automatic restraint device such as air bags and seat belt pretensioners. This not only includes seat belt systems in use by people of adult size, but seat belt systems used to secure child restraints, infant carriers and booster seats, including LATCH system and top tether anchorages. * Replace any seat belt system that has torn, worn, or damaged components. This not only includes adult seat belt systems, but built-in child restraints and LATCH system components, if any. * Replace any seat belt system if you observe the words "REPLACE" or "CAUTION", or if a yellow tag is visible. Do not replace a seat belt if only the child seat caution label is visible. * Replace any seat belt system if you are doubtful about its condition. This not only includes adult seat belt systems, but built-in child restraints, LATCH system components, and any restraint system used to secure infant carriers, child restraints, and booster seats. Do NOT replace single seat belt system components in vehicles that have been in a collision as described above. Always replace the entire seat belt system with the buckle, guide and retractor assembly, which includes the latch and webbing material. After a minor collision where no automatic restraint device was deployed, seat belt system replacement may not be necessary, unless some of the parts are torn, worn, or damaged. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair > Seat Belts > Page 13819 Repairs and Inspections Required After a Collision: Service and Repair Supplemental Inflatable Restraints Repairs and Inspections Required After a Collision Accident With or Without Inflator Module Deployment - Component Inspections Caution: Proper operation of the SIR sensing system requires that any repairs to the vehicle structure return the vehicle structure to the original production configuration. Not properly repairing the vehicle structure could cause non-deployment in a collision or deployment for conditions less severe than intended. After any collision, inspect the following components as indicated. If you detect any damage, replace the component. If you detect any damage to the mounting points or mounting hardware, repair or replace the mounting points and mounting hardware as needed. * Hybrid vehicles-Perform an inspection of the high voltage system for damage. Refer to High Voltage System Inspection (). * The steering column-Perform the steering column accident damage checking procedures. Refer to Steering Column Accident Damage Inspection (See: Steering and Suspension/Steering/Steering Column/Testing and Inspection/Initial Inspection and Diagnostic Overview). * The instrument panel (I/P) knee bolsters and mounting points-Inspect the knee bolsters for bending, twisting, buckling, or any other type of damage. * The I/P brackets, braces, etc.-Inspect for bending, twisting, buckling, or any other type of damage. * The seat belts-Perform the seat belt operational and functional checks. Refer to Seat Belt System Operational and Functional Checks (See: Seat Belt Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview). * The I/P mounting points and brackets-Inspect for bending, twisting, buckling, or any other type of damage. * The roof rail and roof rail module mounting points-Inspect for bending, twisting, buckling, or any other type of damage. * The seats and seat mounting points-Inspect for bending, twisting, buckling, or any other type of damage. * Passenger seat bottom equipped with Passenger Presence System (PPS)-Check for any DTCs or problems that may cause the PPS not to function properly. Accident With Frontal Air Bag Deployment - Component Replacement and Inspections After a collision involving air bag deployment, replace the following components. If you detect any damage, replace the component. If you detect any damage to the mounting points or mounting hardware, repair or replace the mounting points and mounting hardware as needed. Important: The front passenger seat is equipped with a PPS, which detects an occupant. If the requirements for disabling the I/P air bag are met then the PPS will communicate with the SDM to disable/turn off the I/P air bag, even in a accident. For more information on the PPS refer to SIR System Description and Operation (See: Air Bag Systems/Description and Operation). * Inflatable restraint front end sensors * Inflatable restraint I/P module, if deployed and after performing the necessary inspections listed above * Inflatable restraint sensing and diagnostic module (SDM) * Inflatable restraint steering wheel module * Inflatable restraint steering wheel module coil * Seat belt pretensioners Perform additional inspections on the following components: * Steering wheel module coil and the coil wiring pigtail-Inspect for melting, scorching, or other damage due to excessive heat. * Mounting points or mounting hardware for the I/P module, steering wheel module, SDM, front end sensors, seat belt pretensioners, and vehicle rollover sensor-Inspect for any damage and repair or replace each component as needed. Accident With Side Air Bag Deployment - Component Replacement and Inspections After a collision involving side air bag deployment, replace the following components: * Inflatable restraint roof rail module, on the side of the impact. * Inflatable restraint side impact sensors (SIS) (front/rear), on the side of the impact * Inflatable restraint SDM * Seat belt pretensioner, on the side of impact. Perform additional inspections on the following components: * Mounting points or mounting hardware for the SIS, roof rail module (left/right), and seat belt pretensioner on the side of impact-Inspect for any damage and repair or replace each component as needed. * Mounting points or mounting hardware for the SDM and vehicle rollover sensor-Inspect for any damage and repair or replace each component as needed. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair > Seat Belts > Page 13820 Sensor Replacement Guidelines The SIR/side air bag sensor replacement policy requires replacing sensors in the area of accident damage. The area of accident damage is defined as the portion of the vehicle which is crushed, bent, or damaged due to a collision. An example of this would be a moderate collision where the front of the vehicle impacts a tree, if the vehicle has an SIR sensor mounted forward of the radiator, replace the SIR sensor. * Replace the sensor whether or not the air bags have deployed. * Replace the sensor even if the sensor appears to be undamaged. Sensor damage which is not visible, such as slight bending of the mounting bracket or cuts in the wire insulation, can cause improper operation of the SIR/side air bag sensing system. Do not try to determine whether the sensor is undamaged. Replace the sensor. Also, if you follow a diagnostic trouble code (DTC) table and a malfunctioning sensor is indicated, replace the sensor. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling SIR component location affects how a vehicle should be serviced. There are parts of the SIR system installed in various locations around a vehicle. To find the location of the SIR components refer to SIR Identification Views (See: Locations). There are several reasons for disabling the SIR system, such as repairs to the SIR system or servicing a component near or attached to an SIR component. There are several ways to disable the SIR system depending on what type of service is being performed. The following information covers the proper procedures for disabling/enabling the SIR system. SIR Service Precautions Warning When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. The inflatable restraint sensing and diagnostic module (SDM) maintains a reserved energy supply. The reserved energy supply provides deployment power for the air bags if the SDM loses battery power during a collision. Deployment power is available for as much as 1 minute after disconnecting the vehicle power. Waiting 1 minute before working on the system after disabling the SIR system prevents deployment of the air bags from the reserved energy supply. General Service Instructions The following are general service instructions which must be followed in order to properly repair the vehicle and return it to its original integrity: * Do not expose air bags to temperatures above 65°C (149°F). * Verify the correct replacement part number. Do not substitute a component from a different vehicle. * Use only original GM replacement parts available from your authorized GM dealer. Do not use salvaged parts for repairs to the SIR system. Discard any of the following components if it has been dropped from a height of 92 cm (3 feet) or greater: * Inflatable restraint sensing and diagnostic module (SDM) * Any air bag * Driver steering wheel air bag coil * Any impact sensor * Seat belt anchor and/or retractor pretensioners * Passenger presence module and/or occupant sensor Disabling Procedure - Air Bag Fuse 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. Note: The SDM may have more than one fused power input. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove all fuses supplying power to the SDM. With all SDM fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate a SIR system malfunction. 3. Locate and remove the fuse(s) supplying power to the SDM. Refer to SIR Schematics (See: Diagrams/Electrical Diagrams) or Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse/Application and ID). 4. Wait 1 minute before working on the system. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Page 13825 Enabling Procedure - Air Bag Fuse 1. Place the ignition in the OFF position. 2. Install the fuse(s) supplying power to the SDM. Refer to SIR Schematics (See: Diagrams/Electrical Diagrams) or Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse/Application and ID). 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle). Disabling Procedure - Negative Battery Cable 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. 3. Disconnect the negative battery cable from the battery. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 4. Wait 1 minute before working on system. Enabling Procedure - Negative Battery Cable 1. Place the ignition in the OFF position. 2. Connect the negative battery cable to the battery. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Technical Service Bulletins > Customer Interest for Air Bag Harness: > 08-09-41-002F > Jun > 10 > Restraints - Air Bag Lamp ON/Multiple DTC Set Air Bag Harness: Customer Interest Restraints - Air Bag Lamp ON/Multiple DTC Set TECHNICAL Bulletin No.: 08-09-41-002F Date: June 10, 2010 Subject: Diagnostic Information for Supplemental Inflatable Restraint (SIR) System, Intermittent AIR BAG Indicator/Lamp Illuminated with DTC(s) B0012, B0013, B0015, B0016, B0019, B0020, B0022, B0023, B0026, B0033, B0040, B0042 or B0044 Set (Inspect and Replace Connector Position Assurance (CPA) Retainer) Models: 2005-2007 Buick Rainier 2006-2009 Buick Allure (Canada only), LaCrosse, Lucerne 2008-2010 Buick Enclave 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade Models 2008-2009 Cadillac SRX, XLR 2008-2010 Cadillac CTS, STS 2005-2006 Chevrolet SSR 2005-2009 Chevrolet TrailBlazer, TrailBlazer EXT 2005-2010 Chevrolet Cobalt 2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Corvette, HHR, Impala, Malibu Models (includes Malibu Classic) 2007-2009 Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet Traverse 2005-2009 GMC Envoy Models 2007-2010 GMC Acadia, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2010 GMC Savana 2005-2006 Pontiac Pursuit 2005-2009 Pontiac G6 2006-2009 Pontiac Solstice 2007-2009 Pontiac G5, Torrent 2008-2009 Pontiac G8 2005-2009 Saab 9-7X 2007-2009 Saturn AURA, OUTLOOK, SKY 2008-2009 Saturn VUE 2008-2009 HUMMER H2 2007-2008 Daewoo G2X 2007-2009 Opel GT Supercede: This bulletin is being revised to update the Warranty Information and add Saab Warranty Information. Please discard Corporate Bulletin Number 08-09-41-002E (Section 09 Restraints). Condition - Some customers may comment on an intermittent or current AIR BAG indicator or lamp being illuminated on the instrument panel cluster (IPC). Important This bulletin only applies to the following DTCs: - Technicians may observe DTC(s) B0012 04, 0D, 0E; B0013 04, 0D, 0E; B0015 04, 0D, 0E; B0016 04, 0D, 0E; B0019 04, 0D, 0E; B0020 04, 0D, 0E; B0022, B0023 04, 0D, 0E; B0033 04, 0D, 0E; B0040 04, 0D, 0E; B0042 or B0044 set as Current or in History in the sensing and diagnostic module (SDM). Cause This condition may be caused by a loose, missing, or damaged connector position assurance (CPA) retainer at a supplemental inflatable restraint (SIR) module electrical connector, or a deployment loop wiring harness electrical connector. Correction Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Technical Service Bulletins > Customer Interest for Air Bag Harness: > 08-09-41-002F > Jun > 10 > Restraints - Air Bag Lamp ON/Multiple DTC Set > Page 13835 Caution When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. 1. Perform the Diagnostic System Check-Vehicle. 2. Identify the DTC that is set AND review the DTC Descriptor in the corresponding diagnostic procedure. Refer to Diagnostic Trouble Code (DTC) List-Vehicle in SI. 3. Using the information from the DTC Descriptor, determine the location of the affected electrical connector. Refer to SIR Identification Views and the Master Electrical Component List in SI. 4. Turn OFF the ignition and disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 5. BEFORE removing, INSPECT the CPA retainer at the electrical connector. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. ‹› If the CPA retainer is loose, damaged, or will not seat in the connector, replace it with a new one. Reinstall the CPA correctly by first pushing the connector body in completely, and then pushing the CPA retainer in completely. ‹› If the CPA retainer is not loose or damaged and is properly seated, proceed to Step 6. 6. Remove the CPA retainer and disconnect the electrical connector. Inspect the terminals for the following conditions: - Corrosion - Contamination - Terminal tension - Damage Important The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. DO NOT substitute any other terminals for those in the repair kit. ‹› If the terminals are damaged, corrosion is observed, or have poor tension, repair or replace as necessary. Apply dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins and terminals when reassembling. Refer to SIR/SRS Wiring Repairs in SI. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. 7. Connect the electrical connector, and install the CPA retainer. 8. Enable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 9. Clear the DTC with a scan tool. 10. Verify that the DTC does not reset by performing the Diagnostic Repair Verification in SI. ‹› If any DTC resets, then refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Parts Information Note If the CPA retainer P/N 54590003 (Orange CPA) cannot be located in the J-38125 SIR/SRS terminal repair kit, contact Kent Moore Tools and order P/N 54590003-PKG to obtain a package of 5. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Technical Service Bulletins > Customer Interest for Air Bag Harness: > 08-09-41-002F > Jun > 10 > Restraints - Air Bag Lamp ON/Multiple DTC Set > Page 13836 Warranty Information (excluding Saab U.S. Models) Important Select the appropriate Labor Operation for the repair that is performed. For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Harness: > 08-09-41-002F > Jun > 10 > Restraints - Air Bag Lamp ON/Multiple DTC Set Air Bag Harness: All Technical Service Bulletins Restraints - Air Bag Lamp ON/Multiple DTC Set TECHNICAL Bulletin No.: 08-09-41-002F Date: June 10, 2010 Subject: Diagnostic Information for Supplemental Inflatable Restraint (SIR) System, Intermittent AIR BAG Indicator/Lamp Illuminated with DTC(s) B0012, B0013, B0015, B0016, B0019, B0020, B0022, B0023, B0026, B0033, B0040, B0042 or B0044 Set (Inspect and Replace Connector Position Assurance (CPA) Retainer) Models: 2005-2007 Buick Rainier 2006-2009 Buick Allure (Canada only), LaCrosse, Lucerne 2008-2010 Buick Enclave 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade Models 2008-2009 Cadillac SRX, XLR 2008-2010 Cadillac CTS, STS 2005-2006 Chevrolet SSR 2005-2009 Chevrolet TrailBlazer, TrailBlazer EXT 2005-2010 Chevrolet Cobalt 2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Corvette, HHR, Impala, Malibu Models (includes Malibu Classic) 2007-2009 Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet Traverse 2005-2009 GMC Envoy Models 2007-2010 GMC Acadia, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2010 GMC Savana 2005-2006 Pontiac Pursuit 2005-2009 Pontiac G6 2006-2009 Pontiac Solstice 2007-2009 Pontiac G5, Torrent 2008-2009 Pontiac G8 2005-2009 Saab 9-7X 2007-2009 Saturn AURA, OUTLOOK, SKY 2008-2009 Saturn VUE 2008-2009 HUMMER H2 2007-2008 Daewoo G2X 2007-2009 Opel GT Supercede: This bulletin is being revised to update the Warranty Information and add Saab Warranty Information. Please discard Corporate Bulletin Number 08-09-41-002E (Section 09 Restraints). Condition - Some customers may comment on an intermittent or current AIR BAG indicator or lamp being illuminated on the instrument panel cluster (IPC). Important This bulletin only applies to the following DTCs: - Technicians may observe DTC(s) B0012 04, 0D, 0E; B0013 04, 0D, 0E; B0015 04, 0D, 0E; B0016 04, 0D, 0E; B0019 04, 0D, 0E; B0020 04, 0D, 0E; B0022, B0023 04, 0D, 0E; B0033 04, 0D, 0E; B0040 04, 0D, 0E; B0042 or B0044 set as Current or in History in the sensing and diagnostic module (SDM). Cause This condition may be caused by a loose, missing, or damaged connector position assurance (CPA) retainer at a supplemental inflatable restraint (SIR) module electrical connector, or a deployment loop wiring harness electrical connector. Correction Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Harness: > 08-09-41-002F > Jun > 10 > Restraints - Air Bag Lamp ON/Multiple DTC Set > Page 13842 Caution When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. 1. Perform the Diagnostic System Check-Vehicle. 2. Identify the DTC that is set AND review the DTC Descriptor in the corresponding diagnostic procedure. Refer to Diagnostic Trouble Code (DTC) List-Vehicle in SI. 3. Using the information from the DTC Descriptor, determine the location of the affected electrical connector. Refer to SIR Identification Views and the Master Electrical Component List in SI. 4. Turn OFF the ignition and disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 5. BEFORE removing, INSPECT the CPA retainer at the electrical connector. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. ‹› If the CPA retainer is loose, damaged, or will not seat in the connector, replace it with a new one. Reinstall the CPA correctly by first pushing the connector body in completely, and then pushing the CPA retainer in completely. ‹› If the CPA retainer is not loose or damaged and is properly seated, proceed to Step 6. 6. Remove the CPA retainer and disconnect the electrical connector. Inspect the terminals for the following conditions: - Corrosion - Contamination - Terminal tension - Damage Important The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. DO NOT substitute any other terminals for those in the repair kit. ‹› If the terminals are damaged, corrosion is observed, or have poor tension, repair or replace as necessary. Apply dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins and terminals when reassembling. Refer to SIR/SRS Wiring Repairs in SI. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. 7. Connect the electrical connector, and install the CPA retainer. 8. Enable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 9. Clear the DTC with a scan tool. 10. Verify that the DTC does not reset by performing the Diagnostic Repair Verification in SI. ‹› If any DTC resets, then refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Parts Information Note If the CPA retainer P/N 54590003 (Orange CPA) cannot be located in the J-38125 SIR/SRS terminal repair kit, contact Kent Moore Tools and order P/N 54590003-PKG to obtain a package of 5. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Harness: > 08-09-41-002F > Jun > 10 > Restraints - Air Bag Lamp ON/Multiple DTC Set > Page 13843 Warranty Information (excluding Saab U.S. Models) Important Select the appropriate Labor Operation for the repair that is performed. For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Customer Interest for Air Bag Control Module: > 08-09-41-002F > Jun > 10 > Restraints - Air Bag Lamp ON/Multiple DTC Set Air Bag Control Module: Customer Interest Restraints - Air Bag Lamp ON/Multiple DTC Set TECHNICAL Bulletin No.: 08-09-41-002F Date: June 10, 2010 Subject: Diagnostic Information for Supplemental Inflatable Restraint (SIR) System, Intermittent AIR BAG Indicator/Lamp Illuminated with DTC(s) B0012, B0013, B0015, B0016, B0019, B0020, B0022, B0023, B0026, B0033, B0040, B0042 or B0044 Set (Inspect and Replace Connector Position Assurance (CPA) Retainer) Models: 2005-2007 Buick Rainier 2006-2009 Buick Allure (Canada only), LaCrosse, Lucerne 2008-2010 Buick Enclave 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade Models 2008-2009 Cadillac SRX, XLR 2008-2010 Cadillac CTS, STS 2005-2006 Chevrolet SSR 2005-2009 Chevrolet TrailBlazer, TrailBlazer EXT 2005-2010 Chevrolet Cobalt 2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Corvette, HHR, Impala, Malibu Models (includes Malibu Classic) 2007-2009 Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet Traverse 2005-2009 GMC Envoy Models 2007-2010 GMC Acadia, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2010 GMC Savana 2005-2006 Pontiac Pursuit 2005-2009 Pontiac G6 2006-2009 Pontiac Solstice 2007-2009 Pontiac G5, Torrent 2008-2009 Pontiac G8 2005-2009 Saab 9-7X 2007-2009 Saturn AURA, OUTLOOK, SKY 2008-2009 Saturn VUE 2008-2009 HUMMER H2 2007-2008 Daewoo G2X 2007-2009 Opel GT Supercede: This bulletin is being revised to update the Warranty Information and add Saab Warranty Information. Please discard Corporate Bulletin Number 08-09-41-002E (Section 09 Restraints). Condition - Some customers may comment on an intermittent or current AIR BAG indicator or lamp being illuminated on the instrument panel cluster (IPC). Important This bulletin only applies to the following DTCs: - Technicians may observe DTC(s) B0012 04, 0D, 0E; B0013 04, 0D, 0E; B0015 04, 0D, 0E; B0016 04, 0D, 0E; B0019 04, 0D, 0E; B0020 04, 0D, 0E; B0022, B0023 04, 0D, 0E; B0033 04, 0D, 0E; B0040 04, 0D, 0E; B0042 or B0044 set as Current or in History in the sensing and diagnostic module (SDM). Cause This condition may be caused by a loose, missing, or damaged connector position assurance (CPA) retainer at a supplemental inflatable restraint (SIR) module electrical connector, or a deployment loop wiring harness electrical connector. Correction Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Customer Interest for Air Bag Control Module: > 08-09-41-002F > Jun > 10 > Restraints - Air Bag Lamp ON/Multiple DTC Set > Page 13852 Caution When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. 1. Perform the Diagnostic System Check-Vehicle. 2. Identify the DTC that is set AND review the DTC Descriptor in the corresponding diagnostic procedure. Refer to Diagnostic Trouble Code (DTC) List-Vehicle in SI. 3. Using the information from the DTC Descriptor, determine the location of the affected electrical connector. Refer to SIR Identification Views and the Master Electrical Component List in SI. 4. Turn OFF the ignition and disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 5. BEFORE removing, INSPECT the CPA retainer at the electrical connector. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. ‹› If the CPA retainer is loose, damaged, or will not seat in the connector, replace it with a new one. Reinstall the CPA correctly by first pushing the connector body in completely, and then pushing the CPA retainer in completely. ‹› If the CPA retainer is not loose or damaged and is properly seated, proceed to Step 6. 6. Remove the CPA retainer and disconnect the electrical connector. Inspect the terminals for the following conditions: - Corrosion - Contamination - Terminal tension - Damage Important The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. DO NOT substitute any other terminals for those in the repair kit. ‹› If the terminals are damaged, corrosion is observed, or have poor tension, repair or replace as necessary. Apply dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins and terminals when reassembling. Refer to SIR/SRS Wiring Repairs in SI. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. 7. Connect the electrical connector, and install the CPA retainer. 8. Enable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 9. Clear the DTC with a scan tool. 10. Verify that the DTC does not reset by performing the Diagnostic Repair Verification in SI. ‹› If any DTC resets, then refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Parts Information Note If the CPA retainer P/N 54590003 (Orange CPA) cannot be located in the J-38125 SIR/SRS terminal repair kit, contact Kent Moore Tools and order P/N 54590003-PKG to obtain a package of 5. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Customer Interest for Air Bag Control Module: > 08-09-41-002F > Jun > 10 > Restraints - Air Bag Lamp ON/Multiple DTC Set > Page 13853 Warranty Information (excluding Saab U.S. Models) Important Select the appropriate Labor Operation for the repair that is performed. For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 08-09-41-002F > Jun > 10 > Restraints - Air Bag Lamp ON/Multiple DTC Set Air Bag Control Module: All Technical Service Bulletins Restraints - Air Bag Lamp ON/Multiple DTC Set TECHNICAL Bulletin No.: 08-09-41-002F Date: June 10, 2010 Subject: Diagnostic Information for Supplemental Inflatable Restraint (SIR) System, Intermittent AIR BAG Indicator/Lamp Illuminated with DTC(s) B0012, B0013, B0015, B0016, B0019, B0020, B0022, B0023, B0026, B0033, B0040, B0042 or B0044 Set (Inspect and Replace Connector Position Assurance (CPA) Retainer) Models: 2005-2007 Buick Rainier 2006-2009 Buick Allure (Canada only), LaCrosse, Lucerne 2008-2010 Buick Enclave 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade Models 2008-2009 Cadillac SRX, XLR 2008-2010 Cadillac CTS, STS 2005-2006 Chevrolet SSR 2005-2009 Chevrolet TrailBlazer, TrailBlazer EXT 2005-2010 Chevrolet Cobalt 2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Corvette, HHR, Impala, Malibu Models (includes Malibu Classic) 2007-2009 Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet Traverse 2005-2009 GMC Envoy Models 2007-2010 GMC Acadia, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2010 GMC Savana 2005-2006 Pontiac Pursuit 2005-2009 Pontiac G6 2006-2009 Pontiac Solstice 2007-2009 Pontiac G5, Torrent 2008-2009 Pontiac G8 2005-2009 Saab 9-7X 2007-2009 Saturn AURA, OUTLOOK, SKY 2008-2009 Saturn VUE 2008-2009 HUMMER H2 2007-2008 Daewoo G2X 2007-2009 Opel GT Supercede: This bulletin is being revised to update the Warranty Information and add Saab Warranty Information. Please discard Corporate Bulletin Number 08-09-41-002E (Section 09 Restraints). Condition - Some customers may comment on an intermittent or current AIR BAG indicator or lamp being illuminated on the instrument panel cluster (IPC). Important This bulletin only applies to the following DTCs: - Technicians may observe DTC(s) B0012 04, 0D, 0E; B0013 04, 0D, 0E; B0015 04, 0D, 0E; B0016 04, 0D, 0E; B0019 04, 0D, 0E; B0020 04, 0D, 0E; B0022, B0023 04, 0D, 0E; B0033 04, 0D, 0E; B0040 04, 0D, 0E; B0042 or B0044 set as Current or in History in the sensing and diagnostic module (SDM). Cause This condition may be caused by a loose, missing, or damaged connector position assurance (CPA) retainer at a supplemental inflatable restraint (SIR) module electrical connector, or a deployment loop wiring harness electrical connector. Correction Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 08-09-41-002F > Jun > 10 > Restraints - Air Bag Lamp ON/Multiple DTC Set > Page 13859 Caution When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. 1. Perform the Diagnostic System Check-Vehicle. 2. Identify the DTC that is set AND review the DTC Descriptor in the corresponding diagnostic procedure. Refer to Diagnostic Trouble Code (DTC) List-Vehicle in SI. 3. Using the information from the DTC Descriptor, determine the location of the affected electrical connector. Refer to SIR Identification Views and the Master Electrical Component List in SI. 4. Turn OFF the ignition and disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 5. BEFORE removing, INSPECT the CPA retainer at the electrical connector. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. ‹› If the CPA retainer is loose, damaged, or will not seat in the connector, replace it with a new one. Reinstall the CPA correctly by first pushing the connector body in completely, and then pushing the CPA retainer in completely. ‹› If the CPA retainer is not loose or damaged and is properly seated, proceed to Step 6. 6. Remove the CPA retainer and disconnect the electrical connector. Inspect the terminals for the following conditions: - Corrosion - Contamination - Terminal tension - Damage Important The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. DO NOT substitute any other terminals for those in the repair kit. ‹› If the terminals are damaged, corrosion is observed, or have poor tension, repair or replace as necessary. Apply dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins and terminals when reassembling. Refer to SIR/SRS Wiring Repairs in SI. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. 7. Connect the electrical connector, and install the CPA retainer. 8. Enable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 9. Clear the DTC with a scan tool. 10. Verify that the DTC does not reset by performing the Diagnostic Repair Verification in SI. ‹› If any DTC resets, then refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Parts Information Note If the CPA retainer P/N 54590003 (Orange CPA) cannot be located in the J-38125 SIR/SRS terminal repair kit, contact Kent Moore Tools and order P/N 54590003-PKG to obtain a package of 5. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 08-09-41-002F > Jun > 10 > Restraints - Air Bag Lamp ON/Multiple DTC Set > Page 13860 Warranty Information (excluding Saab U.S. Models) Important Select the appropriate Labor Operation for the repair that is performed. For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 13861 Air Bag Control Module: Locations Harness Routing Views Body Harness Routing (Regular Cab) 1 - X200 2 - G302 3 - X319 (AZ3/D07 with UQ3) 4 - JX339 (except MEX) 5 - X305 (except MEX) 6 - G304 (except MEX) 7 - J304 (AG2) 8 - J303 9 - X303 (except MEX) 10 - Inflatable Restraint Sensing and Diagnostic Module (SDM) Connector 11 - X275 12 - X202 13 - X500 (YE9 without AN3/DL3) 14 - X501 (YE9 without AN3/DL3) 15 - X601 (ASF) 16 - X600 (YE9 without AN3/DL3) Body Harness Routing (Extended Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 13862 1 - X700 2 - G303 3 - X303 4 - Inflatable Restraint Sensing and Diagnostic Module (SDM) Connector 5 - X501 (YE9 without AN3/DL3) 6 - X275 7 - X208 (A48) 8 - X202 9 - X500 (YE9 without AN3/DL3) 10 - G301 11 - J304 12 - X200 13 - X601 (ASF) 14 - X600 (YE9 without AN3/DL3) 15 - G302 16 - JX339 17 - X305 18 - X319 (AZ3/D07 with UQ3) 19 - X800 20 - J302 21 G304 22 - X320 (A48) 23 - J303 24 - X322 (UD7) 25 - Floor Panel Body Harness Routing (Crew Cab except HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 13863 1 - X601 (ASF) 2 - X309 (Y91) 3 - G302 4 - J302 5 - JX339 6 - G301 7 - J304 8 - X305 9 - X800 10 - G304 11 - G307 12 - X320 (A48) 13 - J303 14 - G303 15 - X700 16 - X303 17 - Inflatable Restraint Sensing and Diagnostic Module (SDM) Connector 18 - X501 (YE9 without AN3/DL3) 19 X502 (ASF without YE9 or with AN3) 20 - X202 21 - X500 (YE9 without AN3/DL3) 22 - X208 (A48) 23 - X600 (YE9 without AN3/DL3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 13864 Air Bag Control Module: Diagrams Component Connector End Views Inflatable Restraint Sensing and Diagnostic Module (SDM) X1 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 13865 Inflatable Restraint Sensing and Diagnostic Module (SDM) X2 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 13866 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 13867 Inflatable Restraint Side Impact Module - Left (10 Series except HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 13868 Inflatable Restraint Side Impact Module - Left (HP2) Inflatable Restraint Side Impact Module - Right (10 Series except HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 13869 Inflatable Restraint Side Impact Module - Right (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 13870 Air Bag Control Module: Service and Repair Inflatable Restraint Sensing and Diagnostic Module Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Indicator > Component Information > Locations Air Bag Deactivation Indicator: Locations Harness Routing Views Overhead Console Harness Routing 1 - X304 (except MEX) 2 - Inflatable Restraint Passenger Air Bag On/Off Indicator (AL0/C99 except MEX) 3 - Cellular Telephone Microphone (UE1/U3U/UVB) 4 - Roof Beacon Switch (5X7/5Y0/TRW) 5 - Sliding Rear Window Switch (A48) 6 - Dome/Reading Lamps - Front 7 - J322 (TRW/UG1/A48) 8 - J323 9 - X313 (CF5/TRW/5X7/5Y0) 10 - Blunt Cut - Roof Mounted Beacon Provision (TRW) 11 Roof Beacon Relay (TRW) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Indicator > Component Information > Locations > Page 13874 Air Bag Deactivation Indicator: Diagrams Component Connector End Views Inflatable Restraint I/P Module Indicator (AL0 or C99 except MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Indicator > Component Information > Locations > Page 13875 Air Bag Deactivation Indicator: Service and Repair Inflatable Restraint Instrument Panel Module Indicator Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Diagrams Air Bag Deactivation Switch: Diagrams Component Connector End Views Inflatable Restraint I/P Module Disable Switch (C99 or MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Diagrams > Page 13879 Air Bag Deactivation Switch: Service and Repair Instrument Panel Inflatable Restraint Module Switch Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams Clockspring Assembly / Spiral Cable: Diagrams Component Connector End Views Inflatable Restraint Steering Wheel Module Coil X1 Inflatable Restraint Steering Wheel Module Coil X2 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Page 13883 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service and Repair > Procedures Clockspring Assembly / Spiral Cable: Procedures Inflatable Restraint Steering Wheel Module Coil Centering Caution: The new SIR coil assembly will be centered. Improper alignment of the SIR coil assembly may damage the unit, causing an inflatable restraint malfunction. 1. Verify the following conditions before centering the SIR coil: * The front wheels of the vehicle are in the straight ahead position. * The block tooth (1) of the steering shaft assembly is in the 12 o'clock position. * The ignition switch is in the LOCK position. Note: If a double wire harness strap is installed onto the wire harness assembly and the column, you must reuse the holder for the wire straps during the installation. 2. Remove the wire harness strap or straps where necessary. 3. Hold the SIR coil and look at the side with the letters POM (1). 4. Rotate the coil hub clockwise until the coil ribbon stops. Caution: Do not rotate the SIR coil more than 3 turns counterclockwise from the center position. There is no stop in the counterclockwise direction. Rotating the SIR coil more than 3 turns counterclockwise from the center position will damage the SIR coil, causing an inflatable restraint malfunction. 5. From the clockwise stop, rotate the coil hub slowly counterclockwise approximately 3.3 turns. Place the uplead connector (2) in the 12 o'clock position. Ensure the flat wire cable loop appears in the centering window (4). This is the CENTER position. 6. If you have the orange lock pin (3), use the lock pin to lock the SIR coil in the center position. If you do not have the orange lock pin, hold the SIR coil in the center position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service and Repair > Procedures > Page 13886 7. Align the SIR coil with the horn tower and slide the SIR coil onto the steering shaft assembly. 8. If a double wire harness strap is installed onto the wire harness assembly and the column, you must route the wires up against the steering column. One wire harness strap will surround one lead from the coil to the steering column. The other wire harness strap will surround all other leads to the steering column. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service and Repair > Procedures > Page 13887 Clockspring Assembly / Spiral Cable: Removal and Replacement Steering Wheel Inflatable Restraint Module Coil Replacement Special Tools J 42640 Steering Column Anti-rotation Pin Removal Procedure Caution: With wheels of the vehicle facing straight ahead, secure the steering wheel utilizing steering column anti-rotation pin, steering column lock, or a strap to prevent rotation. Locking of the steering column will prevent damage and a possible malfunction of the SIR system. The steering wheel must be secured in position before disconnecting the following components: * The steering column * The intermediate shaft(s) * The steering gear After disconnecting these components, do not rotate the steering wheel or move the front tires and wheels. Failure to follow this procedure may cause the SIR coil assembly to become un-centered and cause possible damage to the SIR coil. If you think the SIR coil has became un-centered, refer to your specific SIR coil's centering procedure to re-center SIR Coil. 1. Verify the following before removing the inflatable restraint steering wheel module coil: * The wheels on the vehicle are straight ahead. * That anti-rotation pin J 42640 is installed or the ignition and start switch is in the LOCK position. 2. Remove the steering wheel. Refer to Steering Wheel Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Wheel Replacement). 3. Remove the steering column shroud. Refer to Steering Column Shroud Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Column Shroud Replacement). 4. Disconnect any electrical connectors as needed. 5. Remove the inflatable restraint steering wheel module coil retaining ring (2) and discard it. DO NOT reuse the ring. 6. Remove the inflatable restraint steering wheel module coil (1) from the steering shaft. 7. If replacing, discard the old inflatable restraint steering wheel module coil. Installation Procedure Caution: The new SIR coil assembly will be centered. Improper alignment of the SIR coil assembly may damage the unit, causing an inflatable restraint malfunction. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service and Repair > Procedures > Page 13888 Note: Do not remove the centering tab from the new inflatable restraint steering wheel module coil until the installation is complete. If the centering tab is missing then re-center the assembly. 1. If reusing the existing inflatable restraint steering wheel module coil it MUST be centered. Refer to Inflatable Restraint Steering Wheel Module Coil Centering (See: Procedures). 2. Align the inflatable restraint steering wheel module coil (1) with the horn tower on the turn signal switch cancel cam (2). 3. Slide the inflatable restraint steering wheel module coil (4) onto the steering shaft (2). 4. Firmly seat the new inflatable restraint steering wheel module coil retaining ring (3) into the appropriate groove on the steering shaft (2). 5. Remove and discard the centering tab from the new inflatable restraint steering wheel module coil (4). 6. Connect any electrical connectors as needed. 7. Install the steering column shroud. Refer to Steering Column Shroud Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Column Shroud Replacement). 8. Install the steering wheel. Refer to Steering Wheel Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Wheel Replacement). 9. Remove anti-rotation pin J 42640 . Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams Impact Sensor: Diagrams Component Connector End Views Inflatable Restraint Front End Sensor - Left (10 Series) Inflatable Restraint Front End Sensor - Right (10 Series) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Page 13892 Inflatable Restraint Front End Sensor (except 10 Series) Inflatable Restraint Side Impact Sensor (SIS) - Left Front (ASF) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Page 13893 Inflatable Restraint Side Impact Sensor (SIS) - Left Rear (Extended or Crew Cab with ASF) Inflatable Restraint Side Impact Sensor (SIS) - Right Front (ASF) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Page 13894 Inflatable Restraint Side Impact Sensor (SIS) - Right Rear (Extended or Crew Cab with ASF) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement Impact Sensor: Service and Repair Inflatable Restraint Front End Sensor Replacement Inflatable Restraint Front End Sensor Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 13897 Impact Sensor: Service and Repair Inflatable Restraint Side Impact Sensor Replacement (Crew Cab/Extended Cab/Regular Cab) Inflatable Restraint Side Impact Sensor Replacement (Crew Cab/Extended Cab/Regular Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 13898 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 13899 Impact Sensor: Service and Repair Inflatable Restraint Side Impact Sensor Replacement (Crew Cab, Rear Door) Inflatable Restraint Side Impact Sensor Replacement (Crew Cab, Rear Door) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 13900 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 13901 Impact Sensor: Service and Repair Inflatable Restraint Side Impact Sensor Replacement (Extended Cab, Rear Door ) Inflatable Restraint Side Impact Sensor Replacement (Extended Cab, Rear Door ) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 13902 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Classification Module - Air Bag > Component Information > Diagrams Seat Occupant Classification Module - Air Bag: Diagrams Component Connector End Views Inflatable Restraint Passenger Presence System (PPS) Module (AL0) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Restraints - Passenger Presence System Information Seat Occupant Sensor: Technical Service Bulletins Restraints - Passenger Presence System Information INFORMATION Bulletin No.: 06-08-50-009F Date: December 23, 2010 Subject: Information on Passenger Presence Sensing System (PPS or PSS) Concerns With Custom Upholstery, Accessory Seat Heaters or Other Comfort Enhancing Devices Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Passenger Presence Sensing System Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-08-50-009E (Section 08 - Body and Accessories). Concerns About Safety and Alterations to the Front Passenger Seat Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE THE SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER THE SEAT COVERS OR SEAT-RELATED EQUIPMENT. ANY ALTERATIONS TO SEAT COVERS OR GM ACCESSORIES DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. The front passenger seat in many GM vehicles is equipped with a passenger sensing system that will turn off the right front passenger's frontal airbag under certain conditions, such as when an infant or child seat is present. In some vehicles, the passenger sensing system will also turn off the right front passenger's seat mounted side impact airbag. For the system to function properly, sensors are used in the seat to detect the presence of a properly-seated occupant. The passenger sensing system may not operate properly if the original seat trim is replaced (1) by non-GM covers, upholstery or trim, or (2) by GM covers, upholstery or trim designed for a different vehicle or (3) by GM covers, upholstery or trim that has been altered by a trim shop, or (4) if any object, such as an aftermarket seat heater or a comfort enhancing pad or device is installed under the seat fabric or between the occupant and the seat fabric. Aftermarket Seat Heaters, Custom Upholstery, and Comfort Enhancing Pads or Devices Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE ONLY SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT RELEASED AS GM ACCESSORIES FOR THAT VEHICLE. DO NOT USE ANY OTHER TYPE OF SEAT COVERS OR SEAT-RELATED EQUIPMENT, OR GM ACCESSORIES RELEASED FOR OTHER VEHICLE APPLICATIONS. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ACCESSORIES, INCLUDING ANY WARRANTY REPAIRS MADE NECESSARY BY SUCH USE. Many types of aftermarket accessories are available to customers, upfitting shops, and dealers. Some of these devices sit on top of, or are Velcro(R) strapped to the seat while others such as seat heaters are installed under the seat fabric. Additionally, seat covers made of leather or other materials may have different padding thickness installed that could prevent the Passenger Sensing System from functioning properly. Never alter the vehicle seats. Never add pads or other devices to the seat cushion, as this may interfere with the operation of the Passenger Sensing System and either prevent proper deployment of the passenger airbag or prevent proper suppression of the passenger air bag. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Page 13910 Seat Occupant Sensor: Service and Repair Inflatable Restraint Passenger Presence System Replacement - Front (without HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Page 13911 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Position Sensor > Component Information > Locations Seat Position Sensor: Locations Harness Routing Views Driver Seat Harness Routing 1 - Seat Recline Motor - Driver (AN3) 2 - Seat Lumbar Vertical Motor Position Sensor - Driver (AN3) 3 - Seat Lumbar Vertical Motor - Driver (AN3) 4 - X324 (AN3) 5 - Seat Lumbar Horizontal Motor - Driver (AN3) 6 - Seat Lumbar Horizontal Motor Position Sensor - Driver (AN3) 7 - Seat Recline Position Sensor - Driver (AN3) 8 - Seat Lumbar Switch - Driver (AN3) 9 - Seat Adjuster Switch - Driver (AG1) 10 - Memory Seat Module (MSM) (AN3) 11 - Inflatable Restraint Seat Position Sensor (SPS) - Driver (10 Series) 12 - Seat Adjuster Motor Assembly - Driver (AG1) 13 Seat Belt Buckle - Driver Passenger Seat Harness Routing Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Position Sensor > Component Information > Locations > Page 13915 1 - Seat Frame 2 - X325 (AN3) 3 - Seat Lumbar Vertical Motor - Passenger (AN3) 4 - Seat Adjuster Switch - Passenger (AG2) 5 - Seat Lumbar Switch - Passenger (AN3) 6 - Seat Belt Buckle Passenger 7 - Inflatable Restraint Passenger Presence System (PPS) Module (AL0) 8 - Seat Adjuster Motor Assembly - Passenger (AG2) 9 - Inflatable Restraint Passenger Presence System (PPS) Sensor (AL0) 10 - Seat Recline Motor - Passenger (AN3) 11 - Seat Lumbar Horizontal Motor - Passenger (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Position Sensor > Component Information > Locations > Page 13916 Seat Position Sensor: Diagrams Component Connector End Views Inflatable Restraint Seat Position Sensor - Driver (10 Series except MEX) Inflatable Restraint Seat Position Sensor - Passenger (10 Series except Crew Cab or MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Position Sensor > Component Information > Locations > Page 13917 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Position Sensor > Component Information > Locations > Page 13918 Seat Position Sensor: Service and Repair Inflatable Restraint Seat Position Sensor Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Head Restraint System > System Information > Technical Service Bulletins > Restraints - Driver/Passenger Seat Head Rest Information Head Restraint System: Technical Service Bulletins Restraints - Driver/Passenger Seat Head Rest Information INFORMATION Bulletin No.: 10-08-50-003A Date: March 24, 2011 Subject: Information on Driver or Passenger Seat Head Restraint Concerns with Comfort, Custom Upholstery or Other Comfort Enhancing Devices Models: 2012 and Prior GM Passenger Cars and Trucks Equipped with Adjustable Head Restraints Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 10-08-50-003 (Section 08 - Body and Accessories). Important ON A GM VEHICLE EQUIPPED WITH ADJUSTABLE HEAD RESTRAINTS, USE THE HEAD RESTRAINT COVERS, FOAM AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER OR REPOSITION THE HEAD RESTRAINT SYSTEM. ANY ALTERATIONS TO HEAD RESTRAINTS DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER DESIGN ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. You may have a customer with a concern that the head restraint is uncomfortable or sits too far forward. The front driver and passenger seats are equipped with head restraints that have been designed to help minimize injuries while still providing comfort to the occupants. Each GM vehicle has its own specifically designed head restraint. The head restraints should only be used in the vehicle for which they were designed. The head restraint will not operate to its design intent if the original foam is replaced (1) by non-GM foam or head restraint, (2) by GM foam or head restraint designed for a different vehicle, (3) by GM foam or head restraint that has been altered by a trim shop or (4) if any object, such as an aftermarket comfort enhancing pad or device, is installed. Never modify the design of the head restraint or remove the head restraint from the vehicle as this may interfere with the operation of the seating and restraint systems and may prevent proper positioning of the passenger within the vehicle. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Knee Diverter > Component Information > Service and Repair > Knee Bolster Replacement (With SLT) Knee Diverter: Service and Repair Knee Bolster Replacement (With SLT) Knee Bolster Replacement (With SLT) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Knee Diverter > Component Information > Service and Repair > Knee Bolster Replacement (With SLT) > Page 13927 Knee Diverter: Service and Repair Knee Bolster Replacement (Without SLT) Knee Bolster Replacement (Without SLT) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Customer Interest for Air Bag Control Module: > 08-09-41-002F > Jun > 10 > Restraints - Air Bag Lamp ON/Multiple DTC Set Air Bag Control Module: Customer Interest Restraints - Air Bag Lamp ON/Multiple DTC Set TECHNICAL Bulletin No.: 08-09-41-002F Date: June 10, 2010 Subject: Diagnostic Information for Supplemental Inflatable Restraint (SIR) System, Intermittent AIR BAG Indicator/Lamp Illuminated with DTC(s) B0012, B0013, B0015, B0016, B0019, B0020, B0022, B0023, B0026, B0033, B0040, B0042 or B0044 Set (Inspect and Replace Connector Position Assurance (CPA) Retainer) Models: 2005-2007 Buick Rainier 2006-2009 Buick Allure (Canada only), LaCrosse, Lucerne 2008-2010 Buick Enclave 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade Models 2008-2009 Cadillac SRX, XLR 2008-2010 Cadillac CTS, STS 2005-2006 Chevrolet SSR 2005-2009 Chevrolet TrailBlazer, TrailBlazer EXT 2005-2010 Chevrolet Cobalt 2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Corvette, HHR, Impala, Malibu Models (includes Malibu Classic) 2007-2009 Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet Traverse 2005-2009 GMC Envoy Models 2007-2010 GMC Acadia, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2010 GMC Savana 2005-2006 Pontiac Pursuit 2005-2009 Pontiac G6 2006-2009 Pontiac Solstice 2007-2009 Pontiac G5, Torrent 2008-2009 Pontiac G8 2005-2009 Saab 9-7X 2007-2009 Saturn AURA, OUTLOOK, SKY 2008-2009 Saturn VUE 2008-2009 HUMMER H2 2007-2008 Daewoo G2X 2007-2009 Opel GT Supercede: This bulletin is being revised to update the Warranty Information and add Saab Warranty Information. Please discard Corporate Bulletin Number 08-09-41-002E (Section 09 Restraints). Condition - Some customers may comment on an intermittent or current AIR BAG indicator or lamp being illuminated on the instrument panel cluster (IPC). Important This bulletin only applies to the following DTCs: - Technicians may observe DTC(s) B0012 04, 0D, 0E; B0013 04, 0D, 0E; B0015 04, 0D, 0E; B0016 04, 0D, 0E; B0019 04, 0D, 0E; B0020 04, 0D, 0E; B0022, B0023 04, 0D, 0E; B0033 04, 0D, 0E; B0040 04, 0D, 0E; B0042 or B0044 set as Current or in History in the sensing and diagnostic module (SDM). Cause This condition may be caused by a loose, missing, or damaged connector position assurance (CPA) retainer at a supplemental inflatable restraint (SIR) module electrical connector, or a deployment loop wiring harness electrical connector. Correction Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Customer Interest for Air Bag Control Module: > 08-09-41-002F > Jun > 10 > Restraints - Air Bag Lamp ON/Multiple DTC Set > Page 13937 Caution When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. 1. Perform the Diagnostic System Check-Vehicle. 2. Identify the DTC that is set AND review the DTC Descriptor in the corresponding diagnostic procedure. Refer to Diagnostic Trouble Code (DTC) List-Vehicle in SI. 3. Using the information from the DTC Descriptor, determine the location of the affected electrical connector. Refer to SIR Identification Views and the Master Electrical Component List in SI. 4. Turn OFF the ignition and disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 5. BEFORE removing, INSPECT the CPA retainer at the electrical connector. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. ‹› If the CPA retainer is loose, damaged, or will not seat in the connector, replace it with a new one. Reinstall the CPA correctly by first pushing the connector body in completely, and then pushing the CPA retainer in completely. ‹› If the CPA retainer is not loose or damaged and is properly seated, proceed to Step 6. 6. Remove the CPA retainer and disconnect the electrical connector. Inspect the terminals for the following conditions: - Corrosion - Contamination - Terminal tension - Damage Important The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. DO NOT substitute any other terminals for those in the repair kit. ‹› If the terminals are damaged, corrosion is observed, or have poor tension, repair or replace as necessary. Apply dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins and terminals when reassembling. Refer to SIR/SRS Wiring Repairs in SI. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. 7. Connect the electrical connector, and install the CPA retainer. 8. Enable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 9. Clear the DTC with a scan tool. 10. Verify that the DTC does not reset by performing the Diagnostic Repair Verification in SI. ‹› If any DTC resets, then refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Parts Information Note If the CPA retainer P/N 54590003 (Orange CPA) cannot be located in the J-38125 SIR/SRS terminal repair kit, contact Kent Moore Tools and order P/N 54590003-PKG to obtain a package of 5. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Customer Interest for Air Bag Control Module: > 08-09-41-002F > Jun > 10 > Restraints - Air Bag Lamp ON/Multiple DTC Set > Page 13938 Warranty Information (excluding Saab U.S. Models) Important Select the appropriate Labor Operation for the repair that is performed. For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 08-09-41-002F > Jun > 10 > Restraints - Air Bag Lamp ON/Multiple DTC Set Air Bag Control Module: All Technical Service Bulletins Restraints - Air Bag Lamp ON/Multiple DTC Set TECHNICAL Bulletin No.: 08-09-41-002F Date: June 10, 2010 Subject: Diagnostic Information for Supplemental Inflatable Restraint (SIR) System, Intermittent AIR BAG Indicator/Lamp Illuminated with DTC(s) B0012, B0013, B0015, B0016, B0019, B0020, B0022, B0023, B0026, B0033, B0040, B0042 or B0044 Set (Inspect and Replace Connector Position Assurance (CPA) Retainer) Models: 2005-2007 Buick Rainier 2006-2009 Buick Allure (Canada only), LaCrosse, Lucerne 2008-2010 Buick Enclave 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade Models 2008-2009 Cadillac SRX, XLR 2008-2010 Cadillac CTS, STS 2005-2006 Chevrolet SSR 2005-2009 Chevrolet TrailBlazer, TrailBlazer EXT 2005-2010 Chevrolet Cobalt 2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Corvette, HHR, Impala, Malibu Models (includes Malibu Classic) 2007-2009 Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet Traverse 2005-2009 GMC Envoy Models 2007-2010 GMC Acadia, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2010 GMC Savana 2005-2006 Pontiac Pursuit 2005-2009 Pontiac G6 2006-2009 Pontiac Solstice 2007-2009 Pontiac G5, Torrent 2008-2009 Pontiac G8 2005-2009 Saab 9-7X 2007-2009 Saturn AURA, OUTLOOK, SKY 2008-2009 Saturn VUE 2008-2009 HUMMER H2 2007-2008 Daewoo G2X 2007-2009 Opel GT Supercede: This bulletin is being revised to update the Warranty Information and add Saab Warranty Information. Please discard Corporate Bulletin Number 08-09-41-002E (Section 09 Restraints). Condition - Some customers may comment on an intermittent or current AIR BAG indicator or lamp being illuminated on the instrument panel cluster (IPC). Important This bulletin only applies to the following DTCs: - Technicians may observe DTC(s) B0012 04, 0D, 0E; B0013 04, 0D, 0E; B0015 04, 0D, 0E; B0016 04, 0D, 0E; B0019 04, 0D, 0E; B0020 04, 0D, 0E; B0022, B0023 04, 0D, 0E; B0033 04, 0D, 0E; B0040 04, 0D, 0E; B0042 or B0044 set as Current or in History in the sensing and diagnostic module (SDM). Cause This condition may be caused by a loose, missing, or damaged connector position assurance (CPA) retainer at a supplemental inflatable restraint (SIR) module electrical connector, or a deployment loop wiring harness electrical connector. Correction Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 08-09-41-002F > Jun > 10 > Restraints - Air Bag Lamp ON/Multiple DTC Set > Page 13944 Caution When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. 1. Perform the Diagnostic System Check-Vehicle. 2. Identify the DTC that is set AND review the DTC Descriptor in the corresponding diagnostic procedure. Refer to Diagnostic Trouble Code (DTC) List-Vehicle in SI. 3. Using the information from the DTC Descriptor, determine the location of the affected electrical connector. Refer to SIR Identification Views and the Master Electrical Component List in SI. 4. Turn OFF the ignition and disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 5. BEFORE removing, INSPECT the CPA retainer at the electrical connector. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. ‹› If the CPA retainer is loose, damaged, or will not seat in the connector, replace it with a new one. Reinstall the CPA correctly by first pushing the connector body in completely, and then pushing the CPA retainer in completely. ‹› If the CPA retainer is not loose or damaged and is properly seated, proceed to Step 6. 6. Remove the CPA retainer and disconnect the electrical connector. Inspect the terminals for the following conditions: - Corrosion - Contamination - Terminal tension - Damage Important The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. DO NOT substitute any other terminals for those in the repair kit. ‹› If the terminals are damaged, corrosion is observed, or have poor tension, repair or replace as necessary. Apply dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins and terminals when reassembling. Refer to SIR/SRS Wiring Repairs in SI. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. 7. Connect the electrical connector, and install the CPA retainer. 8. Enable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 9. Clear the DTC with a scan tool. 10. Verify that the DTC does not reset by performing the Diagnostic Repair Verification in SI. ‹› If any DTC resets, then refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Parts Information Note If the CPA retainer P/N 54590003 (Orange CPA) cannot be located in the J-38125 SIR/SRS terminal repair kit, contact Kent Moore Tools and order P/N 54590003-PKG to obtain a package of 5. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 08-09-41-002F > Jun > 10 > Restraints - Air Bag Lamp ON/Multiple DTC Set > Page 13945 Warranty Information (excluding Saab U.S. Models) Important Select the appropriate Labor Operation for the repair that is performed. For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 13946 Air Bag Control Module: Locations Harness Routing Views Body Harness Routing (Regular Cab) 1 - X200 2 - G302 3 - X319 (AZ3/D07 with UQ3) 4 - JX339 (except MEX) 5 - X305 (except MEX) 6 - G304 (except MEX) 7 - J304 (AG2) 8 - J303 9 - X303 (except MEX) 10 - Inflatable Restraint Sensing and Diagnostic Module (SDM) Connector 11 - X275 12 - X202 13 - X500 (YE9 without AN3/DL3) 14 - X501 (YE9 without AN3/DL3) 15 - X601 (ASF) 16 - X600 (YE9 without AN3/DL3) Body Harness Routing (Extended Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 13947 1 - X700 2 - G303 3 - X303 4 - Inflatable Restraint Sensing and Diagnostic Module (SDM) Connector 5 - X501 (YE9 without AN3/DL3) 6 - X275 7 - X208 (A48) 8 - X202 9 - X500 (YE9 without AN3/DL3) 10 - G301 11 - J304 12 - X200 13 - X601 (ASF) 14 - X600 (YE9 without AN3/DL3) 15 - G302 16 - JX339 17 - X305 18 - X319 (AZ3/D07 with UQ3) 19 - X800 20 - J302 21 G304 22 - X320 (A48) 23 - J303 24 - X322 (UD7) 25 - Floor Panel Body Harness Routing (Crew Cab except HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 13948 1 - X601 (ASF) 2 - X309 (Y91) 3 - G302 4 - J302 5 - JX339 6 - G301 7 - J304 8 - X305 9 - X800 10 - G304 11 - G307 12 - X320 (A48) 13 - J303 14 - G303 15 - X700 16 - X303 17 - Inflatable Restraint Sensing and Diagnostic Module (SDM) Connector 18 - X501 (YE9 without AN3/DL3) 19 X502 (ASF without YE9 or with AN3) 20 - X202 21 - X500 (YE9 without AN3/DL3) 22 - X208 (A48) 23 - X600 (YE9 without AN3/DL3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 13949 Air Bag Control Module: Diagrams Component Connector End Views Inflatable Restraint Sensing and Diagnostic Module (SDM) X1 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 13950 Inflatable Restraint Sensing and Diagnostic Module (SDM) X2 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 13951 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 13952 Inflatable Restraint Side Impact Module - Left (10 Series except HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 13953 Inflatable Restraint Side Impact Module - Left (HP2) Inflatable Restraint Side Impact Module - Right (10 Series except HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 13954 Inflatable Restraint Side Impact Module - Right (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 13955 Air Bag Control Module: Service and Repair Inflatable Restraint Sensing and Diagnostic Module Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Diagrams Seat Occupant Classification Module - Air Bag: Diagrams Component Connector End Views Inflatable Restraint Passenger Presence System (PPS) Module (AL0) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling SIR component location affects how a vehicle should be serviced. There are parts of the SIR system installed in various locations around a vehicle. To find the location of the SIR components refer to SIR Identification Views (See: Air Bag Systems/Locations). There are several reasons for disabling the SIR system, such as repairs to the SIR system or servicing a component near or attached to an SIR component. There are several ways to disable the SIR system depending on what type of service is being performed. The following information covers the proper procedures for disabling/enabling the SIR system. SIR Service Precautions Warning When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. The inflatable restraint sensing and diagnostic module (SDM) maintains a reserved energy supply. The reserved energy supply provides deployment power for the air bags if the SDM loses battery power during a collision. Deployment power is available for as much as 1 minute after disconnecting the vehicle power. Waiting 1 minute before working on the system after disabling the SIR system prevents deployment of the air bags from the reserved energy supply. General Service Instructions The following are general service instructions which must be followed in order to properly repair the vehicle and return it to its original integrity: * Do not expose air bags to temperatures above 65°C (149°F). * Verify the correct replacement part number. Do not substitute a component from a different vehicle. * Use only original GM replacement parts available from your authorized GM dealer. Do not use salvaged parts for repairs to the SIR system. Discard any of the following components if it has been dropped from a height of 92 cm (3 feet) or greater: * Inflatable restraint sensing and diagnostic module (SDM) * Any air bag * Driver steering wheel air bag coil * Any impact sensor * Seat belt anchor and/or retractor pretensioners * Passenger presence module and/or occupant sensor Disabling Procedure - Air Bag Fuse 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. Note: The SDM may have more than one fused power input. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove all fuses supplying power to the SDM. With all SDM fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate a SIR system malfunction. 3. Locate and remove the fuse(s) supplying power to the SDM. Refer to SIR Schematics (See: Air Bag Systems/Diagrams/Electrical Diagrams) or Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse/Application and ID). 4. Wait 1 minute before working on the system. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Page 13963 Enabling Procedure - Air Bag Fuse 1. Place the ignition in the OFF position. 2. Install the fuse(s) supplying power to the SDM. Refer to SIR Schematics (See: Air Bag Systems/Diagrams/Electrical Diagrams) or Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse/Application and ID). 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle). Disabling Procedure - Negative Battery Cable 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. 3. Disconnect the negative battery cable from the battery. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 4. Wait 1 minute before working on system. Enabling Procedure - Negative Battery Cable 1. Place the ignition in the OFF position. 2. Connect the negative battery cable to the battery. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Service and Repair Child Seat Tether Attachment: Service and Repair Child Seat Restraint System Belt Bracket Replacement (Ext Cab/Crew Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Restraint System - Normal Safety Belt Locking Conditions Seat Belt: Technical Service Bulletins Restraint System - Normal Safety Belt Locking Conditions INFORMATION Bulletin No.: 05-09-40-002E Date: October 21, 2010 Subject: Safety Belt Locking Conditions (Normal Operating Characteristic) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2010 HUMMER H2, H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 05-09-40-002D (Section 09 - Restraints). The purpose of this bulletin is to explain when the safety belts are supposed to lock. There are several different locking situations for both front and rear safety belts. Overspool Lock There is an unintentional locking condition that ALL safety belts from ALL manufacturers may experience called "overspool lock". If the webbing snaps back to the stowed position rapidly enough, the retractor will lock with the belt fully stowed. This is more likely to occur when customers "help" the belt to retract. Without the weight of the latch plate and friction to slow the retractive speed of the webbing, the higher than normal webbing retraction speed that occurs engages the locking mechanism when a sudden stop occurs at the end of web travel. Since the webbing is now fully loaded on the spool, the retractor cannot rewind itself further to release the locking mechanism. When this happens, the occupant cannot extract the belt to wear it. DO NOT replace the retractor for this condition until first attempting to disengage the locking mechanism by following the recommendation listed below. Recommendation Pull hard on the locked webbing and then release. The hard pull extracts a small amount of webbing from the retractor which, in turn, permits a small amount of retraction to occur when released. This is all that is needed to disengage the locking mechanism. The safety belt will now function properly. Vehicle Sensing This type of locking occurs in response to the vehicle under the following conditions: - The vehicle changes speed or direction abruptly (the vehicle goes into rapid acceleration OR rapid deceleration or there is aggressive cornering). - It can also occur in a static condition when a vehicle is parked on a large slant (fore-aft or side-to-side), such as streets in San Francisco, California. - It may also occur over rough road conditions where the retractor mechanism is bounced into a locked condition. In all of these conditions, as long as tension is maintained on the webbing, the belt will stay locked. When the tension is released, the belt retracts slightly, the lock bar disengages and the safety belt should return to normal function. Please inform customers that may comment that "the belt locks intermittently" that this is the design intent and the belt is functioning properly. Web Sensing This type of locking occurs in response to the extraction of webbing. When the webbing reels out at an accelerated rate, it goes into lock mode and stays there until tension is again released. To observe this condition, extract the webbing quickly. Customers may refer to this condition as "intermittent lock-up" and encounter it when trying to put the belt on too quickly. Automatic Locking (ALR) When the webbing is pulled all the way out, it automatically converts the retractor into a cinch-down mode (i.e. ALR). This is typically used to tightly secure a child seat to the vehicle. Some customers may experience inadvertent activation of ALR mode if they happen to pull the belt all the way out to the end of travel while they are putting the belt on. The ALR mode of operation is automatically cancelled when the belt is unfastened and stowed (the belt returns to normal sensitive function). Corvette only - This locking mechanism is also provided at the driver's position of the Corvette only, as a unique feature. Corvette customers may find this feature appealing when they plan to operate the vehicle in a "spirited" manner (such as driving in mountainous terrain). With the ALR active, the operator is snugly cinched into the seat and kept firmly in place during high G-force driving maneuvers. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Restraint System - Normal Safety Belt Locking Conditions > Page 13972 Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Seat Belt Latch Stop Installation Seat Belt: Service and Repair Seat Belt Latch Stop Installation Seat Belt Latch Stop Installation Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Seat Belt Latch Stop Installation > Page 13975 Seat Belt: Service and Repair Seat Belt Replacement - Center Rear (Extended Cab) Seat Belt Replacement - Center Rear (Extended Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Seat Belt Latch Stop Installation > Page 13976 Seat Belt: Service and Repair Seat Belt Replacement - Center Rear (Crew Cab) Seat Belt Replacement - Center Rear (Crew Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > Customer Interest: > 09-09-40-001A > Feb > 11 > Restraints - Seat Belt Warning Lamp On/Buckling Issues Seat Belt Buckle: Customer Interest Restraints - Seat Belt Warning Lamp On/Buckling Issues INFORMATION Bulletin No.: 09-09-40-001A Date: February 02, 2011 Subject: Seat Belt Buckle Latching Issues and/or Seat Belt Warning Lights Illuminated Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7 X Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-09-40-001 (Section 09 - Restraints). This bulletin is being published to advise dealers about seat belt buckles not operating and/or seat belt warning light illumination, as well as difficulty latching and unlatching the buckle or the buckle release button sticking. Analysis of warranty data has determined that this condition may be caused by sticky beverages being spilled onto or into the seat belt buckle assembly. Foreign debris from food, candy wrappers, paper and coins can also contribute to this condition. Important If foreign material (debris) or sticky liquids are the cause of the concern, show the customer the condition of the component (buckle assembly) and explain how it is affecting the function of the restraint system. Strongly recommend that the component be replaced. Point out the fact that this is not a manufacturing defect and is not covered by the new vehicle warranty. If the customer declines to have parts replaced, the service department management must make a notation on the service record that the lack of functionality of seating position with an inoperative buckle was fully explained to the customer. The service department management must advise the customer that having a non-functioning buckle in a seating position voids ability to use that seating position (no one should ride in the seat). Also make the customer aware that it may be against the law to ride in a vehicle without wearing a restraint system. Important Never insert anything other than the seat belt latch plate into the buckle assembly. Do not attempt to dig anything out of a buckle with a tool. Never try to wash out a buckle to remove a spilled liquid as this may damage the buckle. Use the following steps to determine the cause of the concern. 1. Inspect the buckle assembly with a light shining on the latch plate insertion area. Look for any debris or foreign objects in the buckle. 2. If any debris or foreign objects are observed, try to vacuum out the item. After the foreign material is removed, latch and unlatch the seat belt. If the system functions properly, do not replace the seat belt buckle assembly. 3. If the condition has not been corrected, inspect the buckle assembly for any sticky residue. If sticky residue is found, inform the customer that a substance was spilled on the seat belt buckle assembly causing the malfunction. The buckle assembly will need to be replaced at the customer's expense. 4. Refer to SI for seat belt component replacement. Important If foreign material (debris) or sticky liquids are the cause of the concern, show the customer the condition of the component (buckle assembly) and explain how it is affecting the function of the restraint system. Strongly recommend that the component be replaced at the customer's expense. Point out the fact that this is not a manufacturing defect and is not covered by the new vehicle warranty. If the customer declines to have parts replaced, the service department management must make a notation on the service record that the lack of functionality of seating position with an inoperative buckle was fully explained to the customer. The service department management must advise customer that having a non-functioning buckle in a seating position voids ability to use that seating position (no one should ride in the seat). Also make the customer aware that it may be against the law to ride in a vehicle without wearing a restraint system. 5. If further restraint diagnosis is required, refer to Seat Belt System Operational and Functional Checks in SI. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > Customer Interest: > 09-09-40-001A > Feb > 11 > Restraints - Seat Belt Warning Lamp On/Buckling Issues > Page 13985 Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > Customer Interest: > 07-09-41-010D > May > 10 > Restraints - Airbag Light On DTC B0071 And B0081 Set Seat Belt Buckle: Customer Interest Restraints - Airbag Light On DTC B0071 And B0081 Set TECHNICAL Bulletin No.: 07-09-41-010D Date: May 03, 2010 Subject: Airbag Light On, DTC B0071 and B0081 Set (Diagnose and Replace Right Front Seatbelt Buckle, If Necessary) Models: 2006-2010 Buick Lucerne 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2006-2007 Chevrolet Monte Carlo 2006-2008 Chevrolet Impala 2007-2010 Chevrolet Avalanche, Colorado, Silverado LD, Suburban, Tahoe 2007-2010 GMC Canyon, Sierra LD, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2006-2010 HUMMER H3 2009-2010 HUMMER H3T Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 07-09-41-010C (Section 09 - Restraints). Condition Some customers may comment on the airbag light being illuminated. Upon investigation, the technician may find DTC B0071 set in the passenger presence system (PPS) and a DTC B0081 in the sensing and diagnostics module (SDM). Correction Verify proper system electrical connections. Inspect the passenger seat belt tension sensor signal, voltage reference and low reference circuits, carefully for cutting and/or chaffing per SI instructions for DTC B0071. If all checks have been made and no fault has been found, replace the belt tension sensor. Important The seat belt tension sensor is not serviced separately. The seat belt buckle with the tension sensor must be serviced as a complete unit. Parts Information For part number and usage of seatbelt buckles, refer to Group 14.875 (cars) or Group 16.714 (trucks) of the appropriate parts catalog. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Buckle: > 09-09-40-001A > Feb > 11 > Restraints - Seat Belt Warning Lamp On/Buckling Issues Seat Belt Buckle: All Technical Service Bulletins Restraints - Seat Belt Warning Lamp On/Buckling Issues INFORMATION Bulletin No.: 09-09-40-001A Date: February 02, 2011 Subject: Seat Belt Buckle Latching Issues and/or Seat Belt Warning Lights Illuminated Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7 X Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-09-40-001 (Section 09 - Restraints). This bulletin is being published to advise dealers about seat belt buckles not operating and/or seat belt warning light illumination, as well as difficulty latching and unlatching the buckle or the buckle release button sticking. Analysis of warranty data has determined that this condition may be caused by sticky beverages being spilled onto or into the seat belt buckle assembly. Foreign debris from food, candy wrappers, paper and coins can also contribute to this condition. Important If foreign material (debris) or sticky liquids are the cause of the concern, show the customer the condition of the component (buckle assembly) and explain how it is affecting the function of the restraint system. Strongly recommend that the component be replaced. Point out the fact that this is not a manufacturing defect and is not covered by the new vehicle warranty. If the customer declines to have parts replaced, the service department management must make a notation on the service record that the lack of functionality of seating position with an inoperative buckle was fully explained to the customer. The service department management must advise the customer that having a non-functioning buckle in a seating position voids ability to use that seating position (no one should ride in the seat). Also make the customer aware that it may be against the law to ride in a vehicle without wearing a restraint system. Important Never insert anything other than the seat belt latch plate into the buckle assembly. Do not attempt to dig anything out of a buckle with a tool. Never try to wash out a buckle to remove a spilled liquid as this may damage the buckle. Use the following steps to determine the cause of the concern. 1. Inspect the buckle assembly with a light shining on the latch plate insertion area. Look for any debris or foreign objects in the buckle. 2. If any debris or foreign objects are observed, try to vacuum out the item. After the foreign material is removed, latch and unlatch the seat belt. If the system functions properly, do not replace the seat belt buckle assembly. 3. If the condition has not been corrected, inspect the buckle assembly for any sticky residue. If sticky residue is found, inform the customer that a substance was spilled on the seat belt buckle assembly causing the malfunction. The buckle assembly will need to be replaced at the customer's expense. 4. Refer to SI for seat belt component replacement. Important If foreign material (debris) or sticky liquids are the cause of the concern, show the customer the condition of the component (buckle assembly) and explain how it is affecting the function of the restraint system. Strongly recommend that the component be replaced at the customer's expense. Point out the fact that this is not a manufacturing defect and is not covered by the new vehicle warranty. If the customer declines to have parts replaced, the service department management must make a notation on the service record that the lack of functionality of seating position with an inoperative buckle was fully explained to the customer. The service department management must advise customer that having a non-functioning buckle in a seating position voids ability to use that seating position (no one should ride in the seat). Also make the customer aware that it may be against the law to ride in a vehicle without wearing a restraint system. 5. If further restraint diagnosis is required, refer to Seat Belt System Operational and Functional Checks in SI. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Buckle: > 09-09-40-001A > Feb > 11 > Restraints - Seat Belt Warning Lamp On/Buckling Issues > Page 13995 Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Buckle: > 07-09-41-010D > May > 10 > Restraints - Airbag Light On DTC B0071 And B0081 Set Seat Belt Buckle: All Technical Service Bulletins Restraints - Airbag Light On DTC B0071 And B0081 Set TECHNICAL Bulletin No.: 07-09-41-010D Date: May 03, 2010 Subject: Airbag Light On, DTC B0071 and B0081 Set (Diagnose and Replace Right Front Seatbelt Buckle, If Necessary) Models: 2006-2010 Buick Lucerne 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2006-2007 Chevrolet Monte Carlo 2006-2008 Chevrolet Impala 2007-2010 Chevrolet Avalanche, Colorado, Silverado LD, Suburban, Tahoe 2007-2010 GMC Canyon, Sierra LD, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2006-2010 HUMMER H3 2009-2010 HUMMER H3T Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 07-09-41-010C (Section 09 - Restraints). Condition Some customers may comment on the airbag light being illuminated. Upon investigation, the technician may find DTC B0071 set in the passenger presence system (PPS) and a DTC B0081 in the sensing and diagnostics module (SDM). Correction Verify proper system electrical connections. Inspect the passenger seat belt tension sensor signal, voltage reference and low reference circuits, carefully for cutting and/or chaffing per SI instructions for DTC B0071. If all checks have been made and no fault has been found, replace the belt tension sensor. Important The seat belt tension sensor is not serviced separately. The seat belt buckle with the tension sensor must be serviced as a complete unit. Parts Information For part number and usage of seatbelt buckles, refer to Group 14.875 (cars) or Group 16.714 (trucks) of the appropriate parts catalog. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Buckle: > 07-09-40-002A > Jun > 09 > Restraints Seat Belt Latch Stop Button Availability Seat Belt Buckle: All Technical Service Bulletins Restraints - Seat Belt Latch Stop Button Availability INFORMATION Bulletin No.: 07-09-40-002A Date: June 04, 2009 Subject: Seat Belt Latch Stop Button Available for Service Models: 2005-2010 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2010 HUMMER H2 2006-2010 HUMMER H3 2009-2010 HUMMER H3T .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to update the models and model years. Please discard Corporate Bulletin Number 07-09-40-002 (Section 09 - Restraints). .............................................................................................................................................................. .................................................................................. All seat belt retractor assemblies contain a stop button. If a stop button becomes damaged, the button can be replaced by ordering a replacement button through the GM Parts Catalog. The seat belt retractor assembly does not need replacement. Refer to the Seat Belt Latch Stop Installation procedure in SI for the complete installation procedure. Parts Information For part numbers, usage and availability of stop buttons, see Stop Kit in Group 14.875 (cars) or Group 16.714 (trucks) of the appropriate Parts Catalog. Saturn retailers should refer to the appropriate model year Parts & Illustration Catalog for the vehicle. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Buckle: > 07-09-40-002A > Jun > 09 > Restraints Seat Belt Latch Stop Button Availability Seat Belt Buckle: All Technical Service Bulletins Restraints - Seat Belt Latch Stop Button Availability INFORMATION Bulletin No.: 07-09-40-002A Date: June 04, 2009 Subject: Seat Belt Latch Stop Button Available for Service Models: 2005-2010 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2010 HUMMER H2 2006-2010 HUMMER H3 2009-2010 HUMMER H3T .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to update the models and model years. Please discard Corporate Bulletin Number 07-09-40-002 (Section 09 - Restraints). .............................................................................................................................................................. .................................................................................. All seat belt retractor assemblies contain a stop button. If a stop button becomes damaged, the button can be replaced by ordering a replacement button through the GM Parts Catalog. The seat belt retractor assembly does not need replacement. Refer to the Seat Belt Latch Stop Installation procedure in SI for the complete installation procedure. Parts Information For part numbers, usage and availability of stop buttons, see Stop Kit in Group 14.875 (cars) or Group 16.714 (trucks) of the appropriate Parts Catalog. Saturn retailers should refer to the appropriate model year Parts & Illustration Catalog for the vehicle. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Driver or Passenger Seat Belt Buckle Replacement Seat Belt Buckle: Service and Repair Driver or Passenger Seat Belt Buckle Replacement Driver or Passenger Seat Belt Buckle Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Driver or Passenger Seat Belt Buckle Replacement > Page 14011 Seat Belt Buckle: Service and Repair Rear Seat Center Buckle Side Belt Replacement (Crew Cab) Rear Seat Center Buckle Side Belt Replacement (Crew Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Driver or Passenger Seat Belt Buckle Replacement > Page 14012 Seat Belt Buckle: Service and Repair Rear Seat Center Buckle Side Belt Replacement (Ext Cab w/AM7) Rear Seat Center Buckle Side Belt Replacement (Ext Cab w/AM7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Driver or Passenger Seat Belt Buckle Replacement > Page 14013 Seat Belt Buckle: Service and Repair Rear Seat Center Buckle Side Belt Replacement (Ext Cab w/A68) Rear Seat Center Buckle Side Belt Replacement (Ext Cab w/A68) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Locations Seat Belt Buckle Switch: Locations Harness Routing Views Driver Seat Harness Routing 1 - Seat Recline Motor - Driver (AN3) 2 - Seat Lumbar Vertical Motor Position Sensor - Driver (AN3) 3 - Seat Lumbar Vertical Motor - Driver (AN3) 4 - X324 (AN3) 5 - Seat Lumbar Horizontal Motor - Driver (AN3) 6 - Seat Lumbar Horizontal Motor Position Sensor - Driver (AN3) 7 - Seat Recline Position Sensor - Driver (AN3) 8 - Seat Lumbar Switch - Driver (AN3) 9 - Seat Adjuster Switch - Driver (AG1) 10 - Memory Seat Module (MSM) (AN3) 11 - Inflatable Restraint Seat Position Sensor (SPS) - Driver (10 Series) 12 - Seat Adjuster Motor Assembly - Driver (AG1) 13 Seat Belt Buckle - Driver Passenger Seat Harness Routing Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 14017 1 - Seat Frame 2 - X325 (AN3) 3 - Seat Lumbar Vertical Motor - Passenger (AN3) 4 - Seat Adjuster Switch - Passenger (AG2) 5 - Seat Lumbar Switch - Passenger (AN3) 6 - Seat Belt Buckle Passenger 7 - Inflatable Restraint Passenger Presence System (PPS) Module (AL0) 8 - Seat Adjuster Motor Assembly - Passenger (AG2) 9 - Inflatable Restraint Passenger Presence System (PPS) Sensor (AL0) 10 - Seat Recline Motor - Passenger (AN3) 11 - Seat Lumbar Horizontal Motor - Passenger (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 14018 Seat Belt Buckle Switch: Diagrams Component Connector End Views Seat Belt Buckle - Driver Seat Belt Buckle - Passenger X1 (10 Series without MEX) Seat Belt Buckle - Passenger X2 (AL0) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 14019 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Extension > Component Information > Technical Service Bulletins > Restraints - Extender Availability For Seat Belt Seat Belt Extension: Technical Service Bulletins Restraints - Extender Availability For Seat Belt INFORMATION Bulletin No.: 99-09-40-005F Date: June 23, 2010 Subject: Seat Belt Extender Availability Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add the 2009‐2011 model years and update the Warranty Information. Please discard Corporate Bulletin Number 99-09-40-005E (Section 09 Restraints). Important: DO NOT use belt extenders when securing a child restraint. The seat and shoulder belt restraint systems used in all General Motors vehicles have sufficient belt length to accommodate most drivers and passengers. Consequently, requests for belt extensions (extenders) should be minimal. Seat belt extenders are available ONLY IN BLACK for most GM passenger cars and trucks produced in recent years. They are available in two different lengths, 23 cm (9 in) and 38 cm (15 in). They are designed to be coupled with the existing belts in each vehicle. When in use, the extender makes the belt arrangement a "custom fit" and use by anyone else or in another vehicle will lessen or nullify the protection offered by the vehicle's restraint system. For this reason, it is extremely important that the correct length extender be used for the vehicle and occupant intended. Important: Do not use an extender just to make it easier to buckle the safety belt. Use an extender only when you cannot buckle the safety belt without using an extender. Parts Information For part numbers, usage and availability of extenders, see Extension Kit in Group 14.875 (cars) or Group 16.714 (trucks) of the appropriate parts catalog. Saturn retailers should refer to the appropriate model year Parts & Illustration catalog for the vehicle. U.S. Saab dealers should contact the Parts Help line. Canadian Saab dealers should fax requests to Partech Canada. Warranty Information ^ Seat belt extenders are a NO CHARGE item to all GM customers who request them for their specific vehicles. ^ Dealers should not be charging part costs since these extenders are supplied by GM to the dealers. ^ Dealers should not be charging labor costs since the extender can be customer installed. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair > Seat Belt Height Adjuster Knob Replacement - Front Seat Belt Height Adjuster: Service and Repair Seat Belt Height Adjuster Knob Replacement - Front Seat Belt Height Adjuster Knob Replacement - Front Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair > Seat Belt Height Adjuster Knob Replacement - Front > Page 14028 Seat Belt Height Adjuster: Service and Repair Seat Belt Height Adjuster Replacement - Front Seat Belt Height Adjuster Replacement - Front Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Restraint System - Normal Safety Belt Locking Conditions Seat Belt Retractor: Technical Service Bulletins Restraint System - Normal Safety Belt Locking Conditions INFORMATION Bulletin No.: 05-09-40-002E Date: October 21, 2010 Subject: Safety Belt Locking Conditions (Normal Operating Characteristic) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2010 HUMMER H2, H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 05-09-40-002D (Section 09 - Restraints). The purpose of this bulletin is to explain when the safety belts are supposed to lock. There are several different locking situations for both front and rear safety belts. Overspool Lock There is an unintentional locking condition that ALL safety belts from ALL manufacturers may experience called "overspool lock". If the webbing snaps back to the stowed position rapidly enough, the retractor will lock with the belt fully stowed. This is more likely to occur when customers "help" the belt to retract. Without the weight of the latch plate and friction to slow the retractive speed of the webbing, the higher than normal webbing retraction speed that occurs engages the locking mechanism when a sudden stop occurs at the end of web travel. Since the webbing is now fully loaded on the spool, the retractor cannot rewind itself further to release the locking mechanism. When this happens, the occupant cannot extract the belt to wear it. DO NOT replace the retractor for this condition until first attempting to disengage the locking mechanism by following the recommendation listed below. Recommendation Pull hard on the locked webbing and then release. The hard pull extracts a small amount of webbing from the retractor which, in turn, permits a small amount of retraction to occur when released. This is all that is needed to disengage the locking mechanism. The safety belt will now function properly. Vehicle Sensing This type of locking occurs in response to the vehicle under the following conditions: - The vehicle changes speed or direction abruptly (the vehicle goes into rapid acceleration OR rapid deceleration or there is aggressive cornering). - It can also occur in a static condition when a vehicle is parked on a large slant (fore-aft or side-to-side), such as streets in San Francisco, California. - It may also occur over rough road conditions where the retractor mechanism is bounced into a locked condition. In all of these conditions, as long as tension is maintained on the webbing, the belt will stay locked. When the tension is released, the belt retracts slightly, the lock bar disengages and the safety belt should return to normal function. Please inform customers that may comment that "the belt locks intermittently" that this is the design intent and the belt is functioning properly. Web Sensing This type of locking occurs in response to the extraction of webbing. When the webbing reels out at an accelerated rate, it goes into lock mode and stays there until tension is again released. To observe this condition, extract the webbing quickly. Customers may refer to this condition as "intermittent lock-up" and encounter it when trying to put the belt on too quickly. Automatic Locking (ALR) When the webbing is pulled all the way out, it automatically converts the retractor into a cinch-down mode (i.e. ALR). This is typically used to tightly secure a child seat to the vehicle. Some customers may experience inadvertent activation of ALR mode if they happen to pull the belt all the way out to the end of travel while they are putting the belt on. The ALR mode of operation is automatically cancelled when the belt is unfastened and stowed (the belt returns to normal sensitive function). Corvette only - This locking mechanism is also provided at the driver's position of the Corvette only, as a unique feature. Corvette customers may find this feature appealing when they plan to operate the vehicle in a "spirited" manner (such as driving in mountainous terrain). With the ALR active, the operator is snugly cinched into the seat and kept firmly in place during high G-force driving maneuvers. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Restraint System - Normal Safety Belt Locking Conditions > Page 14033 Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Restraint System - Normal Safety Belt Locking Conditions > Page 14034 Seat Belt Retractor: Technical Service Bulletins Restraints - Seat Belt Latch Stop Button Availability INFORMATION Bulletin No.: 07-09-40-002A Date: June 04, 2009 Subject: Seat Belt Latch Stop Button Available for Service Models: 2005-2010 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2010 HUMMER H2 2006-2010 HUMMER H3 2009-2010 HUMMER H3T .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to update the models and model years. Please discard Corporate Bulletin Number 07-09-40-002 (Section 09 - Restraints). .............................................................................................................................................................. .................................................................................. All seat belt retractor assemblies contain a stop button. If a stop button becomes damaged, the button can be replaced by ordering a replacement button through the GM Parts Catalog. The seat belt retractor assembly does not need replacement. Refer to the Seat Belt Latch Stop Installation procedure in SI for the complete installation procedure. Parts Information For part numbers, usage and availability of stop buttons, see Stop Kit in Group 14.875 (cars) or Group 16.714 (trucks) of the appropriate Parts Catalog. Saturn retailers should refer to the appropriate model year Parts & Illustration Catalog for the vehicle. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Rear Seat Shoulder Belt Retractor Replacement (Crew Cab) Seat Belt Retractor: Service and Repair Rear Seat Shoulder Belt Retractor Replacement (Crew Cab) Rear Seat Shoulder Belt Retractor Replacement (Crew Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Rear Seat Shoulder Belt Retractor Replacement (Crew Cab) > Page 14037 Seat Belt Retractor: Service and Repair Rear Seat Shoulder Belt Retractor Replacement (Extended Cab) Rear Seat Shoulder Belt Retractor Replacement (Extended Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Diagrams Seat Belt Tensioner: Diagrams Component Connector End Views Seat Belt Pretensioner - Driver Seat Belt Pretensioner - Passenger Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Diagrams > Page 14041 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Service and Repair > Procedures Seat Belt Tensioner: Procedures Pretensioner Handling and Scrapping Warning When carrying an undeployed inflatable restraint seat belt pretensioner: * Do not carry the seat belt pretensioner by the wires or connector. * Carry the seat belt pretensioner by the piston tube, keeping hands and fingers away from the cable. * Make sure the open end of the seat belt pretensioner piston tube points away from you and other people. * Do not cover the seat belt pretensioner piston tube opening with your hand. Failure to observe these guidelines may result in personal injury. Scrapping Procedure During the course of a vehicles useful life, certain situations may arise which will require the disposal of a live and undeployed seat belt pretensioner. Do not dispose of a live and undeployed seat belt pretensioner through normal disposal channels until the seat belt pretensioner has been deployed. The following information covers the proper procedures for disposing of a live and undeployed seat belt pretensioner. Do not deploy the seat belt pretensioner in the following situations: * After replacement of a seat belt pretensioner under warranty. The seat belt pretensioner may need to be returned undeployed to the manufacturer. * If the vehicle is the subject of a Product Liability report, GM1241, related to the SIR system or the seat belt system. If the vehicle is subject to the Product Liability report, do not alter the SIR or seat belt system in any manner. * If the vehicle is involved in a campaign affecting the seat belt pretensioners. Follow the instructions in the Campaign Service Bulletin for proper SIR handling procedures. Deployment Procedures The seat belt pretensioner can be deployed inside or outside of the vehicle. The method used depends upon the final disposition of the vehicle. Review the following procedures in order to determine which will work best in a given situation. Deployment Outside Vehicle for Seat Belt Pretensioners Deploy the seat belt pretensioners outside of the vehicle when the vehicle will be returned to service. Situations that require deployment outside of the vehicle include the following: * Using the SIR diagnostics, it is determined that the seat belt pretensioner is malfunctioning. * The seat belt pretensioner pigtail, if equipped, is damaged. * The seat belt pretensioner connector is damaged. * The seat belt pretensioner connector terminals are damaged. Deployment and disposal of a malfunctioning seat belt pretensioner is subject to any required retention period. Warning In order to prevent accidental deployment and the risk of personal injury, do not dispose of an undeployed inflatable restraint seat belt pretensioner as normal shop waste. Undeployed seat belt pretensioners contain substances that could cause severe illness or personal injury if their sealed containers are damaged during disposal. Use the following deployment procedures to safely dispose of an undeployed seat belt pretensioner. Failure to observe the following disposal methods may be a violation of federal, state, or local laws. Special Tools * J 39401-B SIR Deployment Fixture * J 38826 SIR Deployment Harness * An appropriate pigtail adaptor Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Service and Repair > Procedures > Page 14044 1. Turn OFF the ignition. 2. Remove the ignition key. 3. Put on safety glasses. 4. Remove the seat belt pretensioner from the vehicle. Refer to Seat Belt Retractor Pretensioner Replacement - Front (Regular Cab) (See: Removal and Replacement/Seat Belt Retractor Pretensioner Replacement - Front (Regular Cab))Seat Belt Retractor Pretensioner Replacement - Front (Extended Cab) (See: Removal and Replacement/Seat Belt Retractor Pretensioner Replacement - Front (Extended Cab))Seat Belt Retractor Pretensioner Replacement - Front (Crew Cab) (See: Removal and Replacement/Seat Belt Retractor Pretensioner Replacement - Front (Crew Cab) ). 5. When carrying a seat belt pretensioner to the deployment area, keep fingers clear of the seat belt webbing. 6. Clear a space on the ground about 1.85 m (6 ft) in diameter for deployment of the seat belt pretensioner. If possible, use a paved, outdoor location free of activity. Otherwise, use a space free of activity on the shop floor. Make sure you have sufficient ventilation. 7. Make sure no loose or flammable objects are in the area. 8. Place the J 39401-B in the center of the cleared area. 9. Fill the fixture plastic reservoir with water or sand. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Service and Repair > Procedures > Page 14045 10. Mount the seat belt pretensioner (1) in the SIR deployment fixture (3) with the open end facing up using the following mounting method. * Adjust and secure the J 39401-B arms (4) to the deployment fixture. * To mount, use the proper size bolt (2) and nut (5) with washers in order to secure the seat belt pretensioner (1) to the deployment fixture brackets. * Securely tighten all fasteners prior to deployment. 11. Inspect the J 38826 and the appropriate pigtail adapter for damage. Replace as needed. 12. Short the 2 SIR deployment harness (1) leads together using 1 banana plug seated into the other. 13. Connect the appropriate pigtail adapter (2) to the SIR deployment harness. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Service and Repair > Procedures > Page 14046 14. Extend the SIR deployment harness and adapter to full length from the deployment fixture. 15. Connect the seat belt pretensioner connector (1) to the adapter (2) on the deployment harness (3). Note: When deploying a seat belt pretensioner, the rapid expansion of gas is very loud. Notify the people in the immediate area that a seat belt pretensioner will be deployed. 16. Clear the area of people. 17. Separate the 2 banana plugs on the SIR deployment harness. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Service and Repair > Procedures > Page 14047 18. Place a 12 volt minimum/2 amp minimum power source, such as a vehicle battery, near the shorted end of the harness. 19. Connect the SIR deployment harness wires to the power source. Seat belt pretensioner deployment will occur when contact is made. 20. Disconnect the SIR deployment harness from the power source after the seat belt pretensioner deploys. 21. Seat one banana plug into the other in order to short the deployment harness leads. 22. If the seat pretensioner did not deploy, disconnect the adapter and discontinue the procedure. Contact the Technical Assistance Group. Otherwise, proceed to the following steps. 23. Put on a pair of shop gloves. 24. Disconnect the pigtail adapter from the seat belt pretensioner as soon as possible. 25. Dispose of the deployed seat belt pretensioner through normal refuse channels. 26. Wash hands with a mild soap. Deployment Inside Vehicle - Vehicle Scrapping Procedure Deploy the seat belt pretensioners inside of the vehicle when destroying the vehicle or when salvaging the vehicle for parts. This includes but is not limited to the following situations: * The vehicle has completed its useful life. * Irreparable damage occurs to the vehicle in a non-deployment type accident. * Irreparable damage occurs to the vehicle during a theft. * The vehicle is being salvaged for parts to be used on a vehicle with a different VIN as opposed to rebuilding as the same VIN. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Service and Repair > Procedures > Page 14048 1. Turn OFF the ignition. 2. Remove the ignition key. 3. Put on safety glasses. 4. Remove all loose objects from the front seats. 5. Disconnect the seat belt pretensioner connector. Refer to Seat Belt Retractor Pretensioner Replacement - Front (Regular Cab) (See: Removal and Replacement/Seat Belt Retractor Pretensioner Replacement - Front (Regular Cab))Seat Belt Retractor Pretensioner Replacement - Front (Extended Cab) (See: Removal and Replacement/Seat Belt Retractor Pretensioner Replacement - Front (Extended Cab))Seat Belt Retractor Pretensioner Replacement - Front (Crew Cab) (See: Removal and Replacement/Seat Belt Retractor Pretensioner Replacement - Front (Crew Cab)). 6. Cut the seat belt pretensioner harness connector out of the vehicle, leaving at least 16 cm (6 in) of wire at the connector. 7. Strip 13 mm (0.5 in) of insulation from each of the connector wire leads. 8. Cut two 6.1 m (20 ft) deployment wires from a 0.8 mm (18 gauge) or thicker multi-strand wire. These wires will be used for the seat belt pretensioner deployment harness. 9. Strip 13 mm (0.5 in) of insulation from both ends of the wires cut in the previous step. 10. Twist together one end from each of the wires in order to short the wires. Deployment wires shall remain shorted, and not connected to a power source until you are ready to deploy the seat belt pretensioner. 11. Twist together one connector wire lead to one deployment wire. 12. Inspect that the previous connections is secure. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Service and Repair > Procedures > Page 14049 13. Bend flat the twisted connection. 14. Secure and insulate the connection using electrical tape. 15. Twist together, bend, and tape the remaining connector wire lead to the remaining deployment wire. 16. Connect the deployment harness to the seat belt pretensioner connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Service and Repair > Procedures > Page 14050 17. Route the deployment harness out of the driver side of the vehicle. 18. Disconnect the seat belt pretensioner connector. Refer to Seat Belt Retractor Pretensioner Replacement - Front (Regular Cab) (See: Removal and Replacement/Seat Belt Retractor Pretensioner Replacement - Front (Regular Cab))Seat Belt Retractor Pretensioner Replacement - Front (Extended Cab) (See: Removal and Replacement/Seat Belt Retractor Pretensioner Replacement - Front (Extended Cab))Seat Belt Retractor Pretensioner Replacement - Front (Crew Cab) (See: Removal and Replacement/Seat Belt Retractor Pretensioner Replacement - Front (Crew Cab)). 19. Cut the seat belt pretensioner connector out of the vehicle, leaving at least 16 cm (6 in) of wire at the connector. 20. Strip 13 mm (0.5 in) of insulation from each of the connector wire leads. 21. Cut two 6.1 m (20 ft) deployment wires from a 0.8 mm (18 gauge) or thicker multi-strand wire. These wires will be used for the seat belt pretensioner deployment harness. 22. Strip 13 mm (0.5 in) of insulation from both ends of the wires cut in the previous step. 23. Twist together one end from each of the wires in order to short the wires. The deployment wires are to remain shorted, and not connected to a power source until you are ready to deploy the seat belt pretensioner. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Service and Repair > Procedures > Page 14051 24. Twist together one connector wire lead to one deployment wire. 25. Inspect that the previous connection is secure. 26. Bend flat the twisted connection. 27. Secure and insulate the connection using electrical tape. 28. Twist together, bend, and tape the remaining connector wire lead to the remaining deployment wire. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Service and Repair > Procedures > Page 14052 29. Connect the deployment harness to the seat belt pretensioner connector. 30. Route the deployment harness out of the passenger's side of the vehicle. 31. Completely cover the windshield and the front door openings with a drop cloth. 32. Deploy each deployment loop one at a time. 33. Stretch out all of the deployment harness wires on the left and right side of the vehicle to their full length. 34. Place a power source, 12 volt minimum/2 amp minimum, such as a vehicle battery, near the shorted end of the harnesses. 35. Separate one set of wires and touch the wire ends to the power source in order to deploy the seat belt pretensioners. 36. Disconnect the deployment harness from the power source and twist the wire ends together. 37. Continue the same process with the remaining deployment harnesses that are available. 38. Remove the drop cloth from the vehicle. 39. Disconnect all harnesses from the vehicle. 40. Discard the harnesses. 41. Scrap the vehicle in the same manner as a non-SIR equipped vehicle. 42. If one or more of the seat belt pretensioners did not deploy, perform the following steps to remove the undeployed seat belt pretensioner from the vehicle, refer to Seat Belt Retractor Pretensioner Replacement - Front (Regular Cab) (See: Removal and Replacement/Seat Belt Retractor Pretensioner Replacement - Front (Regular Cab))Seat Belt Retractor Pretensioner Replacement - Front (Extended Cab) (See: Removal and Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Service and Repair > Procedures > Page 14053 Replacement/Seat Belt Retractor Pretensioner Replacement - Front (Extended Cab))Seat Belt Retractor Pretensioner Replacement - Front (Crew Cab) (See: Removal and Replacement/Seat Belt Retractor Pretensioner Replacement - Front (Crew Cab)). 43. Call the Technical Assistance Group for further assistance. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Service and Repair > Procedures > Page 14054 Seat Belt Tensioner: Removal and Replacement Seat Belt Retractor Pretensioner Replacement - Front (Regular Cab) Seat Belt Retractor Pretensioner Replacement - Front (Regular Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Service and Repair > Procedures > Page 14055 Seat Belt Retractor Pretensioner Replacement - Front (Extended Cab) Seat Belt Retractor Pretensioner Replacement - Front (Extended Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Service and Repair > Procedures > Page 14056 Seat Belt Retractor Pretensioner Replacement - Front (Crew Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Service and Repair > Procedures > Page 14057 Seat Belt Retractor Pretensioner Replacement - Front (Crew Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Diagrams Air Bag Deactivation Switch: Diagrams Component Connector End Views Inflatable Restraint I/P Module Disable Switch (C99 or MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Diagrams > Page 14062 Air Bag Deactivation Switch: Service and Repair Instrument Panel Inflatable Restraint Module Switch Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams Impact Sensor: Diagrams Component Connector End Views Inflatable Restraint Front End Sensor - Left (10 Series) Inflatable Restraint Front End Sensor - Right (10 Series) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Page 14066 Inflatable Restraint Front End Sensor (except 10 Series) Inflatable Restraint Side Impact Sensor (SIS) - Left Front (ASF) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Page 14067 Inflatable Restraint Side Impact Sensor (SIS) - Left Rear (Extended or Crew Cab with ASF) Inflatable Restraint Side Impact Sensor (SIS) - Right Front (ASF) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Page 14068 Inflatable Restraint Side Impact Sensor (SIS) - Right Rear (Extended or Crew Cab with ASF) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement Impact Sensor: Service and Repair Inflatable Restraint Front End Sensor Replacement Inflatable Restraint Front End Sensor Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 14071 Impact Sensor: Service and Repair Inflatable Restraint Side Impact Sensor Replacement (Crew Cab/Extended Cab/Regular Cab) Inflatable Restraint Side Impact Sensor Replacement (Crew Cab/Extended Cab/Regular Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 14072 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 14073 Impact Sensor: Service and Repair Inflatable Restraint Side Impact Sensor Replacement (Crew Cab, Rear Door) Inflatable Restraint Side Impact Sensor Replacement (Crew Cab, Rear Door) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 14074 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 14075 Impact Sensor: Service and Repair Inflatable Restraint Side Impact Sensor Replacement (Extended Cab, Rear Door ) Inflatable Restraint Side Impact Sensor Replacement (Extended Cab, Rear Door ) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 14076 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations Seat Belt Buckle Switch: Locations Harness Routing Views Driver Seat Harness Routing 1 - Seat Recline Motor - Driver (AN3) 2 - Seat Lumbar Vertical Motor Position Sensor - Driver (AN3) 3 - Seat Lumbar Vertical Motor - Driver (AN3) 4 - X324 (AN3) 5 - Seat Lumbar Horizontal Motor - Driver (AN3) 6 - Seat Lumbar Horizontal Motor Position Sensor - Driver (AN3) 7 - Seat Recline Position Sensor - Driver (AN3) 8 - Seat Lumbar Switch - Driver (AN3) 9 - Seat Adjuster Switch - Driver (AG1) 10 - Memory Seat Module (MSM) (AN3) 11 - Inflatable Restraint Seat Position Sensor (SPS) - Driver (10 Series) 12 - Seat Adjuster Motor Assembly - Driver (AG1) 13 Seat Belt Buckle - Driver Passenger Seat Harness Routing Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 14080 1 - Seat Frame 2 - X325 (AN3) 3 - Seat Lumbar Vertical Motor - Passenger (AN3) 4 - Seat Adjuster Switch - Passenger (AG2) 5 - Seat Lumbar Switch - Passenger (AN3) 6 - Seat Belt Buckle Passenger 7 - Inflatable Restraint Passenger Presence System (PPS) Module (AL0) 8 - Seat Adjuster Motor Assembly - Passenger (AG2) 9 - Inflatable Restraint Passenger Presence System (PPS) Sensor (AL0) 10 - Seat Recline Motor - Passenger (AN3) 11 - Seat Lumbar Horizontal Motor - Passenger (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 14081 Seat Belt Buckle Switch: Diagrams Component Connector End Views Seat Belt Buckle - Driver Seat Belt Buckle - Passenger X1 (10 Series without MEX) Seat Belt Buckle - Passenger X2 (AL0) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 14082 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Restraints - Passenger Presence System Information Seat Occupant Sensor: Technical Service Bulletins Restraints - Passenger Presence System Information INFORMATION Bulletin No.: 06-08-50-009F Date: December 23, 2010 Subject: Information on Passenger Presence Sensing System (PPS or PSS) Concerns With Custom Upholstery, Accessory Seat Heaters or Other Comfort Enhancing Devices Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Passenger Presence Sensing System Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-08-50-009E (Section 08 - Body and Accessories). Concerns About Safety and Alterations to the Front Passenger Seat Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE THE SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER THE SEAT COVERS OR SEAT-RELATED EQUIPMENT. ANY ALTERATIONS TO SEAT COVERS OR GM ACCESSORIES DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. The front passenger seat in many GM vehicles is equipped with a passenger sensing system that will turn off the right front passenger's frontal airbag under certain conditions, such as when an infant or child seat is present. In some vehicles, the passenger sensing system will also turn off the right front passenger's seat mounted side impact airbag. For the system to function properly, sensors are used in the seat to detect the presence of a properly-seated occupant. The passenger sensing system may not operate properly if the original seat trim is replaced (1) by non-GM covers, upholstery or trim, or (2) by GM covers, upholstery or trim designed for a different vehicle or (3) by GM covers, upholstery or trim that has been altered by a trim shop, or (4) if any object, such as an aftermarket seat heater or a comfort enhancing pad or device is installed under the seat fabric or between the occupant and the seat fabric. Aftermarket Seat Heaters, Custom Upholstery, and Comfort Enhancing Pads or Devices Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE ONLY SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT RELEASED AS GM ACCESSORIES FOR THAT VEHICLE. DO NOT USE ANY OTHER TYPE OF SEAT COVERS OR SEAT-RELATED EQUIPMENT, OR GM ACCESSORIES RELEASED FOR OTHER VEHICLE APPLICATIONS. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ACCESSORIES, INCLUDING ANY WARRANTY REPAIRS MADE NECESSARY BY SUCH USE. Many types of aftermarket accessories are available to customers, upfitting shops, and dealers. Some of these devices sit on top of, or are Velcro(R) strapped to the seat while others such as seat heaters are installed under the seat fabric. Additionally, seat covers made of leather or other materials may have different padding thickness installed that could prevent the Passenger Sensing System from functioning properly. Never alter the vehicle seats. Never add pads or other devices to the seat cushion, as this may interfere with the operation of the Passenger Sensing System and either prevent proper deployment of the passenger airbag or prevent proper suppression of the passenger air bag. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Page 14087 Seat Occupant Sensor: Service and Repair Inflatable Restraint Passenger Presence System Replacement - Front (without HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Page 14088 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Position Sensor > Component Information > Locations Seat Position Sensor: Locations Harness Routing Views Driver Seat Harness Routing 1 - Seat Recline Motor - Driver (AN3) 2 - Seat Lumbar Vertical Motor Position Sensor - Driver (AN3) 3 - Seat Lumbar Vertical Motor - Driver (AN3) 4 - X324 (AN3) 5 - Seat Lumbar Horizontal Motor - Driver (AN3) 6 - Seat Lumbar Horizontal Motor Position Sensor - Driver (AN3) 7 - Seat Recline Position Sensor - Driver (AN3) 8 - Seat Lumbar Switch - Driver (AN3) 9 - Seat Adjuster Switch - Driver (AG1) 10 - Memory Seat Module (MSM) (AN3) 11 - Inflatable Restraint Seat Position Sensor (SPS) - Driver (10 Series) 12 - Seat Adjuster Motor Assembly - Driver (AG1) 13 Seat Belt Buckle - Driver Passenger Seat Harness Routing Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Position Sensor > Component Information > Locations > Page 14092 1 - Seat Frame 2 - X325 (AN3) 3 - Seat Lumbar Vertical Motor - Passenger (AN3) 4 - Seat Adjuster Switch - Passenger (AG2) 5 - Seat Lumbar Switch - Passenger (AN3) 6 - Seat Belt Buckle Passenger 7 - Inflatable Restraint Passenger Presence System (PPS) Module (AL0) 8 - Seat Adjuster Motor Assembly - Passenger (AG2) 9 - Inflatable Restraint Passenger Presence System (PPS) Sensor (AL0) 10 - Seat Recline Motor - Passenger (AN3) 11 - Seat Lumbar Horizontal Motor - Passenger (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Position Sensor > Component Information > Locations > Page 14093 Seat Position Sensor: Diagrams Component Connector End Views Inflatable Restraint Seat Position Sensor - Driver (10 Series except MEX) Inflatable Restraint Seat Position Sensor - Passenger (10 Series except Crew Cab or MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Position Sensor > Component Information > Locations > Page 14094 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Position Sensor > Component Information > Locations > Page 14095 Seat Position Sensor: Service and Repair Inflatable Restraint Seat Position Sensor Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna Mast > Component Information > Technical Service Bulletins > Audio System - Difficult To Install Fixed Radio Antenna Antenna Mast: Technical Service Bulletins Audio System - Difficult To Install Fixed Radio Antenna INFORMATION Bulletin No.: 07-08-44-001F Date: June 15, 2010 Subject: Information on Difficult to Install Fixed Radio Antenna Mast Models: 2006-2011 Cadillac Escalade EXT 2005-2010 Chevrolet Cobalt 2006-2009 Chevrolet TrailBlazer Models 2006-2011 Chevrolet Avalanche, Colorado, Silverado (Classic and New Style) 2006-2009 GMC Envoy 2006-2011 GMC Canyon, Sierra (Classic and New Style) 2006-2010 Pontiac G5 2006-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years, a graphic with accompanying text and additional text in the Parts Information Description. Please discard Corporate Bulletin Number 07-08-44-001E (Section 08 - Body and Accessories). - A design change was made to the antenna base and antenna mast starting in October 2005. The radio antenna base size increased from 6 mm (0.23 in) to 7 mm (0.27 in) for improved stability and radio reception. - There are two different design antenna masts available. The antenna masts can be distinguished by the outer bottom of the antenna mast. The first design antenna mast (1) will have a six-sided hex design and a 6 mm (0.23 in) inside diameter thread. The second design antenna mast (2) will have two flats on the outer mast and a 7 mm (0.27 in) inside diameter thread. - The second design antenna mast will have more resistance when installing due to the interference fit of the threads in the mast as identified by the arrows in the graphic. Note Before proceeding, verify that the mast and base stud are properly aligned. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna Mast > Component Information > Technical Service Bulletins > Audio System - Difficult To Install Fixed Radio Antenna > Page 14102 - A wrench will be needed to install the antenna mast. When starting to thread the antenna mast onto the base stud, interference will be felt. The interference is similar to the feeling of a cross threaded fastener. Important Use a protective tape or a cloth inside an adjustable wrench when installing the antenna mast. This will help prevent damage to the painted coating on the antenna mast. - Tighten the antenna mast. Tighten Tighten to 6 Nm (53 lb in). Parts Information Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna Mast > Component Information > Technical Service Bulletins > Page 14103 Antenna Mast: Service and Repair Electronic Navigation Antenna Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Phone > Component Information > Service and Repair Antenna, Phone: Service and Repair Mobile Telephone Digital Antenna Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Application and ID Antenna Cable: Application and ID Antenna Coaxial/Connector Cable Identification Table Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Radio Antenna Cable Extension Cable Replacement (without RPO SLT) Antenna Cable: Service and Repair Radio Antenna Cable Extension Cable Replacement (without RPO SLT) Radio Antenna Cable Extension Cable Replacement (without RPO SLT) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Radio Antenna Cable Extension Cable Replacement (without RPO SLT) > Page 14113 Antenna Cable: Service and Repair Radio Antenna Cable Extension Cable Replacement (with RPO SLT) Radio Antenna Cable Extension Cable Replacement (with RPO SLT) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Radio Antenna Cable Extension Cable Replacement (without RPO SLT) > Page 14114 Antenna Cable: Service and Repair Mobile Telephone and Navigation Antenna Coaxial Cable Replacement Mobile Telephone and Navigation Antenna Coaxial Cable Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams Alarm Module: Diagrams Component Connector End Views Theft Deterrent Module (TDM) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Page 14119 Alarm Module: Service and Repair Theft Deterrent Module Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Hood Sensor/Switch (For Alarm) > Component Information > Diagrams Hood Sensor/Switch (For Alarm): Diagrams Component Connector End Views Hood Ajar Switch (AP3, AP8 or PTO) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Antenna - Keyless Entry > Component Information > Service and Repair > Keyless Entry Antenna Replacement (Regular Cab) Antenna - Keyless Entry: Service and Repair Keyless Entry Antenna Replacement (Regular Cab) Keyless Entry Antenna Replacement (Regular Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Antenna - Keyless Entry > Component Information > Service and Repair > Keyless Entry Antenna Replacement (Regular Cab) > Page 14128 Antenna - Keyless Entry: Service and Repair Keyless Entry Antenna Replacement (Extended/Crew Cab) Keyless Entry Antenna Replacement (Extended/Crew Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Service and Repair Keyless Entry Module: Service and Repair Remote Control Door Lock Receiver Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Receiver > Component Information > Diagrams Keyless Entry Receiver: Diagrams Component Connector End Views Remote Control Door Lock Receiver (RCDLR) (AP3 or AP8) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Starting System > Keyless Start Transmitter > Component Information > Technical Service Bulletins > Keyless System - Remote Start Transmitter Diagnostic Tip Keyless Start Transmitter: Technical Service Bulletins Keyless System - Remote Start Transmitter Diagnostic Tip INFORMATION Bulletin No.: 09-08-52-004A Date: January 08, 2010 Subject: Diagnostic Tips/Recommendations on GM Accessory 2-Way Remote Start Transmitter When Transmitter Battery is Weak or Dead Models: 2007-2010 Buick Lucerne 2008-2010 Buick Enclave 2007-2010 Cadillac DTS, Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Cobalt, HHR, Impala, Silverado, Tahoe 2009-2010 Chevrolet Malibu, Traverse 2007-2010 GMC Acadia, Sierra, Yukon 2007-2009 Pontiac G5, G6, Solstice, Torrent 2008-2009 Pontiac G8 2007-2010 Saturn AURA, OUTLOOK, SKY, VUE 2007-2010 HUMMER H2 Supercede: This bulletin is being revised to update the models and model years. Please discard Corporate Bulletin Number 09-08-52-004 (Section 08 - Body and Accessories). Follow these procedures if a customer comments that their GM Accessory 2-way transmitter stopped communicating with the vehicle. About GM Accessory 2-Way Remote Start The GM Accessory 2-way transmitter has the ability to operate a second vehicle equipped with a 2-way advanced remote start system, but often the 2-way transmitter may only be coded to one vehicle. If the customer presses the left side button twice within one second, the 2-way transmitter will enter second vehicle mode and will not control the original vehicle until a subsequent double press of the left side button places the transmitter back in first vehicle mode. Each vehicle mode of the 2-way transmitter should be thought of as an individual transmitter with its own unique code. Test the Transmitter Battery Note This test should be performed prior to releasing the vehicle or transmitter to the customer. All transmitter batteries should be tested immediately after installation of a 2-way remote start kit or replacement of a transmitter battery using the following procedure. 1. Press the unlock button on the transmitter eight times consecutively. 2. After the eighth press of the unlock button, observe the battery gauge located in the upper right corner of the LCD display. The gauge should read full (three bars inside the battery icon). If after having a new battery installed, the battery goes dead within five months, the transmitter could have high sleep current, causing the battery to go dead. Replace the transmitter. Please follow this diagnostic or repair process thoroughly and complete each step. If the condition exhibited is resolved without completing every step, the remaining steps do not need to be performed. Determine if Transmitter is in Second Vehicle Mode 1. Press and release any of the face buttons on the 2-way transmitter and observe the display on power-up. 2. If the 2-way transmitter is in second vehicle mode, the second vehicle icon will be displayed on the left side of the transmitter display. Is the 2-way transmitter in second vehicle mode? If Yes, the 2-way transmitter is working properly. - Press and release the left side button twice within one second. The 2-way transmitter should exit second vehicle mode. - Press and release the lock button. Press and release the unlock button. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Starting System > Keyless Start Transmitter > Component Information > Technical Service Bulletins > Keyless System - Remote Start Transmitter Diagnostic Tip > Page 14140 - Confirm that the vehicle responds with the appropriate lock and unlock function. - If Yes , the 2-way transmitter was in mode B. - Press and release the left side button twice within one second. The 2-way transmitter should enter second vehicle mode. - Use the "next available slot" method in the scan tool to program the 2-way transmitter to the 2-way RCDLR. Refer to Remote Control Door Lock Transmitter Programming in SI. - Both vehicle modes of the 2-way transmitter should now be coded to the vehicle. If No: The 2-way transmitter is not exhibiting the failure mode addressed by this bulletin. Refer to normal diagnostic procedures. Parts Information For part numbers, usage and availability of 2-way remote start, refer to the Accessory Parts Catalog or Corporate Bulletin Number 09-00-89-025A. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Starting System > Keyless Start Transmitter > Component Information > Technical Service Bulletins > Keyless System - Remote Start Transmitter Diagnostic Tip > Page 14141 Keyless Start Transmitter: Technical Service Bulletins Keyless Start - 2-Way Advanced Remote Start INFORMATION Bulletin No.: 09-00-89-025A Date: October 26, 2009 Subject: GM Accessories: 2-Way Advanced Remote Start Systems Part Information Models: 2007-2010 Buick Lucerne 2008-2010 Buick Enclave 2007-2010 Cadillac Escalade ESV, EXT 2008-2010 Cadillac DTS 2007-2009 Chevrolet Equinox, HHR 2007-2010 Chevrolet Avalanche, Cobalt, Silverado, Tahoe 2008-2010 Chevrolet Impala, Malibu 2009-2010 Chevrolet Traverse 2007-2010 GMC Acadia, Sierra, Yukon 2008-2010 HUMMER H2 2007-2009 Pontiac Torrent 2007-2010 Pontiac G5, G6 2008-2010 Pontiac G8 2010 Pontiac Solstice 2007-2010 Saturn AURA, OUTLOOK 2009-2010 Saturn VUE 2010 Saturn SKY Attention: This bulletin does not apply to GMODC dealers. Supercede: This bulletin is being revised to add part numbers. Please discard Corporate Bulletin Number 09-00-89-025 (Section 00 - General Information). This bulletin is being published to provide information on locating service part numbers for GM Accessory, 2-Way Advanced Remote Start Systems. Dealers should consult the chart below and use the correct service part. Dealers should not use entire kit for warranty or repair work. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Starting System > Keyless Start Transmitter > Component Information > Technical Service Bulletins > Keyless System - Remote Start Transmitter Diagnostic Tip > Page 14142 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Starting System > Keyless Start Transmitter > Component Information > Technical Service Bulletins > Keyless System - Remote Start Transmitter Diagnostic Tip > Page 14143 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Starting System > Keyless Start Transmitter > Component Information > Technical Service Bulletins > Keyless System - Remote Start Transmitter Diagnostic Tip > Page 14144 Parts Information Service parts common to all 2-Way Advanced Remote Start Systems Transmitter Battery 12493150 Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Customer Interest: > 08-08-52-001G > Aug > 10 > Keyless Entry - Intermittent/Inoperative Remote Keyless Entry Transmitter: Customer Interest Keyless Entry - Intermittent/Inoperative Remote TECHNICAL Bulletin No.: 08-08-52-001G Date: August 24, 2010 Subject: EI08028 - Intermittent, Inoperative Remote Keyless Entry (RKE) (Reprogram Key Fobs) Models: 2008-2011 Buick Enclave 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2009-2011 Chevrolet Traverse 2007-2011 GMC Acadia, Sierra, Sierra Denali, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2007-2010 Saturn OUTLOOK Supercede: This bulletin is being revised to change the labor operation number. Please discard Corporate Bulletin Number 08-08-52-001F (Section 08 - Body and Accessories). Condition Some customers may comment that one or more key fobs are inoperative. A number of warranty claims have been submitted that show relearning the key fobs has corrected this concern. Cause Based on technician feedback, engineering has determined two possible causes for key fob concerns: - The fobs may not be programmed when the vehicles leave the plant. - There may be Issues with the fobs internal components. Correction To correct the customer's concern, reprogram the transmitter (key fob). Refer to the procedure for Transmitter Programming found in Service Information. If reprogramming the transmitter is not successful, it will be necessary to replace the transmitter. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter: > 08-08-52-001G > Aug > 10 > Keyless Entry - Intermittent/Inoperative Remote Keyless Entry Transmitter: All Technical Service Bulletins Keyless Entry - Intermittent/Inoperative Remote TECHNICAL Bulletin No.: 08-08-52-001G Date: August 24, 2010 Subject: EI08028 - Intermittent, Inoperative Remote Keyless Entry (RKE) (Reprogram Key Fobs) Models: 2008-2011 Buick Enclave 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2009-2011 Chevrolet Traverse 2007-2011 GMC Acadia, Sierra, Sierra Denali, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2007-2010 Saturn OUTLOOK Supercede: This bulletin is being revised to change the labor operation number. Please discard Corporate Bulletin Number 08-08-52-001F (Section 08 - Body and Accessories). Condition Some customers may comment that one or more key fobs are inoperative. A number of warranty claims have been submitted that show relearning the key fobs has corrected this concern. Cause Based on technician feedback, engineering has determined two possible causes for key fob concerns: - The fobs may not be programmed when the vehicles leave the plant. - There may be Issues with the fobs internal components. Correction To correct the customer's concern, reprogram the transmitter (key fob). Refer to the procedure for Transmitter Programming found in Service Information. If reprogramming the transmitter is not successful, it will be necessary to replace the transmitter. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter: > 10-08-52-003 > Jul > 10 > Keyless Entry - Transmitter Button Inop/Won't Program Keyless Entry Transmitter: All Technical Service Bulletins Keyless Entry - Transmitter Button Inop/Won't Program INFORMATION Bulletin No.: 10-08-52-003 Date: July 21, 2010 Subject: Remote Keyless Entry Transmitter (RKE) Button Inoperative or Will Not Reprogram to Vehicle Models: 2006-2008 Buick Allure/LaCrosse 2006-2010 Buick Lucerne 2008-2010 Buick Enclave 2006-2007 Cadillac SRX 2006-2009 Cadillac DTS 2008-2009 Cadillac CTS (Non-EZ Key), Escalade, Escalade ESV, Escalade EXT 2006-2010 Chevrolet Impala 2007-2009 Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Silverado, Tahoe, Suburban 2008-2010 Chevrolet Express 2009-2010 Chevrolet Captiva 2007-2010 GMC Acadia, Sierra, Yukon, Yukon XL (Including Denali Models) 2008-2010 GMC Savana 2007-2009 Pontiac Torrent 2007-2010 Saturn OUTLOOK 2008-2010 Saturn VUE 2008-2010 HUMMER H2, H2 SUT with Remote Keyless Entry Attention: This bulletin should be distributed and reviewed by the Service Manager and Service Advisors. A copy of this bulletin may be given to your customer to assist in explaining the remote keyless entry (RKE) transmitter operation. This bulletin provides information regarding any remote keyless entry/transmitter (key fob) that may be inoperative intermittently or in which a particular button(s) does not work. To prevent transmitter battery drain, the RKE transmitter will disable any button or buttons that are depressed longer than 30 seconds. The disabled button or buttons will remain disabled until another button that has not been disabled is pressed. If a button or buttons on a transmitter are not functioning, or if a transmitter cannot be programmed to a vehicle, press and release each and every button on the fob one at a time until you find one that works then retest the other buttons. If all buttons are now working, the button(s) were disabled and the transmitter is working as designed. If the transmitter still fails to function properly, use the J-43241 tester and follow normal diagnostics as shown in SI. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Transmitter: > 10-08-52-003 > Jul > 10 > Keyless Entry - Transmitter Button Inop/Won't Program Keyless Entry Transmitter: All Technical Service Bulletins Keyless Entry - Transmitter Button Inop/Won't Program INFORMATION Bulletin No.: 10-08-52-003 Date: July 21, 2010 Subject: Remote Keyless Entry Transmitter (RKE) Button Inoperative or Will Not Reprogram to Vehicle Models: 2006-2008 Buick Allure/LaCrosse 2006-2010 Buick Lucerne 2008-2010 Buick Enclave 2006-2007 Cadillac SRX 2006-2009 Cadillac DTS 2008-2009 Cadillac CTS (Non-EZ Key), Escalade, Escalade ESV, Escalade EXT 2006-2010 Chevrolet Impala 2007-2009 Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Silverado, Tahoe, Suburban 2008-2010 Chevrolet Express 2009-2010 Chevrolet Captiva 2007-2010 GMC Acadia, Sierra, Yukon, Yukon XL (Including Denali Models) 2008-2010 GMC Savana 2007-2009 Pontiac Torrent 2007-2010 Saturn OUTLOOK 2008-2010 Saturn VUE 2008-2010 HUMMER H2, H2 SUT with Remote Keyless Entry Attention: This bulletin should be distributed and reviewed by the Service Manager and Service Advisors. A copy of this bulletin may be given to your customer to assist in explaining the remote keyless entry (RKE) transmitter operation. This bulletin provides information regarding any remote keyless entry/transmitter (key fob) that may be inoperative intermittently or in which a particular button(s) does not work. To prevent transmitter battery drain, the RKE transmitter will disable any button or buttons that are depressed longer than 30 seconds. The disabled button or buttons will remain disabled until another button that has not been disabled is pressed. If a button or buttons on a transmitter are not functioning, or if a transmitter cannot be programmed to a vehicle, press and release each and every button on the fob one at a time until you find one that works then retest the other buttons. If all buttons are now working, the button(s) were disabled and the transmitter is working as designed. If the transmitter still fails to function properly, use the J-43241 tester and follow normal diagnostics as shown in SI. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions Keyless Entry Transmitter: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Schematic Symbols Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14169 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14170 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14171 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14172 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14173 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14174 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14175 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14176 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14177 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14178 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14179 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14180 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14181 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14182 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14183 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14184 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14185 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14186 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14187 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14188 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14189 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14190 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14191 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14192 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14193 Chevrolet Silverado 3500 4wd Workshop 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Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14197 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14198 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14199 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14200 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14201 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14202 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14203 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14204 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14205 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14206 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14207 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14208 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14209 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14210 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14211 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14212 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14213 Keyless Entry Transmitter: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed with Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14214 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14215 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Connector Test Adapters) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14216 Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Test Lamp) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Fused Jumper Wires) * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage Drop) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Frequency) * Testing Ground and Low Reference Circuits (See: Testing and Inspection/Component Tests and General Diagnostics/Testing Ground and Low Reference Circuits) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fuses) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Circuit Breakers) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fusible Links) Troubleshooting with a Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Testing for a Short to Voltage Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14217 Testing for a Short to Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure tests for a short to voltage in a circuit. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the Digital Multimeter (DMM) to the V (DC) position. 4. Connect the positive lead of the DMM to one end of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. Turn ON the ignition and operate all accessories. 7. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Special Tools J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure). Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents). Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14218 The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the frequency of a signal. Note: Connecting the Digital Multimeter (DMM) to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Set to Hz on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14219 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the Digital Multimeter (DMM). 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the difference in voltage potential between 2 points. 1. Set the Digital Multimeter (DMM) to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14220 Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Backprobe Note: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14221 (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for Continuity Testing for Continuity Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures verify good continuity in a circuit. With a Digital Multimeter (DMM) 1. Set the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Select the MIN MAX function on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14222 Testing for Electrical Intermittents Testing for Electrical Intermittents Special Tools J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. Note: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions). 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14223 visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing for Terminal Fretting Some intermittent conditions can be caused by wire terminal fretting corrosion. Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can pile up enough at the electrical contact spots that the electrical resistance across the connection increases. Movement between the contacting surfaces as small as 10 to 100 microns can cause fretting. To put this in perspective, a sheet of paper is about 100 microns thick, so fretting motion is small and hard to see. Vibration and thermal expansion/contraction are the main sources that create fretting motion. Since vehicles vibrate and can experience large temperature swings, they are a good source for fretting motion. Tin, copper, nickel, and iron surfaces are all susceptible to fretting corrosion. Fretting corrosion can be difficult to see but it looks like small, dark smudges on the terminals contact surface. To correct a fretting condition disconnect the suspect connector and add Nyogel lubricant 760G (dielectric grease) to both sides of the connector terminals. Then reconnect the connector and wipe away any excess lubricant. This will correct the additional terminal contact resistance due to the terminal fretting corrosion. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14224 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics). * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Ground Distribution Schematics). Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Checking Aftermarket Accessories). * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14225 Note: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures test for a short to ground in a circuit. With a Digital Multimeter (DMM) 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohms position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Danger: High voltage circuits should only be tested using a digital multimeter (DMM) and test leads with at least a CAT III rating, such as the J 39200-A Digital Multimeter. Failure to follow the procedures exactly as written may result in serious injury or death. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Digital Multimeter (DMM) Basic Requirements Service information is validated using digital multimeters that meet or exceed the following requirements. Using a multimeter that does not meet these basic requirements may give inaccurate readings which could lead to an incorrect diagnosis. Display and Settings 1. Four digits displayed 2. Voltage, amperage, resistance, frequency, diode test settings, and min-max function 3. Display positive and negative values Voltage 1. Have at least 10 M ohm input impedance Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14226 2. Test a DC voltage range of 0.1-1000 V. 3. Test an AC voltage range of 0.1-1000 V. Amperage 1. Test a DC amperage range of 0.1µA-10 A. 2. Test an AC amperage range of 0.1µA-10 A. Resistance Test a resistance range of 0.1 ohm-40 Mohm and displays infinite for a value greater than 40 M ohm (O.L. (Over-load)) Frequency Test for a frequency range of 0.5 HZ-199 K HZ Diode Test 1. Apply at least 1 mA when performing the diode bias test 2. Display the break over voltage drop (0-3 V) of a forward biased diode 3. Display infinite (O.L. (Over-load)) when a diode is reverse biased Min-Max Readings 1. Can update at a 1 ms sample rate 2. Saves and displays minimum and maximum values Note: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Probe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors). * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the EL-38125-580 GM Approved Terminal Release Tool Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the EL-38125-580 GM Approved Terminal Release Tool Kit , ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the EL-38125-580 GM Approved Terminal Release Tool Kit label on the inside of the EL-38125-580 GM Approved Terminal Release Tool Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14227 Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/EPC Connectors AFL/EPC Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14228 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 3. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14229 View showing depressing of the lever lock release tab. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14230 6. Release the rear lower half of the wiredress cover. 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14231 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14232 Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Bosch Connectors (ECM) Bosch Connectors (ECM) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14233 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. 2. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14234 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-bladed tool to release the locking tabs and remove the dress cover. 4. The terminal positive assurance (TPA) is located in the front of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14235 5. Use a small flat-blade tool to remove TPA from the connector. 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14236 Note: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14237 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14238 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Terminal Replacement Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14239 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14240 5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Position Assurance Locks) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Terminal Position Assurance Locks) * AFL/EPC Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/AFL/EPC Connectors) * Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (BSK))Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (0.64))Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (2.8 JPT))Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (ECM)) * Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Weather Pack))Delphi Connectors (Push To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Push to Seat))Delphi Connectors Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14241 (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Pull to Seat))Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro-Pack 100W))Delphi Connectors (Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro .64))Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (12-Way)) * FCI Connectors (Lever Lock) (See: General Electrical Diagnostic Procedures/Connector Repairs/FCI Connectors (Lever Lock)) * JST Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/JST Connectors) * Kostal Connectors (Glow Plug Control Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Glow Plug Control Module))Kostal Connectors (Transmission) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Transmission)) * Molex Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Molex Connectors) * Sumitomo Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Sumitomo Connectors) * Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (CM 42-Way))Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Sensor))Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (0.25 Cap))Tyco/AMP Connectors (43-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (43-Way))Tyco/AMP Connectors (Door Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Door Module))Tyco/AMP Connectors (102-Way Inline) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (102-Way Inline))Tyco/AMP Connectors (Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Seat))Tyco/AMP Connectors (SIR) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (SIR)) * Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (2-Way))Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (16-Way)) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14242 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14243 * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14244 * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14245 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14246 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14247 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Push to Seat) Delphi Connectors (Push To Seat) Special Tools J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14248 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs). 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Terminated Lead Repair 1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice sleeves depending on the gauge size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Delphi Connectors (Pull to Seat) Delphi Connectors (Pull To Seat) Special Tools Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14249 J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Note: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14250 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. View of a typical Micro 64 connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14251 Depress the lock and pull the lever over and past the lock. View of the connector when released from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14252 View of another type of Micro 64 connector. Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14253 View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14254 Note: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14255 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14256 Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Note: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14257 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14258 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14259 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14260 1. Cut the wire as close to the terminal as possible. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14261 Terminal Replacement Procedure After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Special Tools J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Note: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals). 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12-Way) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14262 Delphi Connectors (12-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14263 4. Release the lower wire dress cover locking tab. 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14264 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14265 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors (Lever Lock) FCI Connectors (Lever Lock) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14266 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. The release tab is located on the top of the wiredress cover. 3. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14267 6. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14268 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14269 1. While depressing the lock, remove the connector from the component. 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14270 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. 4. View of the TPA when removed from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14271 5. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Glow Plug Control Module) Kostal Connectors (Glow Plug Control Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14272 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14273 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14274 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. Note: The front TPA cannot be removed from the connector. Only move it to the preset position. 6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm). 7. Use a small flat-blade tool to completely remove the rear TPA from the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14275 8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Transmission) Kostal Connectors (Transmission) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14276 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14277 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Terminal Replacement Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14278 After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14279 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14280 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14281 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14282 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14283 3. To assemble the connector, reverse the connector disassembly procedure. Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14284 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14285 7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14286 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14287 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14288 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14289 Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14290 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14291 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14292 6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (102-Way Inline) Tyco/AMP Connectors (102-Way Inline) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14293 View of a typical connector in the assembled position. 1. Pull the locking lever to the 90 degree position from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14294 2. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal. 3. Slide the male connector body out away from the guide plates. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14295 Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 4. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. 5. Using terminal release tool J 38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14296 6. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 7. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14297 8. The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool J-38125-11A or equivalent to release the locking tab and slide the connector off the female body. 9. Move the locking lever 180 degrees from the connected position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14298 10. With the locking lever in the 180 degree position the guide plates can be removed from the connector body. Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 11. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14299 12. Using terminal release tool J 38125-216, lift the terminal plate past the terminals and out of the connector body cavity. 13. Terminal plate will bind slightly on each corner. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14300 14. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 15. Using terminal release tool J 38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14301 16. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 17. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14302 18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever. 19. Slide the male connector body back inward toward the guide plates. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14303 20. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly. 21. Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Seat) Tyco/AMP Connectors (Seat) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14304 Removal Procedure 1. Grasp the locking slide lever and pull outward from the end of the connector. 2. As the slide lever is pulled out the mating connector is lifted from the seated position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14305 Note: TPA is keyed and can only be inserted in one direction. 3. Using terminal release tool J 38125-11A or equivalent, push the TPA tabs into the connector body. 4. Pull the TPA from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14306 5. Using terminal release tool J 38125-11A or equivalent, release the connector wire dress cover locking tab. 6. With the lock tab released, lift the connector wire dress cover from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14307 7. Using terminal release tool J 38125-212, press the prongs into the holes each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 8. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14308 9. Using terminal release tool J 38125-556, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (SIR) Tyco/AMP Connectors (SIR) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14309 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14310 3. Using terminal tool J-38125-11A or equivalent, release the wire dress cover locking tabs. 4. Pivot connector wire dress cover while removing from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14311 5. Using terminal tool J-38125-11A or equivalent, remove the TPA by lifting straight off the connector body. 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals Repairing Connector Terminals Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14312 Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gauge size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14313 2. Disconnect the connector from the component. 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14314 4. Relieve the tension on the nose piece retainers by inserting J 38125-12A into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. 5. Once the nose piece retainers are relaxed, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14315 6. On the opposite side of the nose piece, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14316 8. Insert the J 38125-553 tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14317 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. If the TPA is removed, be sure to reinstall it before reconnecting the connector. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14318 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Special Tools Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14319 J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Note: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14320 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14321 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14322 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14323 1. While depressing the lock, pull the two connector halves apart. Note: The TPA is fragile and may break if not done carefully. 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. 3. View of the male half of the connector with female terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14324 4. View of the female half of the connector with male terminals. 5. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. View of the female half of the connector with male terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14325 7. View of the male half of the connector with female terminals. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14326 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are a one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine if the element in the fuse is broken (2). If not broken (1), also check for continuity using a Digital Multimeter (DMM) or a continuity tester. If the element is broken or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a Digital Multimeter (DMM) at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gauge size. Repairing a Fusible Link Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14327 Flat Wire Repairs The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Special Tools J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool * J 38125-5 Ultra Torch Special Tool The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Note: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation). GMLAN Connector Terminal Repair Note: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) for the appropriate connector repair procedure. GMLAN Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14328 Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14329 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Special Tools J-38125 Terminal Repair Kit Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14330 repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs High Temperature Wiring Repairs Special Tools J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gauge size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14331 splice. Note: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14332 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14333 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the wire insulation has been chafed, or broken, enough to show the conductive portion of the wire, and the wire is not damaged, determine the length of insulation that needs to be repaired. If the repair is less than 280 mm (11 in), cut the wire within the damaged area. Then slide the appropriate heat shrink tubing (listed below) over the wire, and repair the wire by splicing the wires together. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Once the wire is spliced together slide heat shrink tubing over the damaged area and apply heat to seal the repaired wire. If the wire is damaged, or the damaged area is larger than 280 mm (11 in), then replace the damaged wire by splicing in a new section of wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14334 SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Special Tools J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14335 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14336 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14337 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Special Tools J-38125 Terminal Repair Kit Note: Use only DuraSeal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use DuraSeal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use DuraSeal splice sleeves where there are special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14338 * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14339 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14340 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the instructions for Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Staggering the splices by 65 mm (2.5 in) is recommended. Note: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product AL-36FR to replace the damaged mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Flat Wire Repairs) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/GMLAN Wiring Repairs) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Heated Oxygen Sensor Wiring Repairs) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves) * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Twisted or Shielded Cable) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Inline Harness Diodes) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/SIR/SRS Wiring Repairs) US English/Metric Conversion US English/Metric Conversion Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14341 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14342 Testing Ground and Low Reference Circuits Testing Ground and Low Reference Circuits Because a test lamp can light with up to 200 ohm in a ground or low reference circuit they are not recommended to be used for this type of test. A low impedance test lamp can light and indicate the circuit is good when there is as much as 20-30 ohm present, while a high impedance test lamp can light with up to 200 ohm present in the circuit. This is why the Digital Multi-Meter (DMM) is used when validating a ground or low reference circuit continuity. When using the DMM there are many vehicle conditions that can affect the ground and low reference continuity testing. If these conditions are not met, a ground or low reference circuit test can fail on a good circuit. This may cause longer diagnosis time and incorrect component replacement. Any current flow through a ground or low reference circuit, while being tested, will skew the DMM continuity reading, or display a reading higher than when there is no current flowing. Performing a ground or low reference circuit continuity test, in reference to the vehicles battery negative terminal, will have the highest risk of failing a good ground or low reference circuit test than any other ground reference point. The best ground test points would be a control module housing (if the control modules housing is metal and grounded), door jamb striker (if attached to metal), under dash metal frame work, engine block, or body ground studs (other than where the negative battery cable is attached). A typical DMM ground or low reference circuit continuity reading can be as high as 100 ohm with the ignition ON, and drop to 15-25 ohm after the ignition is turned OFF. The reading will drop below 10 ohm after 30-40 seconds, then below 5 ohm after 60 seconds. Once the vehicle completely goes to sleep (generally 3-10 minutes) the reading will drop below 0.3 ohm. The following list of conditions may need to be met to ensure a valid continuity reading on a ground or low reference circuit: * Ignition OFF * Key out of the ignition switch (when not equipped with keyless entry and remote start) * Retained Accessory Power (RAP) OFF (open and close the driver door after ignition OFF) * Battery charger set at a 2 A or less charge rate * Scan tool not communicating with any vehicle control module (in some cases it may need to be disconnected from the DLC) * All entry doors closed * Headlamps OFF (auto headlamps disabled) * Any delay lighting OFF * HVAC after blow OFF * Any accessory that can work when the ignition is OFF * Wait up to 60 seconds (after all other listed conditions are met) Activating the DOOR LOCK function with a key fob can greatly reduce the time to achieve a valid ground or low reference continuity test result. Terminal Removal Terminal Removal Special Tools * EL-38125-580 - Terminal Release Tool Kit * EL-35616 - Connector Test Adapter Kit For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repair procedures. 1. Find the appropriate connector end view within the connector end view section. The connector end view has the following information: Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14343 * Diagnostic probe tool * Terminal release tool * Terminal/terminated lead part numbers Note: Not using the proper test kit probe may cause damage to the terminal(s) that are probed. 2. Determine if a terminal is damaged. * Locate the diagnostic probe tool from the connector end view. The connector end view describes the color and part number to help the technician find and use the correct tool. * Connect the probe tool to the Digital Multimeter. * Insert the probe tool into the cavity and follow the procedures from the Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter). 3. Disconnect the connector body to perform the repair. 4. Use the following procedure to remove the terminal from the connector body. Note: Several procedures for specific connector bodies are called out in the Wiring Repairs section. * The terminal position assurance (TPA) and connector position assurance (CPA) should be removed before releasing the terminal for the connector body. * Look at the connector end view to locate the cavity of the damaged terminal and find the proper terminal release tool from the terminal release tool kit. Note: Using the incorrect terminal release tool can damage the connector body. * Insert the terminal release tool into the cavity. Note: Some terminals have a lever that must be disengaged before the terminal can be released. 5. Gently pull the wire out of the back of the connector. 6. Repair the terminal by following the Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) procedure. 7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminated Lead Repair Terminated Lead Repair Special Tools * J-38125-8 - Splice Sleeve Crimp Tool Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14344 * J-38125-5 - Ultra Torch For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) procedures. Terminated leads are terminals that are crimped onto wires. The terminated lead can be used throughout the vehicle since it is designed for temperatures up to 150°C. The length of the wire is 450 mm. The DuraSeal splice sleeve has the following 2 critical features: * A special heat shrink tubing that environmentally seals the splice. The shrink tubing contains a sealing adhesive inside the shrink tubing. * A cross hatched (knurled) core crimp that provides the necessary contact integrity for sensitive low energy circuits. 1. Use the connector end view to identify the correct terminated lead. 2. The terminated lead package should include a DuraSeal splice sleeve. If not, use the chart to identify the correct part. 3. Open the harness by removing any tape: Use a sewing seam ripper, or a comparable tool, to cut open the harness, to avoid wire insulation damage. 4. Depending on how many terminals need repairs, cut the terminal and wire back at least 40 mm. Try to keep the harness wire length the same. If more than one terminated lead is required, stagger the lengths by 40 mm. This helps reduce the bundle size of the wire harness. 5. Use the EL-38125-10 - tool in order to position the DuraSeal splice sleeve in the proper color nest of the splice sleeve crimp tool. The crimp tool has four nests, one for each color. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14345 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the J-38125-5 - ultra torch , apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14346 Keyless Entry Transmitter: Electrical Diagrams Remote Function Schematics Keyless Entry Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Page 14347 Keyless Entry Transmitter: Tools and Equipment Special Tools Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Security Lamp/Indicator > Component Information > Diagrams Security Lamp/Indicator: Diagrams Component Connector End Views Security Indicator Lamp (SPO Alarm) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Shock Sensor, Antitheft > Component Information > Diagrams Shock Sensor: Diagrams Component Connector End Views Vehicle Shock Sensor (SPO Alarm) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Tow Sensor, Antitheft > Component Information > Diagrams Tow Sensor: Diagrams Component Connector End Views Vehicle Inclination Sensor (SPO Alarm) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > Customer Interest for Cellular Phone Microphone: > 10-08-44-003B > Oct > 10 > Audio - Buzz Noise When Using Bluetooth(R) Cellular Phone Microphone: Customer Interest Audio - Buzz Noise When Using Bluetooth(R) TECHNICAL Bulletin No.: 10-08-44-003B Date: October 13, 2010 Subject: Buzz Noise During Call When Using Bluetooth(R) (Replace Microphone and Bezel) Models: 2009-2011 Buick Enclave, LaCrosse, Lucerne 2008-2011 Cadillac CTS, CTS-V 2009-2011 Cadillac DTS, Escalade, Escalade ESV, Escalade EXT, SRX, STS (with RPO YQ1 or YQ2), XLR 2009-2010 Chevrolet Cobalt, Corvette, Equinox, HHR, Impala, Malibu, Silverado, Suburban, Tahoe, TrailBlazer, Traverse 2010-2011 Chevrolet Camaro 2009-2010 GMC Envoy 2009-2011 GMC Acadia, Sierra, Yukon, Yukon XL 2009-2010 Pontiac G5, G6, Solstice, Torrent 2009-2010 HUMMER H2, H3 2009-2010 Saturn AURA, OUTLOOK, SKY, VUE 2009 Saab 9-7X All Equipped with OnStar(R) (UE1) and Bluetooth (UPF) Supercede: This bulletin is being revised to replace the microphone and bezel (if needed) and update model years. Please discard Corporate Bulletin Number 10-08-44-003A (Section 08 - Body and Accessories). Condition Some customers may comment on a buzz noise (from the land-line side only) during a call. On any vehicle equipped with OnStar(R) (UE1) and Bluetooth(R) (UPF), an electromagnetic compatibility (EMC) buzz can be heard from the land-line side only of the phone during a Bluetooth(R) phone call made with an older model global system for mobile communications (GSM) phone. The buzz is only heard with older model GSM phones and is dependent on the distance of the phone from the microphone. The newer 3G GSM phones or other cellular phones (CDMA, TDMA, etc.) have not shown this concern. Correction Equipped with Headliner Microphone (Cobalt, HHR (non-sunroof) H2, H3) A new microphone and bezel has been developed to address this concern. Replace the existing microphone with GM P/N 20951265. Also replace the bezel. Refer to the parts information table below for correct color/part number. Equipped with Overhead Console Microphone Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > Customer Interest for Cellular Phone Microphone: > 10-08-44-003B > Oct > 10 > Audio - Buzz Noise When Using Bluetooth(R) > Page 14366 A new microphone has been developed to address this concern. Replace the existing microphone with GM P/N 20951265. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone Microphone: > 10-08-44-003B > Oct > 10 > Audio - Buzz Noise When Using Bluetooth(R) Cellular Phone Microphone: All Technical Service Bulletins Audio - Buzz Noise When Using Bluetooth(R) TECHNICAL Bulletin No.: 10-08-44-003B Date: October 13, 2010 Subject: Buzz Noise During Call When Using Bluetooth(R) (Replace Microphone and Bezel) Models: 2009-2011 Buick Enclave, LaCrosse, Lucerne 2008-2011 Cadillac CTS, CTS-V 2009-2011 Cadillac DTS, Escalade, Escalade ESV, Escalade EXT, SRX, STS (with RPO YQ1 or YQ2), XLR 2009-2010 Chevrolet Cobalt, Corvette, Equinox, HHR, Impala, Malibu, Silverado, Suburban, Tahoe, TrailBlazer, Traverse 2010-2011 Chevrolet Camaro 2009-2010 GMC Envoy 2009-2011 GMC Acadia, Sierra, Yukon, Yukon XL 2009-2010 Pontiac G5, G6, Solstice, Torrent 2009-2010 HUMMER H2, H3 2009-2010 Saturn AURA, OUTLOOK, SKY, VUE 2009 Saab 9-7X All Equipped with OnStar(R) (UE1) and Bluetooth (UPF) Supercede: This bulletin is being revised to replace the microphone and bezel (if needed) and update model years. Please discard Corporate Bulletin Number 10-08-44-003A (Section 08 - Body and Accessories). Condition Some customers may comment on a buzz noise (from the land-line side only) during a call. On any vehicle equipped with OnStar(R) (UE1) and Bluetooth(R) (UPF), an electromagnetic compatibility (EMC) buzz can be heard from the land-line side only of the phone during a Bluetooth(R) phone call made with an older model global system for mobile communications (GSM) phone. The buzz is only heard with older model GSM phones and is dependent on the distance of the phone from the microphone. The newer 3G GSM phones or other cellular phones (CDMA, TDMA, etc.) have not shown this concern. Correction Equipped with Headliner Microphone (Cobalt, HHR (non-sunroof) H2, H3) A new microphone and bezel has been developed to address this concern. Replace the existing microphone with GM P/N 20951265. Also replace the bezel. Refer to the parts information table below for correct color/part number. Equipped with Overhead Console Microphone Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone Microphone: > 10-08-44-003B > Oct > 10 > Audio - Buzz Noise When Using Bluetooth(R) > Page 14372 A new microphone has been developed to address this concern. Replace the existing microphone with GM P/N 20951265. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > Page 14373 Cellular Phone Microphone: Locations Harness Routing Views Overhead Console Harness Routing 1 - X304 (except MEX) 2 - Inflatable Restraint Passenger Air Bag On/Off Indicator (AL0/C99 except MEX) 3 - Cellular Telephone Microphone (UE1/U3U/UVB) 4 - Roof Beacon Switch (5X7/5Y0/TRW) 5 - Sliding Rear Window Switch (A48) 6 - Dome/Reading Lamps - Front 7 - J322 (TRW/UG1/A48) 8 - J323 9 - X313 (CF5/TRW/5X7/5Y0) 10 - Blunt Cut - Roof Mounted Beacon Provision (TRW) 11 Roof Beacon Relay (TRW) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > Page 14374 Cellular Phone Microphone: Diagrams Component Connector End Views Noise Compensation Microphone (UQA with Y91) Cellular Telephone Microphone (UE1, UUL or UUK) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > Page 14375 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > Page 14376 Cellular Phone Microphone: Service and Repair Mobile Telephone Microphone Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > OnStar(R) - Availability for Hearing Impaired Communications Control Module: Technical Service Bulletins OnStar(R) - Availability for Hearing Impaired INFORMATION Bulletin No.: 06-08-46-005B Date: February 11, 2010 Subject: Availability of OnStar(R) for Hearing Impaired Models: 2007-2010 GM Passenger Cars and Light Duty Trucks (Including Saturn and Saab) Except 2007 Cadillac CTS Except 2007-2008 HUMMER H2, H2 SUT Except 2007 Pontiac Montana SV6 Except 2007-2010 Pontiac Vibe Except 2007 Saturn ION, VUE Except 2008 Saturn Astra Supercede: This bulletin is being revised to add a Note regarding 2009 Bluetooth(R)-equipped vehicles, additional models and model years. Please discard Corporate Bulletin Number 06-08-46-005A (Section 08 - Body and Accessories). Important This service bulletin is not applicable to 'GM of Canada' dealers and retailers. Note On 2009 and newer model year vehicles equipped with the Bluetooth(R) feature (option code UPF), when up-fitted with TTY capabilities, the Bluetooth(R) feature will be disabled. OnStar with Text Telephone Capability (TTY) General Motors is pleased to announce that the safety and security of OnStar is now available to our deaf, hard of hearing and speech impaired customers. The current vehicles listed above, as well as forthcoming vehicles equipped with OnStar hardware version 7.0 or higher, have the ability to utilize texting telephones. Vehicle specific TTY capability can be determined by utilizing the VIN lookup Tool. Additional information may be found by referring to www.onstar.com/tty. TTY equipment allows people who are deaf, hard of hearing or speech impaired, in-vehicle access to 911 and basic OnStar(R) services by pressing the OnStar(R) blue button or red emergency button. The keypad provides a means to communicate by allowing customers to type messages back and forth, with an OnStar(R) advisor or other party when using the OnStar(R) Hands-Free Calling feature. A TTY is required at both ends of the conversation in order to communicate. OnStar(R) Turn by Turn Navigation and Virtual Advisor are not available with the addition of TTY. The Reimbursement Program This equipment will be made available to eligible customers through GM Mobility and OnStar(R). Under this program, the customer must complete a GM Mobility application form. To take advantage of the program, vehicles must be adapted at the time of delivery for purchase / lease and a dealer claim ($1,000 Maximum per GM Mobility guidelines) with the application form submitted to GM Mobility. Saab dealers must fax documents. GM Dealers will receive electronic reimbursement directly from GM Mobility. Saab dealers will receive a check directly from OnStar(R). Additional questions or concerns should be directed to the OnStar Dealer Center. How to Order To order the dealer installed kit, contact AutoCraft Electronics or via the web at www.autocraft.com. The kit consists of an OnStar Interface Module, a Dial Pad (for making calls), OTIM wiring harness, the TTY device, installation/Tech 2(R) programming instructions and owner's guide. Warranty Information The Ultra-Tec Compact C TTY device is manufactured by an independent manufacturer and is covered by the manufacturer's warranty. It is not covered under the GM New Vehicle Limited Warranty. All other parts (OTIM, dial pad and OTIM wiring harness) are covered by the standard GM new vehicle parts and labor warranty. Replacement parts are available through AutoCraft Electronics. Contact AutoCraft Electronics or via the web. Warranty claims for the OTIM, dial pad and OTIM wiring harness should be submitted through normal warranty procedures using a sublet warranty claim with GM Labor Operation R5140. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > OnStar(R) - Availability for Hearing Impaired > Page 14381 Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > OnStar(R) - Availability for Hearing Impaired > Page 14382 Communications Control Module: Technical Service Bulletins Audio - Radio Does Not Mute Enough When Using OnStar(R) TECHNICAL Bulletin No.: 10-08-46-001 Date: January 27, 2010 Subject: Radio Does Not Mute Enough When OnStar(R) Turn-by Turn Navigation Directions Are Announced (Increase Volume Setting or Request Soft Mute Feature Change Through OnStar(R) Customer Service) Models: 2009-2010 GM Passenger Cars and Trucks (Including Saturn) 2009-2010 HUMMER H2, H3 2009 Saab 9-7X All Equipped with OnStar(R) (RPO UE1) Condition Some customers may comment that when the radio is on, it does not mute enough when the OnStar(R) Turn-by-Turn Navigation directions are announced. Cause This condition may be caused by the customer improperly setting the radio volume high enough when the Turn-by-Turn Navigation messages are played. The 2009 and 2010 models with OnStar(R) initiates a "soft mute" feature when the radio is on during Turn-by-Turn Navigation direction announcements. During the announcement, the radio can still be heard at a very low volume. Previous model years initiated a "hard mute" during this function which completely muted the radio audio. Correction Instruct the customer to increase the radio volume while getting the Turn-by-Turn Navigation direction announcements. You can control the message volume using the radio volume control, only when the Turn-by-Turn navigation messages are playing. Some customers that were accustomed to previous model vehicles with the "hard mute" feature may be dissatisfied with the function of the "soft mute" feature. For those customers, contact the OnStar(R) Customer Service Center by pushing the Blue OnStar(R) Button to speak to a trained Advisor and request a change be made to the vehicle from the "soft mute" setting to that of the hard or complete muting of audio playback during Turn by Turn directions. OnStar(R) will then create a case number. Advise the customer that the vehicle update should be completed Over the Air within 5 business days, after which an OnStar(R) Customer Care advisor will follow-up with the customer to verify the fix. If the customer does not hear back from OnStar(R) within a week, advise them to press the Blue OnStar(R) Button and ask for Customer Care to check status. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > OnStar(R) - Availability for Hearing Impaired > Page 14383 Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > Page 14384 Communications Control Module: Locations Harness Routing Views I/P Extension Harness Routing (SLT except Y91/MEX) 1 - JX223 (U2K/UK6/UE1) 2 - X203 (UE1/U3U/UVB) 3 - X204 (U42) 4 - X212 5 - X206 (U42) 6 X213 (COAX) 7 - Vehicle Communication Interface Module (VCIM) (UE1) 8 - X301 (UQA/D07) 9 Floor Panel Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > Page 14385 Communications Control Module: Diagrams Component Connector End Views Vehicle Communication Interface Module (VCIM) X1 (UE1) Vehicle Communication Interface Module (VCIM) X2 (UE1) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > Page 14386 Vehicle Communication Interface Module (VCIM) X3 (UE1 with UUL or UUK) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > Page 14387 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Service and Repair > Communication Interface Module Replacement (with RPO SLT) Communications Control Module: Service and Repair Communication Interface Module Replacement (with RPO SLT) Communication Interface Module Replacement (with RPO SLT) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Service and Repair > Communication Interface Module Replacement (with RPO SLT) > Page 14390 Communications Control Module: Service and Repair Communication Interface Module Replacement (without RPO SLT) Communication Interface Module Replacement (without RPO SLT) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Exterior View Display Module > Component Information > Diagrams Exterior View Display Module: Diagrams Component Connector End Views Rearview Camera Image Display Module X1 (UVC) Rearview Camera Image Display Module X2 (UVC) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Exterior View Display Module > Component Information > Diagrams > Page 14395 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Control Module > Component Information > Diagrams Parking Assist Control Module: Diagrams Component Connector End Views Rear Object Sensor Control Module X1 (UD7) Rear Object Sensor Control Module X2 (UD7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Control Module > Component Information > Diagrams > Page 14399 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Control Module > Component Information > Diagrams > Page 14400 Parking Assist Control Module: Service and Repair Rear Object Alarm Module Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Diagrams Parking Assist Distance Sensor: Diagrams Component Connector End Views Object Alarm Sensor - Left Rear Corner (UD7) Object Alarm Sensor - Left Rear Middle (UD7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Diagrams > Page 14404 Object Alarm Sensor - Right Rear Corner (UD7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Diagrams > Page 14405 Object Alarm Sensor - Right Rear Middle (UD7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Diagrams > Page 14406 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Service and Repair > Rear Object Sensor Replacement Parking Assist Distance Sensor: Service and Repair Rear Object Sensor Replacement Rear Object Sensor Replacement Removal Procedure 1. Disconnect electrical from the rear object sensor. 2. Lift the locking tabs on the housing and remove the rear object sensor. Installation Procedure Note: Do not refinish previously painted sensors. Excess paint build up will cause the sensor to be inoperative. 1. Paint the rear object sensor. Refer to Basecoat/Clearcoat Paint Systems (See: Body and Frame/Paint, Striping and Decals/Paint/Application and ID/Basecoat/Clearcoat Paint Systems). 2. Ensure the paint does not exceed 6 mils. Use a paint thickness gauge suitable for non-ferrous metals. Refer to Paint Gauges (). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Service and Repair > Rear Object Sensor Replacement > Page 14409 Note: Ensure the silicone decoupling ring is installed on the sensor to avoid sensor failure. 3. Insert the sensor into the housing. 4. Connect the electrical connector to the rear object sensor. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Service and Repair > Rear Object Sensor Replacement > Page 14410 Parking Assist Distance Sensor: Service and Repair Rear Object Sensor Housing Replacement (Sierra/Silverado) Rear Object Sensor Housing Replacement (Sierra/Silverado) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Service and Repair > Rear Object Sensor Replacement > Page 14411 Parking Assist Distance Sensor: Service and Repair Rear Object Sensor Housing Replacement (All Other Vehicles) Rear Object Sensor Housing Replacement (All Other Vehicles) 1. Remove the center rear bumper step pad or the rear bumper impact bar end cap. Refer to Rear Bumper Step Center Pad Replacement () or Rear Bumper Impact Bar End Cap Replacement (). 2. Disconnect the sensor harness. 3. Remove the sensor from the sensor housing. The sensor housing must be painted if replaced. If reinstalled, painting will not be necessary. Important: Do Not grind off alignment tabs. 4. Sand/grind sonic weld plastic residue from the fascia. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Service and Repair > Rear Object Sensor Replacement > Page 14412 5. Apply structural adhesive epoxy, Lord Fusor(TM) 127EZ or equivalent, to fascia at mating surface. 6. Using the alignment tabs, install the sensor housing to the fascia. 7. Allow adhesive to cure according to manufacturer's directions. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Service and Repair > Rear Object Sensor Replacement > Page 14413 8. Install the sensor to the sensor housing. 9. Connect the electrical harness. 10. Install the center rear bumper step pad or the rear bumper impact bar end cap. Refer to Rear Bumper Step Center Pad Replacement () or Rear Bumper Impact Bar End Cap Replacement (). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Warning Indicator > Component Information > Service and Repair Parking Assist Warning Indicator: Service and Repair Information Center Telltale Assembly Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Rear Vision Camera > Component Information > Diagrams Rear Vision Camera: Diagrams Component Connector End Views Rearview Camera (SPO Rearview Camera) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Rear Vision Camera > Component Information > Diagrams > Page 14420 Rear Vision Camera: Service and Repair Rearview Camera Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver / Vehicle Information Display Switch > Component Information > Diagrams Driver / Vehicle Information Display Switch: Diagrams Component Connector End Views Driver Information Center (DIC) Switch (except MEX or 8S8) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver / Vehicle Information Display Switch > Component Information > Service and Repair > Driver Information Display Switch Replacement (with RPO SLT) Driver / Vehicle Information Display Switch: Service and Repair Driver Information Display Switch Replacement (with RPO SLT) Driver Information Display Switch Replacement (with RPO SLT) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver / Vehicle Information Display Switch > Component Information > Service and Repair > Driver Information Display Switch Replacement (with RPO SLT) > Page 14426 Driver / Vehicle Information Display Switch: Service and Repair Driver Information Display Switch Replacement (without RPO SLT) Driver Information Display Switch Replacement (without RPO SLT) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: Customer Interest OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 14435 Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 14441 Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Auxiliary Input / Output Jack, Entertainment System > Component Information > Technical Service Bulletins > Audio - Information on USB/Multimedia Player Auxiliary Input / Output Jack: Technical Service Bulletins Audio - Information on USB/Multimedia Player INFORMATION Bulletin No.: 10-08-44-004A Date: November 11, 2010 Subject: Information on USB Command and Control Multimedia Player Interface/List of Supported Devices Models: 2011 Buick Regal 2010-2011 Cadillac SRX 2009-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2011 Chevrolet Cruze, Equinox, Volt 2010-2011 GMC Terrain All Equipped with Convenience and Connectivity Package (RPOs UUK, UUL, UYS) Supercede: This bulletin is being revised to update model years. Please discard Corporate Bulletin Number 10-08-44-004 (Section 08 - Body and Accessories). USB Radio and MP3 Functionality The universal serial bus (USB) will be a USB 2.0 port on the radio faceplate, on the IP or in the center console. This interface will give the customer the additional functionality of iPod(R)/MP3 command and control. Customers now have full radio control of the iPod/MP3 audio files via the USB cable. A single USB connection allows digital audio transferring from the iPod to the radio. The iPod will be charging while connected to the radio. The customer will also have playback capability with a USB memory stick (only MP3 and WMA files). Note Not all memory sticks are supported. Note Video from the iPod is NOT capable of being transferred to a Navigation radio display. Problems with iPod Not Connecting If the infotainment system does not operate properly when using a device connected through the USB port, this may be due to an incompatible media device. Important DO NOT replace the radio or multimedia interface module due to a customer device incompatibility issue. Verify the customer's media device is validated for this system using the list below. If the customer's device is a validated device for this system, follow the SI diagnostic procedure to isolate the fault. If the customer's device is not on the validated device list, explain to the customer that their particular unit is not compatible with the system. Troubleshooting Tips for iPod Devices 1. Verify the version of the iPod/MP3 to confirm that it is supported. 2. Unplug and re-insert the iPod to verify the customer concern. 3. Verify the battery charge of the iPod. A low battery condition on the iPod may not allow it to connect to the radio. The iPod may need to be charged before it can be controlled by the radio. 4. If the customer receives a "Device Not Supported" message on their radio or is having general iPod/MP3 connection issues (and they have a supported device), they may need to reset their iPod. To reset the iPod: - For the iPod nano(R) and iPod classic(R), toggle the Hold switch on and off (slide it to Hold, then turn it off again). Press and hold the Menu and Center (Select) buttons simultaneously until the Apple(R) logo appears, about 6 to 8 seconds. You may need to repeat this step. - For the iPod touch(R) and iPhone(R): Press and hold the Sleep/Wake button for a few seconds until the red slider appears, then slide the slider. 5. For iPod touch and iPhone: To obtain full use capabilities of their device, it needs to be fully powered up when connecting to the USB port. If these devices are fully powered down or in "sleep" mode, please advise the customer to press and hold the Sleep/Wake button on the top of the device for a few seconds and if an unlock pass code is required, to enter the pass code as well as slide the lower "Unlock" slider. 6. Have the customer inspect their cable for quality. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Auxiliary Input / Output Jack, Entertainment System > Component Information > Technical Service Bulletins > Audio - Information on USB/Multimedia Player > Page 14447 - Aftermarket cables can wear from use. The customer may need to purchase a new USB cable. - Verify that cable extensions are not present. The extra capacitance may cause too large a signal drop for the iPod to communicate with the radio. 7. If the customer receives a "Device Not Supported" message on their radio with an iPod connected (and they have a supported device), the customer may need to download the latest firmware from the Apple website (Please visit www.apple.com for more information). Validated Apple Device - Both Charge/Support Digital Audio Important None of these device lists below support video. Important Not all iPhone functions are fully supported. For further information on identifying iPod models, please visit http://support.apple.com/kb/HT1353. Important These devices (and additional MP3 players) may be capable of connecting to the other USB options by internally setting the MP3 device to mass storage class (MSC) mode. In this mode, the USB port will see the device as a flash drive. Please have the customer refer to their MP3 device manual on how to set the device to MSC. If the device is not able to be set to MSC, the customer must use the AUX jack. Note MTP mode must be used in order to transfer ANY Digital Rights Management (DRM) protected content. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Auxiliary Input / Output Jack, Entertainment System > Component Information > Technical Service Bulletins > Audio - Information on USB/Multimedia Player > Page 14448 Non-Validated Apple Device Specifications Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Auxiliary Input / Output Jack, Entertainment System > Component Information > Technical Service Bulletins > Audio - Information on USB/Multimedia Player > Page 14449 Playback Operation (X = Supported; - = Not Supported) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Auxiliary Input / Output Jack, Entertainment System > Component Information > Technical Service Bulletins > Audio - Information on USB/Multimedia Player > Page 14450 Other USB Device Supported Requirements (X = Supported; - = Not Supported) Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Auxiliary Input / Output Jack, Entertainment System > Component Information > Technical Service Bulletins > Audio - Information on USB/Multimedia Player > Page 14451 Auxiliary Input / Output Jack: Technical Service Bulletins Audio System - USB/Multimedia Interface Information INFORMATION Bulletin No.: 09-08-44-013C Date: October 05, 2010 Subject: Information on USB Command and Control Multimedia Player Interface/List of Supported Devices Models: 2010-2011 Buick Enclave, LaCrosse 2008-2011 Cadillac CTS 2010-2011 Cadillac Escalade Models, SRX 2009-2010 Chevrolet Cobalt 2009-2011 Chevrolet HHR, Malibu 2010-2011 Chevrolet Avalanche, Camaro, Equinox, Silverado, Suburban, Tahoe, Traverse 2011 Chevrolet Cruze 2010-2011 GMC Acadia, Sierra, Terrain, Yukon 2009-2010 Pontiac G5, G6, Solstice, Solstice Coupe 2009-2010 Saturn AURA, SKY 2010 Saturn OUTLOOK All Equipped with Convenience and Connectivity Package - RPOs KTA, KTB, SRJ, U4H, UUI, UUJ, UUM, UUN, U2S, U2X, U2Y, UAV, UYZ, UY5 Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 09-08-44-013B (Section 08 - Body and Accessories). USB Radio and MP3 Functionality The USB (Universal Serial Bus) will be a USB 2.0 port on the radio faceplate, on the IP or in the center console. This interface will give the customer the additional functionality of iPod/MP3 command and control. Customers now have full radio control of the iPod/MP3 audio files via the USB cable. A single USB connection allows digital audio transferring from the iPod to the radio. The customer will also have playback capability with a USB memory stick (only MP3 and WMA files). Note Not all memory sticks are supported. Customers have full radio control of the iPod/MP3 audio files via the USB cable. A single USB connection allows digital audio transferring from the iPod to the radio. The iPod will be charging while connected to the radio. Note Video from the iPod is NOT capable of being transferred to a Navigation radio display. For the Chevrolet Cobalt, HHR and Malibu; Pontiac G5, G6, Solstice; and Saturn AURA, SKY, the USB port is on the faceplate of the radio. For all other models, it is located in the center console or IP. For the Cadillac CTS only, a special iPod cable (USB and AUX cable) is needed. This special cable comes delivered with the vehicle. In all cases, the iPod will be charging while connected to the radio through the USB port when the vehicle is running or the RPA is active. Problems with iPod Not Connecting If the infotainment system does not operate properly when using a device connected through the USB port, this may be due to an incompatible media device. Important DO NOT replace the radio or multimedia interface module due to a customer device incompatibility issue. Verify the customer's media device is validated for this system using the list below. If the customer's device is a validated device for this system, follow the SI diagnostic procedure to isolate the fault. If the customer's device is not on the validated device list, explain to the customer that their particular unit is not compatible with the system. Troubleshooting Tips for iPod Devices Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Auxiliary Input / Output Jack, Entertainment System > Component Information > Technical Service Bulletins > Audio - Information on USB/Multimedia Player > Page 14452 1. Check the version of the iPod/MP3 to confirm that it is supported. 2. Unplug and Re-insert the iPod to verify the customer complaint. 3. Verify the battery charge of the iPod. A low battery condition on the iPod may not allow it to connect to the radio. The iPod may need to be charged before it can be controlled by the radio. 4. If the customer receives a "Device Not Supported" message on their radio or is having general iPod/MP3 connection issues (and they have a supported device), they may need to reset their iPod. To reset the iPod: - For the iPod Nanos and Classic , Toggle the Hold switch on and off. (Slide it to Hold, then turn it off again. Press and hold the Menu and Center (Select) buttons simultaneously until the Apple logo appears, about 6 to 8 seconds. You may need to repeat this step. - For the iPod Touch and iPhone: Press and hold the Sleep/Wake button for a few seconds until the red slider appears, then slide the slider. 5. Have the customer check their cable for quality. - Aftermarket cables can wear from use. The customer may need to purchase a new USB cable. - Verify that cable extensions are not present. The extra capacitance may cause too large a signal drop for the iPod to communicate with the radio. 6. If the customer receives a "Device Not Supported" message on their radio with an iPod connected (and they have a supported device), the customer may need to download the latest firmware from the Apple website (Please visit www.apple.com for more information). Validated Apple Device - Both Charge/Support Digital Audio (For All RPOs) For further information on identifying iPod models, please visit http://support.apple.com/kb/ht1353 Other Validated Device- Both Charge/Support Digital Audio for Buick LaCrosse, Chevrolet Camaro, Equinox Only (RPO KTA or KTB) Important: Must be set to MTP (Mass Transfer Protocol) in the MP3 Player device setting. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Auxiliary Input / Output Jack, Entertainment System > Component Information > Technical Service Bulletins > Audio - Information on USB/Multimedia Player > Page 14453 Important These devices (and additional MP3 players) may be capable of connecting to the other USB options by internally setting the MP3 device to MSC (Mass Storage Class) mode. In this mode, the USB port will see the device as a flash drive. Please have the customer refer to their MP3 device manual on how to set the device to MSC. If the device is not able to be set to MSC, the customer must use the AUX jack. Note MTP mode must be used in order to transfer ANY Digital Rights Management (DRM) protected content. Non-Validated Apple Device Important The devices above are NOT supported by USB interface. Apple does not support digital media transfer from these devices through the USB port. The customer can still listen to their older iPod on vehicle by connecting it to the Auxiliary Input Jack using a standard 3.5 mm (1/8 in) stereo cable. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Auxiliary Input / Output Jack, Entertainment System > Component Information > Technical Service Bulletins > Audio - Information on USB/Multimedia Player > Page 14454 Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Auxiliary Input / Output Jack, Entertainment System > Component Information > Technical Service Bulletins > Page 14455 Auxiliary Input / Output Jack: Diagrams Component Connector End Views Audio/Video Adapter (U42) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Auxiliary Input / Output Jack, Entertainment System > Component Information > Service and Repair > USB Receptacle Replacement (With SLT) Auxiliary Input / Output Jack: Service and Repair USB Receptacle Replacement (With SLT) USB Receptacle Replacement (With SLT) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Auxiliary Input / Output Jack, Entertainment System > Component Information > Service and Repair > USB Receptacle Replacement (With SLT) > Page 14458 Auxiliary Input / Output Jack: Service and Repair USB Receptacle Replacement (Without SLT) USB Receptacle Replacement (Without SLT) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Television / Monitor > Component Information > Diagrams Television / Monitor: Diagrams Component Connector End Views Digital Video Disc (DVD) Display - Driver Seat Headrest X1 (SPO DVD) Digital Video Disc (DVD) Display - Driver Seat Headrest X2 (SPO DVD) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Television / Monitor > Component Information > Diagrams > Page 14462 Digital Video Disc (DVD) Display - Passenger Seat Headrest X1 (SPO DVD) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Television / Monitor > Component Information > Diagrams > Page 14463 Digital Video Disc (DVD) Display - Passenger Seat Headrest X2 (SPO DVD) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Television / Monitor > Component Information > Diagrams > Page 14464 Video Display (U42) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Television / Monitor > Component Information > Diagrams > Page 14465 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Television / Monitor > Component Information > Diagrams > Page 14466 Television / Monitor: Service and Repair Video Display Replacement (Second Row) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component Information > Diagrams DVD Player: Diagrams Component Connector End Views Digital Video Disc (DVD) Control Module X1 (SPO DVD) Digital Video Disc (DVD) Control Module X2 (SPO DVD) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component Information > Diagrams > Page 14470 Digital Video Disc (DVD) Control Module X3 (SPO DVD) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component Information > Diagrams > Page 14471 Digital Video Disc (DVD) Control Module X4 (SPO DVD) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component Information > Diagrams > Page 14472 Digital Video Disc (DVD) Control Module X5 (SPO DVD) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component Information > Diagrams > Page 14473 Digital Video Disc (DVD) Control Module X6 (SPO DVD) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component Information > Diagrams > Page 14474 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Specifications Garage Door Opener Transmitter: Specifications Fastener Tightening Specifications Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions Garage Door Opener Transmitter: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Schematic Symbols Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14480 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14481 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14482 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14483 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14484 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14485 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14486 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14487 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14488 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14489 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14490 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14491 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14492 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14493 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14494 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14495 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14496 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14497 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14498 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14499 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14500 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14501 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14502 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14503 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14504 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14505 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14506 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14507 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14508 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14509 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14510 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14511 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14512 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14513 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14514 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14515 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14516 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14517 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14518 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14519 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14520 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14521 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14522 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14523 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14524 Garage Door Opener Transmitter: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed with Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14525 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14526 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Connector Test Adapters) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14527 Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Test Lamp) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Fused Jumper Wires) * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage Drop) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Frequency) * Testing Ground and Low Reference Circuits (See: Testing and Inspection/Component Tests and General Diagnostics/Testing Ground and Low Reference Circuits) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fuses) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Circuit Breakers) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fusible Links) Troubleshooting with a Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Testing for a Short to Voltage Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14528 Testing for a Short to Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure tests for a short to voltage in a circuit. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the Digital Multimeter (DMM) to the V (DC) position. 4. Connect the positive lead of the DMM to one end of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. Turn ON the ignition and operate all accessories. 7. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Special Tools J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure). Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents). Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14529 The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the frequency of a signal. Note: Connecting the Digital Multimeter (DMM) to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Set to Hz on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14530 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the Digital Multimeter (DMM). 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the difference in voltage potential between 2 points. 1. Set the Digital Multimeter (DMM) to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14531 Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Backprobe Note: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14532 (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for Continuity Testing for Continuity Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures verify good continuity in a circuit. With a Digital Multimeter (DMM) 1. Set the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Select the MIN MAX function on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14533 Testing for Electrical Intermittents Testing for Electrical Intermittents Special Tools J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. Note: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions). 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14534 visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing for Terminal Fretting Some intermittent conditions can be caused by wire terminal fretting corrosion. Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can pile up enough at the electrical contact spots that the electrical resistance across the connection increases. Movement between the contacting surfaces as small as 10 to 100 microns can cause fretting. To put this in perspective, a sheet of paper is about 100 microns thick, so fretting motion is small and hard to see. Vibration and thermal expansion/contraction are the main sources that create fretting motion. Since vehicles vibrate and can experience large temperature swings, they are a good source for fretting motion. Tin, copper, nickel, and iron surfaces are all susceptible to fretting corrosion. Fretting corrosion can be difficult to see but it looks like small, dark smudges on the terminals contact surface. To correct a fretting condition disconnect the suspect connector and add Nyogel lubricant 760G (dielectric grease) to both sides of the connector terminals. Then reconnect the connector and wipe away any excess lubricant. This will correct the additional terminal contact resistance due to the terminal fretting corrosion. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14535 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics). * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Ground Distribution Schematics). Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Checking Aftermarket Accessories). * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14536 Note: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures test for a short to ground in a circuit. With a Digital Multimeter (DMM) 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohms position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Danger: High voltage circuits should only be tested using a digital multimeter (DMM) and test leads with at least a CAT III rating, such as the J 39200-A Digital Multimeter. Failure to follow the procedures exactly as written may result in serious injury or death. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Digital Multimeter (DMM) Basic Requirements Service information is validated using digital multimeters that meet or exceed the following requirements. Using a multimeter that does not meet these basic requirements may give inaccurate readings which could lead to an incorrect diagnosis. Display and Settings 1. Four digits displayed 2. Voltage, amperage, resistance, frequency, diode test settings, and min-max function 3. Display positive and negative values Voltage 1. Have at least 10 M ohm input impedance Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14537 2. Test a DC voltage range of 0.1-1000 V. 3. Test an AC voltage range of 0.1-1000 V. Amperage 1. Test a DC amperage range of 0.1µA-10 A. 2. Test an AC amperage range of 0.1µA-10 A. Resistance Test a resistance range of 0.1 ohm-40 Mohm and displays infinite for a value greater than 40 M ohm (O.L. (Over-load)) Frequency Test for a frequency range of 0.5 HZ-199 K HZ Diode Test 1. Apply at least 1 mA when performing the diode bias test 2. Display the break over voltage drop (0-3 V) of a forward biased diode 3. Display infinite (O.L. (Over-load)) when a diode is reverse biased Min-Max Readings 1. Can update at a 1 ms sample rate 2. Saves and displays minimum and maximum values Note: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Probe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors). * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the EL-38125-580 GM Approved Terminal Release Tool Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the EL-38125-580 GM Approved Terminal Release Tool Kit , ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the EL-38125-580 GM Approved Terminal Release Tool Kit label on the inside of the EL-38125-580 GM Approved Terminal Release Tool Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14538 Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/EPC Connectors AFL/EPC Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14539 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 3. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14540 View showing depressing of the lever lock release tab. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14541 6. Release the rear lower half of the wiredress cover. 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14542 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14543 Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Bosch Connectors (ECM) Bosch Connectors (ECM) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14544 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. 2. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14545 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-bladed tool to release the locking tabs and remove the dress cover. 4. The terminal positive assurance (TPA) is located in the front of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14546 5. Use a small flat-blade tool to remove TPA from the connector. 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14547 Note: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14548 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14549 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Terminal Replacement Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14550 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14551 5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Position Assurance Locks) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Terminal Position Assurance Locks) * AFL/EPC Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/AFL/EPC Connectors) * Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (BSK))Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (0.64))Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (2.8 JPT))Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (ECM)) * Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Weather Pack))Delphi Connectors (Push To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Push to Seat))Delphi Connectors Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14552 (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Pull to Seat))Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro-Pack 100W))Delphi Connectors (Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro .64))Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (12-Way)) * FCI Connectors (Lever Lock) (See: General Electrical Diagnostic Procedures/Connector Repairs/FCI Connectors (Lever Lock)) * JST Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/JST Connectors) * Kostal Connectors (Glow Plug Control Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Glow Plug Control Module))Kostal Connectors (Transmission) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Transmission)) * Molex Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Molex Connectors) * Sumitomo Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Sumitomo Connectors) * Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (CM 42-Way))Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Sensor))Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (0.25 Cap))Tyco/AMP Connectors (43-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (43-Way))Tyco/AMP Connectors (Door Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Door Module))Tyco/AMP Connectors (102-Way Inline) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (102-Way Inline))Tyco/AMP Connectors (Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Seat))Tyco/AMP Connectors (SIR) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (SIR)) * Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (2-Way))Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (16-Way)) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14553 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14554 * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14555 * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14556 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14557 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14558 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Push to Seat) Delphi Connectors (Push To Seat) Special Tools J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14559 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs). 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Terminated Lead Repair 1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice sleeves depending on the gauge size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Delphi Connectors (Pull to Seat) Delphi Connectors (Pull To Seat) Special Tools Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14560 J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Note: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14561 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. View of a typical Micro 64 connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14562 Depress the lock and pull the lever over and past the lock. View of the connector when released from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14563 View of another type of Micro 64 connector. Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14564 View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14565 Note: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14566 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14567 Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Note: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14568 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14569 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14570 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14571 1. Cut the wire as close to the terminal as possible. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14572 Terminal Replacement Procedure After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Special Tools J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Note: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals). 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12-Way) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14573 Delphi Connectors (12-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14574 4. Release the lower wire dress cover locking tab. 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14575 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14576 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors (Lever Lock) FCI Connectors (Lever Lock) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14577 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. The release tab is located on the top of the wiredress cover. 3. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14578 6. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14579 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14580 1. While depressing the lock, remove the connector from the component. 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14581 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. 4. View of the TPA when removed from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14582 5. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Glow Plug Control Module) Kostal Connectors (Glow Plug Control Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14583 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14584 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14585 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. Note: The front TPA cannot be removed from the connector. Only move it to the preset position. 6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm). 7. Use a small flat-blade tool to completely remove the rear TPA from the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14586 8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Transmission) Kostal Connectors (Transmission) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14587 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14588 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Terminal Replacement Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14589 After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14590 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14591 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14592 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14593 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14594 3. To assemble the connector, reverse the connector disassembly procedure. Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14595 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14596 7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14597 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14598 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14599 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14600 Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14601 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14602 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14603 6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (102-Way Inline) Tyco/AMP Connectors (102-Way Inline) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14604 View of a typical connector in the assembled position. 1. Pull the locking lever to the 90 degree position from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14605 2. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal. 3. Slide the male connector body out away from the guide plates. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14606 Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 4. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. 5. Using terminal release tool J 38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14607 6. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 7. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14608 8. The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool J-38125-11A or equivalent to release the locking tab and slide the connector off the female body. 9. Move the locking lever 180 degrees from the connected position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14609 10. With the locking lever in the 180 degree position the guide plates can be removed from the connector body. Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 11. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14610 12. Using terminal release tool J 38125-216, lift the terminal plate past the terminals and out of the connector body cavity. 13. Terminal plate will bind slightly on each corner. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14611 14. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 15. Using terminal release tool J 38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14612 16. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 17. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14613 18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever. 19. Slide the male connector body back inward toward the guide plates. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14614 20. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly. 21. Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Seat) Tyco/AMP Connectors (Seat) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14615 Removal Procedure 1. Grasp the locking slide lever and pull outward from the end of the connector. 2. As the slide lever is pulled out the mating connector is lifted from the seated position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14616 Note: TPA is keyed and can only be inserted in one direction. 3. Using terminal release tool J 38125-11A or equivalent, push the TPA tabs into the connector body. 4. Pull the TPA from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14617 5. Using terminal release tool J 38125-11A or equivalent, release the connector wire dress cover locking tab. 6. With the lock tab released, lift the connector wire dress cover from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14618 7. Using terminal release tool J 38125-212, press the prongs into the holes each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 8. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14619 9. Using terminal release tool J 38125-556, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (SIR) Tyco/AMP Connectors (SIR) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14620 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14621 3. Using terminal tool J-38125-11A or equivalent, release the wire dress cover locking tabs. 4. Pivot connector wire dress cover while removing from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14622 5. Using terminal tool J-38125-11A or equivalent, remove the TPA by lifting straight off the connector body. 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals Repairing Connector Terminals Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14623 Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gauge size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14624 2. Disconnect the connector from the component. 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14625 4. Relieve the tension on the nose piece retainers by inserting J 38125-12A into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. 5. Once the nose piece retainers are relaxed, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14626 6. On the opposite side of the nose piece, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14627 8. Insert the J 38125-553 tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14628 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. If the TPA is removed, be sure to reinstall it before reconnecting the connector. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14629 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Special Tools Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14630 J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Note: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14631 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14632 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14633 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14634 1. While depressing the lock, pull the two connector halves apart. Note: The TPA is fragile and may break if not done carefully. 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. 3. View of the male half of the connector with female terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14635 4. View of the female half of the connector with male terminals. 5. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. View of the female half of the connector with male terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14636 7. View of the male half of the connector with female terminals. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14637 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are a one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine if the element in the fuse is broken (2). If not broken (1), also check for continuity using a Digital Multimeter (DMM) or a continuity tester. If the element is broken or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a Digital Multimeter (DMM) at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gauge size. Repairing a Fusible Link Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14638 Flat Wire Repairs The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Special Tools J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool * J 38125-5 Ultra Torch Special Tool The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Note: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation). GMLAN Connector Terminal Repair Note: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) for the appropriate connector repair procedure. GMLAN Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14639 Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14640 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Special Tools J-38125 Terminal Repair Kit Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14641 repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs High Temperature Wiring Repairs Special Tools J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gauge size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14642 splice. Note: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14643 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14644 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the wire insulation has been chafed, or broken, enough to show the conductive portion of the wire, and the wire is not damaged, determine the length of insulation that needs to be repaired. If the repair is less than 280 mm (11 in), cut the wire within the damaged area. Then slide the appropriate heat shrink tubing (listed below) over the wire, and repair the wire by splicing the wires together. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Once the wire is spliced together slide heat shrink tubing over the damaged area and apply heat to seal the repaired wire. If the wire is damaged, or the damaged area is larger than 280 mm (11 in), then replace the damaged wire by splicing in a new section of wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14645 SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Special Tools J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14646 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14647 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14648 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Special Tools J-38125 Terminal Repair Kit Note: Use only DuraSeal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use DuraSeal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use DuraSeal splice sleeves where there are special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14649 * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14650 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14651 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the instructions for Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Staggering the splices by 65 mm (2.5 in) is recommended. Note: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product AL-36FR to replace the damaged mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Flat Wire Repairs) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/GMLAN Wiring Repairs) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Heated Oxygen Sensor Wiring Repairs) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves) * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Twisted or Shielded Cable) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Inline Harness Diodes) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/SIR/SRS Wiring Repairs) US English/Metric Conversion US English/Metric Conversion Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14652 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14653 Testing Ground and Low Reference Circuits Testing Ground and Low Reference Circuits Because a test lamp can light with up to 200 ohm in a ground or low reference circuit they are not recommended to be used for this type of test. A low impedance test lamp can light and indicate the circuit is good when there is as much as 20-30 ohm present, while a high impedance test lamp can light with up to 200 ohm present in the circuit. This is why the Digital Multi-Meter (DMM) is used when validating a ground or low reference circuit continuity. When using the DMM there are many vehicle conditions that can affect the ground and low reference continuity testing. If these conditions are not met, a ground or low reference circuit test can fail on a good circuit. This may cause longer diagnosis time and incorrect component replacement. Any current flow through a ground or low reference circuit, while being tested, will skew the DMM continuity reading, or display a reading higher than when there is no current flowing. Performing a ground or low reference circuit continuity test, in reference to the vehicles battery negative terminal, will have the highest risk of failing a good ground or low reference circuit test than any other ground reference point. The best ground test points would be a control module housing (if the control modules housing is metal and grounded), door jamb striker (if attached to metal), under dash metal frame work, engine block, or body ground studs (other than where the negative battery cable is attached). A typical DMM ground or low reference circuit continuity reading can be as high as 100 ohm with the ignition ON, and drop to 15-25 ohm after the ignition is turned OFF. The reading will drop below 10 ohm after 30-40 seconds, then below 5 ohm after 60 seconds. Once the vehicle completely goes to sleep (generally 3-10 minutes) the reading will drop below 0.3 ohm. The following list of conditions may need to be met to ensure a valid continuity reading on a ground or low reference circuit: * Ignition OFF * Key out of the ignition switch (when not equipped with keyless entry and remote start) * Retained Accessory Power (RAP) OFF (open and close the driver door after ignition OFF) * Battery charger set at a 2 A or less charge rate * Scan tool not communicating with any vehicle control module (in some cases it may need to be disconnected from the DLC) * All entry doors closed * Headlamps OFF (auto headlamps disabled) * Any delay lighting OFF * HVAC after blow OFF * Any accessory that can work when the ignition is OFF * Wait up to 60 seconds (after all other listed conditions are met) Activating the DOOR LOCK function with a key fob can greatly reduce the time to achieve a valid ground or low reference continuity test result. Terminal Removal Terminal Removal Special Tools * EL-38125-580 - Terminal Release Tool Kit * EL-35616 - Connector Test Adapter Kit For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repair procedures. 1. Find the appropriate connector end view within the connector end view section. The connector end view has the following information: Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14654 * Diagnostic probe tool * Terminal release tool * Terminal/terminated lead part numbers Note: Not using the proper test kit probe may cause damage to the terminal(s) that are probed. 2. Determine if a terminal is damaged. * Locate the diagnostic probe tool from the connector end view. The connector end view describes the color and part number to help the technician find and use the correct tool. * Connect the probe tool to the Digital Multimeter. * Insert the probe tool into the cavity and follow the procedures from the Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter). 3. Disconnect the connector body to perform the repair. 4. Use the following procedure to remove the terminal from the connector body. Note: Several procedures for specific connector bodies are called out in the Wiring Repairs section. * The terminal position assurance (TPA) and connector position assurance (CPA) should be removed before releasing the terminal for the connector body. * Look at the connector end view to locate the cavity of the damaged terminal and find the proper terminal release tool from the terminal release tool kit. Note: Using the incorrect terminal release tool can damage the connector body. * Insert the terminal release tool into the cavity. Note: Some terminals have a lever that must be disengaged before the terminal can be released. 5. Gently pull the wire out of the back of the connector. 6. Repair the terminal by following the Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) procedure. 7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminated Lead Repair Terminated Lead Repair Special Tools * J-38125-8 - Splice Sleeve Crimp Tool Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14655 * J-38125-5 - Ultra Torch For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) procedures. Terminated leads are terminals that are crimped onto wires. The terminated lead can be used throughout the vehicle since it is designed for temperatures up to 150°C. The length of the wire is 450 mm. The DuraSeal splice sleeve has the following 2 critical features: * A special heat shrink tubing that environmentally seals the splice. The shrink tubing contains a sealing adhesive inside the shrink tubing. * A cross hatched (knurled) core crimp that provides the necessary contact integrity for sensitive low energy circuits. 1. Use the connector end view to identify the correct terminated lead. 2. The terminated lead package should include a DuraSeal splice sleeve. If not, use the chart to identify the correct part. 3. Open the harness by removing any tape: Use a sewing seam ripper, or a comparable tool, to cut open the harness, to avoid wire insulation damage. 4. Depending on how many terminals need repairs, cut the terminal and wire back at least 40 mm. Try to keep the harness wire length the same. If more than one terminated lead is required, stagger the lengths by 40 mm. This helps reduce the bundle size of the wire harness. 5. Use the EL-38125-10 - tool in order to position the DuraSeal splice sleeve in the proper color nest of the splice sleeve crimp tool. The crimp tool has four nests, one for each color. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14656 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the J-38125-5 - ultra torch , apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14657 Garage Door Opener Transmitter: Connector Views Component Connector End Views Garage Door Opener (GDO) (UG1) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 14658 Garage Door Opener Transmitter: Electrical Diagrams Remote Function Schematics Garage Door Opener Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Page 14659 Garage Door Opener Transmitter: Description and Operation Garage Door Opener Description and Operation The garage door opener (GDO) is fixed and rolling code capable. Rolling code is a system that allows the code that the customers receiver receives from the GDO to change every time the GDO is used within operating range of the receiver. Rolling code programming requires the customer to push a learn/program button on the GDO receiver at their home. This button is usually located on the receiver unit under a cover (light cover) on one end of the unit. The customer must follow the GDO manufacturers instructions to program/learn the receiver to accept the Universal Home Remote System as an authorized opener for their unit. When the receiver and the GDO are initially programmed together, a code is established and a new code is created for every new transmission. The software in the receiver recognizes the GDO and accepts the new code. The GDO is compatible with most, but not all types and brands of transmitters. If a problem should occur with a compatibility conflict with a transmitter, refer to 1-866-572-2728. The GDO is a transmitter operating between 288-399 MHz. The power and range of the transmitter is limited to comply with laws governing the generation of radio frequency interference (RFI). The transmitter is programmed by the user to accept the signal generated by the user's transmitters. The GDO has 3 buttons that may be programmed for individual transmitter/receiver combinations to control up to 3 GDOs, security gates, lighting systems, etc. Each button represents a transmitter code section of the transmitter, which operates separately from any other button, and may be considered a separate transmitter. Operation consists of simply pressing a button to activate the corresponding transmitter. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures Garage Door Opener Transmitter: Symptom Related Diagnostic Procedures Symptoms - Remote Functions Symptoms - Remote Functions Important: The following steps must be completed before using the symptom tables. 1. Perform Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check Vehicle) before using the Symptom Tables in order to verify that all of the following are true: * There are no DTCs set. * The control modules can communicate via the serial data link. 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Keyless Entry System Description and Operation (with Accessory 2 Way Remote) (See: Antitheft and Alarm Systems/Keyless Entry/Description and Operation/Keyless Entry System (with Accessory 2 Way Remote))Keyless Entry System Description and Operation (without Accessory 2 Way Remote) (See: Antitheft and Alarm Systems/Keyless Entry/Description and Operation/Keyless Entry System (without Accessory 2 Way Remote)). Visual/Physical Inspection * Inspect for aftermarket devices which could affect the operation of the Keyless Entry System. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Checking Aftermarket Accessories). * Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom. Intermittent Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections ( See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections). Symptom List Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom: * Garage Door Opener Inoperative (See: Garage Door Opener Inoperative) * Keyless Entry System Inoperative (See: Antitheft and Alarm Systems/Keyless Entry/Testing and Inspection/Symptom Related Diagnostic Procedures/Keyless Entry System Inoperative) * Remote Vehicle Start Inoperative (See: Antitheft and Alarm Systems/Keyless Entry/Testing and Inspection/Symptom Related Diagnostic Procedures/Remote Vehicle Start Inoperative) Garage Door Opener Inoperative Garage Door Opener Inoperative Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Circuit/System Description The garage door opener (GDO) is a transmitter operating between 288 and 399 MHz. The GDO has three buttons that may be programmed for individual transmitter/receiver combinations to control up to three GDOs, security gates, lighting systems, etc. Each button represents a unique transmitter code section, which operates independently of the other buttons, and may be considered a separate transmitter. Reference Information Schematic Reference Remote Function Schematics (See: Diagrams/Electrical Diagrams) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 14662 Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views) Description and Operation Garage Door Opener Description and Operation (See: Description and Operation) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning) for scan tool information Special Tools J 41540 Universal Home Remote Tester Circuit/System Testing 1. Ignition OFF, disconnect the harness connector at the GDO. 2. Ignition OFF, test for less than 5 ohm between the ground circuit terminal 3 and ground. ‹› If greater than the specified value, test the ground circuit for an open/high resistance. 3. Ignition ON, verify a test lamp illuminates between the B+ circuit terminal 1 and ground. ‹› If the test lamp does not illuminate, test the B+ circuit for a short to ground or an open/high resistance. Important: This step will clear any learned transmitters from the GDO. This will require reprogramming by the customer to reestablish GDO functionality. 4. Ignition ON, hold the two outer buttons on the GDO for 30 seconds. After 20 seconds, the LEDs will flash indicating that all learned transmitter values have been cleared. After an additional 10 seconds, the LEDs will flash again indicating it has entered the diagnostic mode. Place the J 41540 adjacent to the GDO and press each button of the GDO one at a time. The tester should indicate when each button is pressed. ‹› If the tester indicates that one or more of the buttons does not respond, replace the GDO. 5. Instruct the customer to program the GDO. Refer to the vehicle owners manual. A possible rolling code or incompatibility with the GDO receiver will prevent programming. Repair Instructions Perform the Diagnostic Repair Verification (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. Control Module References (See: Testing and Inspection/Programming and Relearning) for GDO replacement, setup, and programming Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 14663 Garage Door Opener Transmitter: Programming and Relearning Garage Door Opener Programming - Universal Important: Do not use the garage door opener (GDO) with any garage door opener that does not have the stop and reverse safety feature. This includes any garage door opener model manufactured before April 1, 1982. Ensure that people and objects are clear of the garage door while performing programming operations. Programming the GDO for Rolling Code Receivers Important: If the programming procedure is unsuccessful, it may be necessary to perform the Erasing Channels procedure first. This procedure will learn a rolling code garage door opener to the GDO transmitter. The learn process must be completed within 30 seconds. 1. Press the two outside buttons of the GDO for one to two seconds, then immediately release them. 2. Locate the "Learn" or "Smart" button on the garage door opener receiver (located on the garage door opener motor-head unit). It is often found where the hanging antenna wire is attached to the motor-head unit and may be a colored button. Refer to the garage door opener operator's manual or call 1-866-572-2728 for assistance. Press the "Learn" or "Smart" button. The garage door opener operator's manual may provide assistance in determining when the unit is in learn mode. 3. Immediately return to the GDO transmitter in the vehicle. Press and hold the button that is to be learned; the LED above the button will begin to flash slowly. When the garage door moves, immediately release the button. The LED will flash rapidly until programming is complete. 4. Press the button used during the learn operation again in order to verify that the GDO transmitter has been programmed. The GDO is compatible with most, but not all, types of garage door openers. If the GDO LED does not flash rapidly after 90 seconds, there may be a compatibility conflict with the garage door opener. Call 1-866-572-2728 to address compatibility concerns. Programming the GDO for Fixed Code Receivers Important: If the programming procedure is unsuccessful, it may be necessary to perform the Erasing Channels procedure first. This procedure will learn a fixed code garage door opener to the GDO transmitter. To determine if the customer has a fixed code garage door opener, remove the battery cover on the customer supplied transmitter. If a row of dip switches is present, the garage door opener is a fixed code version. The transmitter should have anywhere from 8 to 12 switches. The garage door opener receiver may also have a set of dip switches. If the number of switches on the receiver and the transmitter do not match, use the receiver switches to program the GDO. Each dip switch may have either two or three positions. The two position switch can either be ON or OFF. The three position switch can either be ON, NEUTRAL, or OFF. 1. Write down the positions of the dip switches. The positions of the switches will be entered from left to right into the GDO using the three buttons. 2. Press all three buttons on the GDO for three seconds and immediately release them. The LEDs should flash slowly, indicating that the GDO is in programming mode. 3. Enter the positions of the dip switches one at a time. If a position of a dip switch is on, press the left button on the GDO. If the position is neutral, press the middle button of the GDO. If the position is off, press the right button of the GDO. Enter all of the positions of the dip switches. The procedure must be completed in two and a half minutes. 4. After entering all of the switch positions, firmly press and release all three buttons at the same time. The indicator lights will turn on. 5. Press and hold the button that is to be learned; the LED above the button will begin to flash slowly. When the garage door moves, immediately release the button. The LED will flash rapidly until programming is complete. 6. Press the button used during the learn operation again in order to verify that the GDO transmitter has been programmed. The GDO is compatible with most, but not all, types of garage door openers. If the GDO light does not flash rapidly after 90 seconds, there may be a compatibility conflict with the garage door opener. Call 1-866-572-2728 to address compatibility concerns. Erasing Channels To erase programmed channels, press and hold the two outside buttons until the lights on the GDO transmitter begins to flash. Once the LEDs begin to flash, release both buttons; all learned codes are now erased. Individual channels cannot be erased, but can be reprogrammed using the procedures above. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Page 14664 Garage Door Opener Transmitter: Service and Repair Garage Door Opener Transmitter Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Global Positioning System: Customer Interest OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 14673 Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Global Positioning System: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Global Positioning System: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Global Positioning System: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 14679 Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Global Positioning System: > 06-08-46-005B > Feb > 10 > OnStar(R) - Availability for Hearing Impaired Global Positioning System: All Technical Service Bulletins OnStar(R) - Availability for Hearing Impaired INFORMATION Bulletin No.: 06-08-46-005B Date: February 11, 2010 Subject: Availability of OnStar(R) for Hearing Impaired Models: 2007-2010 GM Passenger Cars and Light Duty Trucks (Including Saturn and Saab) Except 2007 Cadillac CTS Except 2007-2008 HUMMER H2, H2 SUT Except 2007 Pontiac Montana SV6 Except 2007-2010 Pontiac Vibe Except 2007 Saturn ION, VUE Except 2008 Saturn Astra Supercede: This bulletin is being revised to add a Note regarding 2009 Bluetooth(R)-equipped vehicles, additional models and model years. Please discard Corporate Bulletin Number 06-08-46-005A (Section 08 - Body and Accessories). Important This service bulletin is not applicable to 'GM of Canada' dealers and retailers. Note On 2009 and newer model year vehicles equipped with the Bluetooth(R) feature (option code UPF), when up-fitted with TTY capabilities, the Bluetooth(R) feature will be disabled. OnStar with Text Telephone Capability (TTY) General Motors is pleased to announce that the safety and security of OnStar is now available to our deaf, hard of hearing and speech impaired customers. The current vehicles listed above, as well as forthcoming vehicles equipped with OnStar hardware version 7.0 or higher, have the ability to utilize texting telephones. Vehicle specific TTY capability can be determined by utilizing the VIN lookup Tool. Additional information may be found by referring to www.onstar.com/tty. TTY equipment allows people who are deaf, hard of hearing or speech impaired, in-vehicle access to 911 and basic OnStar(R) services by pressing the OnStar(R) blue button or red emergency button. The keypad provides a means to communicate by allowing customers to type messages back and forth, with an OnStar(R) advisor or other party when using the OnStar(R) Hands-Free Calling feature. A TTY is required at both ends of the conversation in order to communicate. OnStar(R) Turn by Turn Navigation and Virtual Advisor are not available with the addition of TTY. The Reimbursement Program This equipment will be made available to eligible customers through GM Mobility and OnStar(R). Under this program, the customer must complete a GM Mobility application form. To take advantage of the program, vehicles must be adapted at the time of delivery for purchase / lease and a dealer claim ($1,000 Maximum per GM Mobility guidelines) with the application form submitted to GM Mobility. Saab dealers must fax documents. GM Dealers will receive electronic reimbursement directly from GM Mobility. Saab dealers will receive a check directly from OnStar(R). Additional questions or concerns should be directed to the OnStar Dealer Center. How to Order To order the dealer installed kit, contact AutoCraft Electronics or via the web at www.autocraft.com. The kit consists of an OnStar Interface Module, a Dial Pad (for making calls), OTIM wiring harness, the TTY device, installation/Tech 2(R) programming instructions and owner's guide. Warranty Information The Ultra-Tec Compact C TTY device is manufactured by an independent manufacturer and is covered by the manufacturer's warranty. It is not covered under the GM New Vehicle Limited Warranty. All other parts (OTIM, dial pad and OTIM wiring harness) are covered by the standard GM new vehicle parts and labor warranty. Replacement parts are available through AutoCraft Electronics. Contact AutoCraft Electronics or via the web. Warranty claims for the OTIM, dial pad and OTIM wiring harness should be submitted through normal warranty procedures using a sublet warranty claim with GM Labor Operation R5140. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Global Positioning System: > 06-08-46-005B > Feb > 10 > OnStar(R) - Availability for Hearing Impaired > Page 14684 Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Global Positioning System: > 06-08-46-005B > Feb > 10 > OnStar(R) - Availability for Hearing Impaired Global Positioning System: All Technical Service Bulletins OnStar(R) - Availability for Hearing Impaired INFORMATION Bulletin No.: 06-08-46-005B Date: February 11, 2010 Subject: Availability of OnStar(R) for Hearing Impaired Models: 2007-2010 GM Passenger Cars and Light Duty Trucks (Including Saturn and Saab) Except 2007 Cadillac CTS Except 2007-2008 HUMMER H2, H2 SUT Except 2007 Pontiac Montana SV6 Except 2007-2010 Pontiac Vibe Except 2007 Saturn ION, VUE Except 2008 Saturn Astra Supercede: This bulletin is being revised to add a Note regarding 2009 Bluetooth(R)-equipped vehicles, additional models and model years. Please discard Corporate Bulletin Number 06-08-46-005A (Section 08 - Body and Accessories). Important This service bulletin is not applicable to 'GM of Canada' dealers and retailers. Note On 2009 and newer model year vehicles equipped with the Bluetooth(R) feature (option code UPF), when up-fitted with TTY capabilities, the Bluetooth(R) feature will be disabled. OnStar with Text Telephone Capability (TTY) General Motors is pleased to announce that the safety and security of OnStar is now available to our deaf, hard of hearing and speech impaired customers. The current vehicles listed above, as well as forthcoming vehicles equipped with OnStar hardware version 7.0 or higher, have the ability to utilize texting telephones. Vehicle specific TTY capability can be determined by utilizing the VIN lookup Tool. Additional information may be found by referring to www.onstar.com/tty. TTY equipment allows people who are deaf, hard of hearing or speech impaired, in-vehicle access to 911 and basic OnStar(R) services by pressing the OnStar(R) blue button or red emergency button. The keypad provides a means to communicate by allowing customers to type messages back and forth, with an OnStar(R) advisor or other party when using the OnStar(R) Hands-Free Calling feature. A TTY is required at both ends of the conversation in order to communicate. OnStar(R) Turn by Turn Navigation and Virtual Advisor are not available with the addition of TTY. The Reimbursement Program This equipment will be made available to eligible customers through GM Mobility and OnStar(R). Under this program, the customer must complete a GM Mobility application form. To take advantage of the program, vehicles must be adapted at the time of delivery for purchase / lease and a dealer claim ($1,000 Maximum per GM Mobility guidelines) with the application form submitted to GM Mobility. Saab dealers must fax documents. GM Dealers will receive electronic reimbursement directly from GM Mobility. Saab dealers will receive a check directly from OnStar(R). Additional questions or concerns should be directed to the OnStar Dealer Center. How to Order To order the dealer installed kit, contact AutoCraft Electronics or via the web at www.autocraft.com. The kit consists of an OnStar Interface Module, a Dial Pad (for making calls), OTIM wiring harness, the TTY device, installation/Tech 2(R) programming instructions and owner's guide. Warranty Information The Ultra-Tec Compact C TTY device is manufactured by an independent manufacturer and is covered by the manufacturer's warranty. It is not covered under the GM New Vehicle Limited Warranty. All other parts (OTIM, dial pad and OTIM wiring harness) are covered by the standard GM new vehicle parts and labor warranty. Replacement parts are available through AutoCraft Electronics. Contact AutoCraft Electronics or via the web. Warranty claims for the OTIM, dial pad and OTIM wiring harness should be submitted through normal warranty procedures using a sublet warranty claim with GM Labor Operation R5140. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Global Positioning System: > 06-08-46-005B > Feb > 10 > OnStar(R) - Availability for Hearing Impaired > Page 14690 Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations Memory Positioning Module: Locations Harness Routing Views Driver Seat Harness Routing 1 - Seat Recline Motor - Driver (AN3) 2 - Seat Lumbar Vertical Motor Position Sensor - Driver (AN3) 3 - Seat Lumbar Vertical Motor - Driver (AN3) 4 - X324 (AN3) 5 - Seat Lumbar Horizontal Motor - Driver (AN3) 6 - Seat Lumbar Horizontal Motor Position Sensor - Driver (AN3) 7 - Seat Recline Position Sensor - Driver (AN3) 8 - Seat Lumbar Switch - Driver (AN3) 9 - Seat Adjuster Switch - Driver (AG1) 10 - Memory Seat Module (MSM) (AN3) 11 - Inflatable Restraint Seat Position Sensor (SPS) - Driver (10 Series) 12 - Seat Adjuster Motor Assembly - Driver (AG1) 13 Seat Belt Buckle - Driver Passenger Seat Harness Routing Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 14695 1 - Seat Frame 2 - X325 (AN3) 3 - Seat Lumbar Vertical Motor - Passenger (AN3) 4 - Seat Adjuster Switch - Passenger (AG2) 5 - Seat Lumbar Switch - Passenger (AN3) 6 - Seat Belt Buckle Passenger 7 - Inflatable Restraint Passenger Presence System (PPS) Module (AL0) 8 - Seat Adjuster Motor Assembly - Passenger (AG2) 9 - Inflatable Restraint Passenger Presence System (PPS) Sensor (AL0) 10 - Seat Recline Motor - Passenger (AN3) 11 - Seat Lumbar Horizontal Motor - Passenger (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 14696 Memory Positioning Module: Diagrams Component Connector End Views Memory Seat Module (MSM) X1 (AN3) Memory Seat Module (MSM) X2 (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 14697 Memory Seat Module (MSM) X3 (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 14698 Memory Seat Module (MSM) X4 (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 14699 Memory Seat Module (MSM) X5 (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 14700 Memory Seat Module (MSM) X6 (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 14701 Memory Seat Module (MSM) X7 (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 14702 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 14703 Memory Positioning Module: Service and Repair Memory Seat Control Module Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations Seat Memory Switch: Locations Harness Routing Views Driver Seat Harness Routing 1 - Seat Recline Motor - Driver (AN3) 2 - Seat Lumbar Vertical Motor Position Sensor - Driver (AN3) 3 - Seat Lumbar Vertical Motor - Driver (AN3) 4 - X324 (AN3) 5 - Seat Lumbar Horizontal Motor - Driver (AN3) 6 - Seat Lumbar Horizontal Motor Position Sensor - Driver (AN3) 7 - Seat Recline Position Sensor - Driver (AN3) 8 - Seat Lumbar Switch - Driver (AN3) 9 - Seat Adjuster Switch - Driver (AG1) 10 - Memory Seat Module (MSM) (AN3) 11 - Inflatable Restraint Seat Position Sensor (SPS) - Driver (10 Series) 12 - Seat Adjuster Motor Assembly - Driver (AG1) 13 Seat Belt Buckle - Driver Passenger Seat Harness Routing Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations > Page 14707 1 - Seat Frame 2 - X325 (AN3) 3 - Seat Lumbar Vertical Motor - Passenger (AN3) 4 - Seat Adjuster Switch - Passenger (AG2) 5 - Seat Lumbar Switch - Passenger (AN3) 6 - Seat Belt Buckle Passenger 7 - Inflatable Restraint Passenger Presence System (PPS) Module (AL0) 8 - Seat Adjuster Motor Assembly - Passenger (AG2) 9 - Inflatable Restraint Passenger Presence System (PPS) Sensor (AL0) 10 - Seat Recline Motor - Passenger (AN3) 11 - Seat Lumbar Horizontal Motor - Passenger (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations > Page 14708 Seat Memory Switch: Service and Repair Driver Seat Adjuster Memory Switch Replacement (Crew Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Navigation System: Customer Interest OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 14717 Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 06-08-44-034E > Feb > 11 > Navigation Radio - Various Noises Explained Navigation System: All Technical Service Bulletins Navigation Radio - Various Noises Explained INFORMATION Bulletin No.: 06-08-44-034E Date: February 11, 2011 Subject: Information on Noise Sources from Navigation Radio - CD/DVD Disc Accessing Noise from Radio Fan, for Cooling, Disc Accessing Noise for Navigation Operation or NAV Traffic Information Models: 2008-2011 Buick Enclave 2007-2009 Cadillac SRX 2007-2011 Cadillac DTS, Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2009-2011 Chevrolet Traverse 2007-2011 GMC Acadia, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2007-2009 HUMMER H2 2007-2010 Saturn OUTLOOK Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 06-08-44-034D (Section 08 - Body and Accessories). Some customers may comment that there are unusual fan type noises coming from the navigation radio. Additionally, the customer may comment on radio noise coming from the CD/DVD or MAP disc mechanisms when CDs/DVDs or MAP discs are present in the CD mechanisms. Some customers have mentioned that radio noise is present when the customer enters the vehicle or that the noise continues after they shut the vehicle off and open the door to leave the vehicle. This noise has been described as a fan sound or hearing a disc spinning. Source of fan sound - It is normal for the radio fan to run when the vehicle is turned on and for up to three minutes after the vehicle has been turned off and the driver's door has been opened or closed. Disc spinning sound - This is a normal operational sound. This is caused by the map disc spinning behind the tilt screen. It is a normal operation after the RKE is used to unlock the vehicle or when the driver's door has been opened. This noise will also be heard during vehicle operation and up to three minutes after the vehicle has been turned off and driver's door has been opened and closed. MAP Disc Accessing "ZIP" sound - As the Navigation Radio accesses the MAP Disc, the customer may describe frequent "zip" type noises. This noise is caused by the CD Read Lens moving across the disc to access needed data for proper MAP display. To determine if the source of the noise is from accessing the MAP Disc, remove the MAP Disc to determine if the noise continues. With the addition of the Real Time NAV Traffic Feature, the MAP CD may be accessed to a greater extent thus resulting in additional MAP Drive noise. Inform the customer about these noises. If the customer believes the noise is not normal, compare the condition to a like vehicle with identical settings to determine if there is a noticeable difference. Do not replace the radio as the described conditions are normal operating characteristics. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Navigation System: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 14727 Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 10-08-44-006 > Oct > 10 > Navigation - Report Missing/Inaccurate Nav. Map Info Navigation System: All Technical Service Bulletins Navigation - Report Missing/Inaccurate Nav. Map Info INFORMATION Bulletin No.: 10-08-44-006 Date: October 11, 2010 Subject: Reporting Missing or Inaccurate Navigation Radio Map Disc Information - Complete and Submit Feedback Form at GM Navigation Disc Center Website Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Navigation Radio Some customers may notice that some navigation radio map discs may have missing or incorrect information. The following list contains some examples: - Missing or incorrect roads, road names or road shapes - Missing or incorrect addresses - Missing or incorrect highway labeling - Missing or incorrect highway exit numbers - Missing or incorrect traffic restrictions - Missing points of interest (POI) or incorrect details, such as location, category or phone number General Motors uses a map database from two different suppliers. The two map suppliers are consistently updating their map database and will gladly accept any input regarding missing or incorrect information on the navigation radio map disc. To report any missing or incorrect information, please access the GM Navigation Disc Center at the following web site: http://www.gmnavdisc.com. At the GM Navigation Disc Center home page, select the tab: Your Feedback. In the Navigation Data Feedback form, fill in the appropriate information as required and then select: Submit, to send the form. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 06-08-44-012E > Apr > 10 > Navigation System - Software/DVD Update Program Navigation System: All Technical Service Bulletins Navigation System - Software/DVD Update Program INFORMATION Bulletin No.: 06-08-44-012E Date: April 20, 2010 Subject: DVD Navigation Update Program, Navigation Disc Diagnostic Aid, AVN Software Update Discs and Ordering Information Models: 2002-2010 GM Passenger Cars and Trucks (including Saturn) 2004-2010 HUMMER H2, H3 2005-2009 Saab 9-7X Attention: Please direct this information to your Sales Consultants, Service Consultants, Parts Personnel and Used Car Department. This bulletin ONLY applies to North American dealers/retailers. Supercede: This bulletin is being revised to include the 2010 model year and update the usage table. Please discard Corporate Bulletin Number 06-08-44-012D (Section 08 - Body and Accessories). DVD Navigation Update Program The data on the DVD map disc ages at a rate of 15-20% per year. As the data ages, the functionality of the navigation system declines. Offering GM customers new navigation DVDs will ensure that the customers have the latest information for their system. General Motors offered a Navigation Disc Update Program for 2006 and 2007 model year vehicles. This program concluded on December 31, 2009. The DVD Navigation Update Program policy has changed and customers are no longer eligible for free annual updates, however, a navigation DVD update disc can be purchased for $199 (USD) + shipping. If the navigation disc is needed for a warranty situation, the disc can be purchased for $120 (USD). The dealer must provide a VIN and RO# to qualify for the reduced price. The dealer must call the GM Navigation Disc Center, as this option is not available on the website. The GM Navigation Disc Center launched on March 15, 2006. There are two ways to obtain an updated disc: - Via the web through gmnavdisc.com - GM Navigation Disc Center Navigation Disc Diagnostic Aid The following table can be used to identify acceptable discs for testing the navigation unit's map drive functionality. This should only be used to verify the map drive's ability to read the map disc properly and to determine if there is an issue with the unit's map drive or the disc. Some functions, such as voice recognition, may not work properly with some of the discs in the list. If the disc is found to be defective always contact the GM Navigation Disc Center to obtain the most recent disc for the vehicle. AVN Software Update Discs Technical Service Bulletins are sometimes generated to address specific navigation radio operational or performance issues. When a navigation radio bulletin is issued, it may contain instructions to utilize an advanced vehicle navigation (AVN) software update with a specific part number. GM dealers must order advanced vehicle navigation (AVN) software update discs as directed in the specific bulletin. AVN software update discs are for the dealer to update the navigation radio software only. They do NOT update or replace the navigation map disc that is supplied with the vehicle. Please order these parts only as needed. There is a limited supply of these discs available. Do not order these discs for stock. AVN software update discs can be used to reprogram more than one vehicle. The first update disc for each P/N is free. Subsequent copies of the same P/N for the same dealer will cost $50 (USD). To obtain an AVN software update disc, follow the specific ordering information provided in the bulletin. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 06-08-44-012E > Apr > 10 > Navigation System - Software/DVD Update Program > Page 14736 Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 06-08-46-005B > Feb > 10 > OnStar(R) - Availability for Hearing Impaired Navigation System: All Technical Service Bulletins OnStar(R) - Availability for Hearing Impaired INFORMATION Bulletin No.: 06-08-46-005B Date: February 11, 2010 Subject: Availability of OnStar(R) for Hearing Impaired Models: 2007-2010 GM Passenger Cars and Light Duty Trucks (Including Saturn and Saab) Except 2007 Cadillac CTS Except 2007-2008 HUMMER H2, H2 SUT Except 2007 Pontiac Montana SV6 Except 2007-2010 Pontiac Vibe Except 2007 Saturn ION, VUE Except 2008 Saturn Astra Supercede: This bulletin is being revised to add a Note regarding 2009 Bluetooth(R)-equipped vehicles, additional models and model years. Please discard Corporate Bulletin Number 06-08-46-005A (Section 08 - Body and Accessories). Important This service bulletin is not applicable to 'GM of Canada' dealers and retailers. Note On 2009 and newer model year vehicles equipped with the Bluetooth(R) feature (option code UPF), when up-fitted with TTY capabilities, the Bluetooth(R) feature will be disabled. OnStar with Text Telephone Capability (TTY) General Motors is pleased to announce that the safety and security of OnStar is now available to our deaf, hard of hearing and speech impaired customers. The current vehicles listed above, as well as forthcoming vehicles equipped with OnStar hardware version 7.0 or higher, have the ability to utilize texting telephones. Vehicle specific TTY capability can be determined by utilizing the VIN lookup Tool. Additional information may be found by referring to www.onstar.com/tty. TTY equipment allows people who are deaf, hard of hearing or speech impaired, in-vehicle access to 911 and basic OnStar(R) services by pressing the OnStar(R) blue button or red emergency button. The keypad provides a means to communicate by allowing customers to type messages back and forth, with an OnStar(R) advisor or other party when using the OnStar(R) Hands-Free Calling feature. A TTY is required at both ends of the conversation in order to communicate. OnStar(R) Turn by Turn Navigation and Virtual Advisor are not available with the addition of TTY. The Reimbursement Program This equipment will be made available to eligible customers through GM Mobility and OnStar(R). Under this program, the customer must complete a GM Mobility application form. To take advantage of the program, vehicles must be adapted at the time of delivery for purchase / lease and a dealer claim ($1,000 Maximum per GM Mobility guidelines) with the application form submitted to GM Mobility. Saab dealers must fax documents. GM Dealers will receive electronic reimbursement directly from GM Mobility. Saab dealers will receive a check directly from OnStar(R). Additional questions or concerns should be directed to the OnStar Dealer Center. How to Order To order the dealer installed kit, contact AutoCraft Electronics or via the web at www.autocraft.com. The kit consists of an OnStar Interface Module, a Dial Pad (for making calls), OTIM wiring harness, the TTY device, installation/Tech 2(R) programming instructions and owner's guide. Warranty Information The Ultra-Tec Compact C TTY device is manufactured by an independent manufacturer and is covered by the manufacturer's warranty. It is not covered under the GM New Vehicle Limited Warranty. All other parts (OTIM, dial pad and OTIM wiring harness) are covered by the standard GM new vehicle parts and labor warranty. Replacement parts are available through AutoCraft Electronics. Contact AutoCraft Electronics or via the web. Warranty claims for the OTIM, dial pad and OTIM wiring harness should be submitted through normal warranty procedures using a sublet warranty claim with GM Labor Operation R5140. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 06-08-46-005B > Feb > 10 > OnStar(R) - Availability for Hearing Impaired > Page 14741 Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 10-08-46-001 > Jan > 10 > Audio Radio Does Not Mute Enough When Using OnStar(R) Navigation System: All Technical Service Bulletins Audio - Radio Does Not Mute Enough When Using OnStar(R) TECHNICAL Bulletin No.: 10-08-46-001 Date: January 27, 2010 Subject: Radio Does Not Mute Enough When OnStar(R) Turn-by Turn Navigation Directions Are Announced (Increase Volume Setting or Request Soft Mute Feature Change Through OnStar(R) Customer Service) Models: 2009-2010 GM Passenger Cars and Trucks (Including Saturn) 2009-2010 HUMMER H2, H3 2009 Saab 9-7X All Equipped with OnStar(R) (RPO UE1) Condition Some customers may comment that when the radio is on, it does not mute enough when the OnStar(R) Turn-by-Turn Navigation directions are announced. Cause This condition may be caused by the customer improperly setting the radio volume high enough when the Turn-by-Turn Navigation messages are played. The 2009 and 2010 models with OnStar(R) initiates a "soft mute" feature when the radio is on during Turn-by-Turn Navigation direction announcements. During the announcement, the radio can still be heard at a very low volume. Previous model years initiated a "hard mute" during this function which completely muted the radio audio. Correction Instruct the customer to increase the radio volume while getting the Turn-by-Turn Navigation direction announcements. You can control the message volume using the radio volume control, only when the Turn-by-Turn navigation messages are playing. Some customers that were accustomed to previous model vehicles with the "hard mute" feature may be dissatisfied with the function of the "soft mute" feature. For those customers, contact the OnStar(R) Customer Service Center by pushing the Blue OnStar(R) Button to speak to a trained Advisor and request a change be made to the vehicle from the "soft mute" setting to that of the hard or complete muting of audio playback during Turn by Turn directions. OnStar(R) will then create a case number. Advise the customer that the vehicle update should be completed Over the Air within 5 business days, after which an OnStar(R) Customer Care advisor will follow-up with the customer to verify the fix. If the customer does not hear back from OnStar(R) within a week, advise them to press the Blue OnStar(R) Button and ask for Customer Care to check status. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 10-08-46-001 > Jan > 10 > Audio Radio Does Not Mute Enough When Using OnStar(R) > Page 14746 Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 06-08-44-034E > Feb > 11 > Navigation Radio - Various Noises Explained Navigation System: All Technical Service Bulletins Navigation Radio - Various Noises Explained INFORMATION Bulletin No.: 06-08-44-034E Date: February 11, 2011 Subject: Information on Noise Sources from Navigation Radio - CD/DVD Disc Accessing Noise from Radio Fan, for Cooling, Disc Accessing Noise for Navigation Operation or NAV Traffic Information Models: 2008-2011 Buick Enclave 2007-2009 Cadillac SRX 2007-2011 Cadillac DTS, Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2009-2011 Chevrolet Traverse 2007-2011 GMC Acadia, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2007-2009 HUMMER H2 2007-2010 Saturn OUTLOOK Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 06-08-44-034D (Section 08 - Body and Accessories). Some customers may comment that there are unusual fan type noises coming from the navigation radio. Additionally, the customer may comment on radio noise coming from the CD/DVD or MAP disc mechanisms when CDs/DVDs or MAP discs are present in the CD mechanisms. Some customers have mentioned that radio noise is present when the customer enters the vehicle or that the noise continues after they shut the vehicle off and open the door to leave the vehicle. This noise has been described as a fan sound or hearing a disc spinning. Source of fan sound - It is normal for the radio fan to run when the vehicle is turned on and for up to three minutes after the vehicle has been turned off and the driver's door has been opened or closed. Disc spinning sound - This is a normal operational sound. This is caused by the map disc spinning behind the tilt screen. It is a normal operation after the RKE is used to unlock the vehicle or when the driver's door has been opened. This noise will also be heard during vehicle operation and up to three minutes after the vehicle has been turned off and driver's door has been opened and closed. MAP Disc Accessing "ZIP" sound - As the Navigation Radio accesses the MAP Disc, the customer may describe frequent "zip" type noises. This noise is caused by the CD Read Lens moving across the disc to access needed data for proper MAP display. To determine if the source of the noise is from accessing the MAP Disc, remove the MAP Disc to determine if the noise continues. With the addition of the Real Time NAV Traffic Feature, the MAP CD may be accessed to a greater extent thus resulting in additional MAP Drive noise. Inform the customer about these noises. If the customer believes the noise is not normal, compare the condition to a like vehicle with identical settings to determine if there is a noticeable difference. Do not replace the radio as the described conditions are normal operating characteristics. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 10-08-44-006 > Oct > 10 > Navigation Report Missing/Inaccurate Nav. Map Info Navigation System: All Technical Service Bulletins Navigation - Report Missing/Inaccurate Nav. Map Info INFORMATION Bulletin No.: 10-08-44-006 Date: October 11, 2010 Subject: Reporting Missing or Inaccurate Navigation Radio Map Disc Information - Complete and Submit Feedback Form at GM Navigation Disc Center Website Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Navigation Radio Some customers may notice that some navigation radio map discs may have missing or incorrect information. The following list contains some examples: - Missing or incorrect roads, road names or road shapes - Missing or incorrect addresses - Missing or incorrect highway labeling - Missing or incorrect highway exit numbers - Missing or incorrect traffic restrictions - Missing points of interest (POI) or incorrect details, such as location, category or phone number General Motors uses a map database from two different suppliers. The two map suppliers are consistently updating their map database and will gladly accept any input regarding missing or incorrect information on the navigation radio map disc. To report any missing or incorrect information, please access the GM Navigation Disc Center at the following web site: http://www.gmnavdisc.com. At the GM Navigation Disc Center home page, select the tab: Your Feedback. In the Navigation Data Feedback form, fill in the appropriate information as required and then select: Submit, to send the form. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 06-08-44-012E > Apr > 10 > Navigation System - Software/DVD Update Program Navigation System: All Technical Service Bulletins Navigation System - Software/DVD Update Program INFORMATION Bulletin No.: 06-08-44-012E Date: April 20, 2010 Subject: DVD Navigation Update Program, Navigation Disc Diagnostic Aid, AVN Software Update Discs and Ordering Information Models: 2002-2010 GM Passenger Cars and Trucks (including Saturn) 2004-2010 HUMMER H2, H3 2005-2009 Saab 9-7X Attention: Please direct this information to your Sales Consultants, Service Consultants, Parts Personnel and Used Car Department. This bulletin ONLY applies to North American dealers/retailers. Supercede: This bulletin is being revised to include the 2010 model year and update the usage table. Please discard Corporate Bulletin Number 06-08-44-012D (Section 08 - Body and Accessories). DVD Navigation Update Program The data on the DVD map disc ages at a rate of 15-20% per year. As the data ages, the functionality of the navigation system declines. Offering GM customers new navigation DVDs will ensure that the customers have the latest information for their system. General Motors offered a Navigation Disc Update Program for 2006 and 2007 model year vehicles. This program concluded on December 31, 2009. The DVD Navigation Update Program policy has changed and customers are no longer eligible for free annual updates, however, a navigation DVD update disc can be purchased for $199 (USD) + shipping. If the navigation disc is needed for a warranty situation, the disc can be purchased for $120 (USD). The dealer must provide a VIN and RO# to qualify for the reduced price. The dealer must call the GM Navigation Disc Center, as this option is not available on the website. The GM Navigation Disc Center launched on March 15, 2006. There are two ways to obtain an updated disc: - Via the web through gmnavdisc.com - GM Navigation Disc Center Navigation Disc Diagnostic Aid The following table can be used to identify acceptable discs for testing the navigation unit's map drive functionality. This should only be used to verify the map drive's ability to read the map disc properly and to determine if there is an issue with the unit's map drive or the disc. Some functions, such as voice recognition, may not work properly with some of the discs in the list. If the disc is found to be defective always contact the GM Navigation Disc Center to obtain the most recent disc for the vehicle. AVN Software Update Discs Technical Service Bulletins are sometimes generated to address specific navigation radio operational or performance issues. When a navigation radio bulletin is issued, it may contain instructions to utilize an advanced vehicle navigation (AVN) software update with a specific part number. GM dealers must order advanced vehicle navigation (AVN) software update discs as directed in the specific bulletin. AVN software update discs are for the dealer to update the navigation radio software only. They do NOT update or replace the navigation map disc that is supplied with the vehicle. Please order these parts only as needed. There is a limited supply of these discs available. Do not order these discs for stock. AVN software update discs can be used to reprogram more than one vehicle. The first update disc for each P/N is free. Subsequent copies of the same P/N for the same dealer will cost $50 (USD). To obtain an AVN software update disc, follow the specific ordering information provided in the bulletin. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 06-08-44-012E > Apr > 10 > Navigation System - Software/DVD Update Program > Page 14760 Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 06-08-46-005B > Feb > 10 > OnStar(R) Availability for Hearing Impaired Navigation System: All Technical Service Bulletins OnStar(R) - Availability for Hearing Impaired INFORMATION Bulletin No.: 06-08-46-005B Date: February 11, 2010 Subject: Availability of OnStar(R) for Hearing Impaired Models: 2007-2010 GM Passenger Cars and Light Duty Trucks (Including Saturn and Saab) Except 2007 Cadillac CTS Except 2007-2008 HUMMER H2, H2 SUT Except 2007 Pontiac Montana SV6 Except 2007-2010 Pontiac Vibe Except 2007 Saturn ION, VUE Except 2008 Saturn Astra Supercede: This bulletin is being revised to add a Note regarding 2009 Bluetooth(R)-equipped vehicles, additional models and model years. Please discard Corporate Bulletin Number 06-08-46-005A (Section 08 - Body and Accessories). Important This service bulletin is not applicable to 'GM of Canada' dealers and retailers. Note On 2009 and newer model year vehicles equipped with the Bluetooth(R) feature (option code UPF), when up-fitted with TTY capabilities, the Bluetooth(R) feature will be disabled. OnStar with Text Telephone Capability (TTY) General Motors is pleased to announce that the safety and security of OnStar is now available to our deaf, hard of hearing and speech impaired customers. The current vehicles listed above, as well as forthcoming vehicles equipped with OnStar hardware version 7.0 or higher, have the ability to utilize texting telephones. Vehicle specific TTY capability can be determined by utilizing the VIN lookup Tool. Additional information may be found by referring to www.onstar.com/tty. TTY equipment allows people who are deaf, hard of hearing or speech impaired, in-vehicle access to 911 and basic OnStar(R) services by pressing the OnStar(R) blue button or red emergency button. The keypad provides a means to communicate by allowing customers to type messages back and forth, with an OnStar(R) advisor or other party when using the OnStar(R) Hands-Free Calling feature. A TTY is required at both ends of the conversation in order to communicate. OnStar(R) Turn by Turn Navigation and Virtual Advisor are not available with the addition of TTY. The Reimbursement Program This equipment will be made available to eligible customers through GM Mobility and OnStar(R). Under this program, the customer must complete a GM Mobility application form. To take advantage of the program, vehicles must be adapted at the time of delivery for purchase / lease and a dealer claim ($1,000 Maximum per GM Mobility guidelines) with the application form submitted to GM Mobility. Saab dealers must fax documents. GM Dealers will receive electronic reimbursement directly from GM Mobility. Saab dealers will receive a check directly from OnStar(R). Additional questions or concerns should be directed to the OnStar Dealer Center. How to Order To order the dealer installed kit, contact AutoCraft Electronics or via the web at www.autocraft.com. The kit consists of an OnStar Interface Module, a Dial Pad (for making calls), OTIM wiring harness, the TTY device, installation/Tech 2(R) programming instructions and owner's guide. Warranty Information The Ultra-Tec Compact C TTY device is manufactured by an independent manufacturer and is covered by the manufacturer's warranty. It is not covered under the GM New Vehicle Limited Warranty. All other parts (OTIM, dial pad and OTIM wiring harness) are covered by the standard GM new vehicle parts and labor warranty. Replacement parts are available through AutoCraft Electronics. Contact AutoCraft Electronics or via the web. Warranty claims for the OTIM, dial pad and OTIM wiring harness should be submitted through normal warranty procedures using a sublet warranty claim with GM Labor Operation R5140. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 06-08-46-005B > Feb > 10 > OnStar(R) Availability for Hearing Impaired > Page 14765 Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 10-08-46-001 > Jan > 10 > Audio - Radio Does Not Mute Enough When Using OnStar(R) Navigation System: All Technical Service Bulletins Audio - Radio Does Not Mute Enough When Using OnStar(R) TECHNICAL Bulletin No.: 10-08-46-001 Date: January 27, 2010 Subject: Radio Does Not Mute Enough When OnStar(R) Turn-by Turn Navigation Directions Are Announced (Increase Volume Setting or Request Soft Mute Feature Change Through OnStar(R) Customer Service) Models: 2009-2010 GM Passenger Cars and Trucks (Including Saturn) 2009-2010 HUMMER H2, H3 2009 Saab 9-7X All Equipped with OnStar(R) (RPO UE1) Condition Some customers may comment that when the radio is on, it does not mute enough when the OnStar(R) Turn-by-Turn Navigation directions are announced. Cause This condition may be caused by the customer improperly setting the radio volume high enough when the Turn-by-Turn Navigation messages are played. The 2009 and 2010 models with OnStar(R) initiates a "soft mute" feature when the radio is on during Turn-by-Turn Navigation direction announcements. During the announcement, the radio can still be heard at a very low volume. Previous model years initiated a "hard mute" during this function which completely muted the radio audio. Correction Instruct the customer to increase the radio volume while getting the Turn-by-Turn Navigation direction announcements. You can control the message volume using the radio volume control, only when the Turn-by-Turn navigation messages are playing. Some customers that were accustomed to previous model vehicles with the "hard mute" feature may be dissatisfied with the function of the "soft mute" feature. For those customers, contact the OnStar(R) Customer Service Center by pushing the Blue OnStar(R) Button to speak to a trained Advisor and request a change be made to the vehicle from the "soft mute" setting to that of the hard or complete muting of audio playback during Turn by Turn directions. OnStar(R) will then create a case number. Advise the customer that the vehicle update should be completed Over the Air within 5 business days, after which an OnStar(R) Customer Care advisor will follow-up with the customer to verify the fix. If the customer does not hear back from OnStar(R) within a week, advise them to press the Blue OnStar(R) Button and ask for Customer Care to check status. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 10-08-46-001 > Jan > 10 > Audio - Radio Does Not Mute Enough When Using OnStar(R) > Page 14770 Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Sensor > Component Information > Service and Repair Pedal Positioning Sensor: Service and Repair Brake and Accelerator Pedal Adjuster Position Sensor Replacement (With Memory Seats) Removal Procedure 1. Turn the ignition switch to the OFF position. 2. Remove the driver knee bolster. Refer to Knee Bolster Replacement (With SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (With SLT))Knee Bolster Replacement (Without SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (Without SLT)). 3. Disconnect the adjustable pedal position sensor jumper harness electrical connector (1). 4. Remove the adjustable pedal position sensor bolts (1). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Sensor > Component Information > Service and Repair > Page 14775 5. Remove the brake and accelerator pedal adjuster position sensor (1). Installation Procedure 1. Install the brake and accelerator pedal adjuster position sensor (1). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Sensor > Component Information > Service and Repair > Page 14776 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the adjustable pedal position sensor bolts (1) and tighten to 2 Nm (18 lb in). 3. Connect the adjustable pedal position sensor jumper harness electrical connector (1). 4. Install the driver knee bolster. Refer to Knee Bolster Replacement (With SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (With SLT))Knee Bolster Replacement (Without SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (Without SLT)). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams Amplifier: Diagrams Component Connector End Views Audio Amplifier X1 (UQA with Y91) Audio Amplifier X1 (UQA without Y91) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Page 14781 Audio Amplifier X2 (UQA) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Page 14782 Audio Amplifier X3 (UQA) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Page 14783 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Page 14784 Amplifier: Service and Repair Radio Speaker Amplifier Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Automatic Volume Control > System Information > Service and Repair Automatic Volume Control: Service and Repair Radio Volume Compensator Interior Noise Microphone Replacement (Floor Console) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 07-08-46-002D > Jul > 09 > Audio System - Noise When Using OnStar(R) Radio/Stereo Noise Filter: Customer Interest Audio System - Noise When Using OnStar(R) TECHNICAL Bulletin No.: 07-08-46-002D Date: July 29, 2009 Subject: Audio Whine Noise from Radio Speakers When Using OnStar(R) (Install Noise Suppression Filter) Models: 2007-2010 GM Passenger Cars and Trucks (Including Saturn) 2007-2010 HUMMER H2, H3 2007-2009 Saab 9-7X Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update the Warranty Information. Please discard Corporate Bulletin Number 07-08-46-002C (Section 08 - Body and Accessories). Condition Some customers may comment on an audio whine coming from the radio speakers when using the OnStar(R) system. The amplitude and frequency of the whine will change with an increase or decrease in engine speed. Cause This condition may be caused by electrical noise on the OnStar(R) Vehicle Communication Interface Module (VCIM) battery feed wire being passed to the microphone output pins at the radio. Correction Technicians are to install a noise suppression filter, P/N 1224205, into the OnStar(R) battery voltage circuit, a few centimeters (inches) from the VCIM. The filter package has three attached wires - a single yellow wire at one end with a yellow wire and a black wire at the other. Install the single yellow wire side into the battery voltage circuit towards the VCIM. Install the remaining single yellow wire into the battery voltage circuit toward the fuse and the black wire to ground. Important The noise suppression filter is polarity sensitive. The filter is designed to be most effective when the end with the capacitor ground is connected towards the source of the electrical noise. Install the filter in this polarity first. If the noise level is still not satisfactory, try disconnecting the capacitor ground. In some cases, if the first installation does not correct the noise, try reversing the filter polarity (removing the filter, turning it end for end and then reinstalling it) and grounding the capacitor lead. Parts Information Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table above. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 07-08-46-002D > Jul > 09 > Audio System - Noise When Using OnStar(R) > Page 14797 Warranty Information (Saab U.S. Models) Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 07-08-46-002D > Jul > 09 > Audio System - Noise When Using OnStar(R) Radio/Stereo Noise Filter: All Technical Service Bulletins Audio System - Noise When Using OnStar(R) TECHNICAL Bulletin No.: 07-08-46-002D Date: July 29, 2009 Subject: Audio Whine Noise from Radio Speakers When Using OnStar(R) (Install Noise Suppression Filter) Models: 2007-2010 GM Passenger Cars and Trucks (Including Saturn) 2007-2010 HUMMER H2, H3 2007-2009 Saab 9-7X Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update the Warranty Information. Please discard Corporate Bulletin Number 07-08-46-002C (Section 08 - Body and Accessories). Condition Some customers may comment on an audio whine coming from the radio speakers when using the OnStar(R) system. The amplitude and frequency of the whine will change with an increase or decrease in engine speed. Cause This condition may be caused by electrical noise on the OnStar(R) Vehicle Communication Interface Module (VCIM) battery feed wire being passed to the microphone output pins at the radio. Correction Technicians are to install a noise suppression filter, P/N 1224205, into the OnStar(R) battery voltage circuit, a few centimeters (inches) from the VCIM. The filter package has three attached wires - a single yellow wire at one end with a yellow wire and a black wire at the other. Install the single yellow wire side into the battery voltage circuit towards the VCIM. Install the remaining single yellow wire into the battery voltage circuit toward the fuse and the black wire to ground. Important The noise suppression filter is polarity sensitive. The filter is designed to be most effective when the end with the capacitor ground is connected towards the source of the electrical noise. Install the filter in this polarity first. If the noise level is still not satisfactory, try disconnecting the capacitor ground. In some cases, if the first installation does not correct the noise, try reversing the filter polarity (removing the filter, turning it end for end and then reinstalling it) and grounding the capacitor lead. Parts Information Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table above. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 07-08-46-002D > Jul > 09 > Audio System - Noise When Using OnStar(R) > Page 14803 Warranty Information (Saab U.S. Models) Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Diagrams Remote Switch: Diagrams Component Connector End Views Rear Seat Audio (RSA) Control X1 (UK6) Rear Seat Audio (RSA) Control X2 (UK6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Diagrams > Page 14807 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams Speaker: Diagrams Component Connector End Views Speaker - Center I/P (UQA with Y91) Speaker - Left Front (UQ3) Speaker - Left Front (UQ5) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Page 14811 Speaker - Left Front (UQA) Speaker - Left Front Tweeter (except MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Page 14812 Speaker - Left Rear (Extended Cab or Crew Cab with UQ3 or UQ5) Speaker - Left Rear (Extended Cab or Crew Cab with UQA) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Page 14813 Speaker - Left Rear (Regular Cab) Speaker - Right Front (UQ3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Page 14814 Speaker - Right Front (UQ5) Speaker - Right Front (UQA) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Page 14815 Speaker - Right Front Tweeter (except MEX) Speaker - Right Rear (Extended Cab or Crew Cab with UQ3 or UQ5) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Page 14816 Speaker - Right Rear (Extended Cab or Crew Cab with UQA) Speaker - Right Rear (Regular Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Page 14817 Speaker - Subwoofer (UQA) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Front Upper Speaker Replacement Speaker: Service and Repair Front Upper Speaker Replacement Front Upper Speaker Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Front Upper Speaker Replacement > Page 14820 Speaker: Service and Repair Radio Front Floor Console Speaker Replacement Radio Front Floor Console Speaker Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Front Upper Speaker Replacement > Page 14821 Speaker: Service and Repair Radio Front Side Door Speaker Replacement Radio Front Side Door Speaker Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Front Upper Speaker Replacement > Page 14822 Speaker: Service and Repair Radio Front Speaker Grille Replacement Radio Front Speaker Grille Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Front Upper Speaker Replacement > Page 14823 Speaker: Service and Repair Front Upper Speaker Replacement Front Upper Speaker Replacement Radio Front Floor Console Speaker Replacement Radio Front Floor Console Speaker Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Front Upper Speaker Replacement > Page 14824 Radio Front Side Door Speaker Replacement Radio Front Side Door Speaker Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Front Upper Speaker Replacement > Page 14825 Radio Front Speaker Grille Replacement Radio Front Speaker Grille Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Front Upper Speaker Replacement > Page 14826 Radio Front Speaker Replacement Radio Front Speaker Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Front Upper Speaker Replacement > Page 14827 Radio Rear Side Door Speaker Replacement (Crew Cab) Radio Rear Side Door Speaker Replacement (Crew Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Front Upper Speaker Replacement > Page 14828 Radio Rear Side Door Speaker Replacement (Extended Cab) Radio Rear Side Door Speaker Replacement (Extended Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Front Upper Speaker Replacement > Page 14829 Rear Pillar Speaker Replacement Rear Pillar Speaker Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Front Upper Speaker Replacement > Page 14830 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams Alarm Module: Diagrams Component Connector End Views Theft Deterrent Module (TDM) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Page 14835 Alarm Module: Service and Repair Theft Deterrent Module Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > OnStar(R) Availability for Hearing Impaired Communications Control Module: Technical Service Bulletins OnStar(R) - Availability for Hearing Impaired INFORMATION Bulletin No.: 06-08-46-005B Date: February 11, 2010 Subject: Availability of OnStar(R) for Hearing Impaired Models: 2007-2010 GM Passenger Cars and Light Duty Trucks (Including Saturn and Saab) Except 2007 Cadillac CTS Except 2007-2008 HUMMER H2, H2 SUT Except 2007 Pontiac Montana SV6 Except 2007-2010 Pontiac Vibe Except 2007 Saturn ION, VUE Except 2008 Saturn Astra Supercede: This bulletin is being revised to add a Note regarding 2009 Bluetooth(R)-equipped vehicles, additional models and model years. Please discard Corporate Bulletin Number 06-08-46-005A (Section 08 - Body and Accessories). Important This service bulletin is not applicable to 'GM of Canada' dealers and retailers. Note On 2009 and newer model year vehicles equipped with the Bluetooth(R) feature (option code UPF), when up-fitted with TTY capabilities, the Bluetooth(R) feature will be disabled. OnStar with Text Telephone Capability (TTY) General Motors is pleased to announce that the safety and security of OnStar is now available to our deaf, hard of hearing and speech impaired customers. The current vehicles listed above, as well as forthcoming vehicles equipped with OnStar hardware version 7.0 or higher, have the ability to utilize texting telephones. Vehicle specific TTY capability can be determined by utilizing the VIN lookup Tool. Additional information may be found by referring to www.onstar.com/tty. TTY equipment allows people who are deaf, hard of hearing or speech impaired, in-vehicle access to 911 and basic OnStar(R) services by pressing the OnStar(R) blue button or red emergency button. The keypad provides a means to communicate by allowing customers to type messages back and forth, with an OnStar(R) advisor or other party when using the OnStar(R) Hands-Free Calling feature. A TTY is required at both ends of the conversation in order to communicate. OnStar(R) Turn by Turn Navigation and Virtual Advisor are not available with the addition of TTY. The Reimbursement Program This equipment will be made available to eligible customers through GM Mobility and OnStar(R). Under this program, the customer must complete a GM Mobility application form. To take advantage of the program, vehicles must be adapted at the time of delivery for purchase / lease and a dealer claim ($1,000 Maximum per GM Mobility guidelines) with the application form submitted to GM Mobility. Saab dealers must fax documents. GM Dealers will receive electronic reimbursement directly from GM Mobility. Saab dealers will receive a check directly from OnStar(R). Additional questions or concerns should be directed to the OnStar Dealer Center. How to Order To order the dealer installed kit, contact AutoCraft Electronics or via the web at www.autocraft.com. The kit consists of an OnStar Interface Module, a Dial Pad (for making calls), OTIM wiring harness, the TTY device, installation/Tech 2(R) programming instructions and owner's guide. Warranty Information The Ultra-Tec Compact C TTY device is manufactured by an independent manufacturer and is covered by the manufacturer's warranty. It is not covered under the GM New Vehicle Limited Warranty. All other parts (OTIM, dial pad and OTIM wiring harness) are covered by the standard GM new vehicle parts and labor warranty. Replacement parts are available through AutoCraft Electronics. Contact AutoCraft Electronics or via the web. Warranty claims for the OTIM, dial pad and OTIM wiring harness should be submitted through normal warranty procedures using a sublet warranty claim with GM Labor Operation R5140. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > OnStar(R) Availability for Hearing Impaired > Page 14840 Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > OnStar(R) Availability for Hearing Impaired > Page 14841 Communications Control Module: Technical Service Bulletins Audio - Radio Does Not Mute Enough When Using OnStar(R) TECHNICAL Bulletin No.: 10-08-46-001 Date: January 27, 2010 Subject: Radio Does Not Mute Enough When OnStar(R) Turn-by Turn Navigation Directions Are Announced (Increase Volume Setting or Request Soft Mute Feature Change Through OnStar(R) Customer Service) Models: 2009-2010 GM Passenger Cars and Trucks (Including Saturn) 2009-2010 HUMMER H2, H3 2009 Saab 9-7X All Equipped with OnStar(R) (RPO UE1) Condition Some customers may comment that when the radio is on, it does not mute enough when the OnStar(R) Turn-by-Turn Navigation directions are announced. Cause This condition may be caused by the customer improperly setting the radio volume high enough when the Turn-by-Turn Navigation messages are played. The 2009 and 2010 models with OnStar(R) initiates a "soft mute" feature when the radio is on during Turn-by-Turn Navigation direction announcements. During the announcement, the radio can still be heard at a very low volume. Previous model years initiated a "hard mute" during this function which completely muted the radio audio. Correction Instruct the customer to increase the radio volume while getting the Turn-by-Turn Navigation direction announcements. You can control the message volume using the radio volume control, only when the Turn-by-Turn navigation messages are playing. Some customers that were accustomed to previous model vehicles with the "hard mute" feature may be dissatisfied with the function of the "soft mute" feature. For those customers, contact the OnStar(R) Customer Service Center by pushing the Blue OnStar(R) Button to speak to a trained Advisor and request a change be made to the vehicle from the "soft mute" setting to that of the hard or complete muting of audio playback during Turn by Turn directions. OnStar(R) will then create a case number. Advise the customer that the vehicle update should be completed Over the Air within 5 business days, after which an OnStar(R) Customer Care advisor will follow-up with the customer to verify the fix. If the customer does not hear back from OnStar(R) within a week, advise them to press the Blue OnStar(R) Button and ask for Customer Care to check status. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > OnStar(R) Availability for Hearing Impaired > Page 14842 Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Page 14843 Communications Control Module: Locations Harness Routing Views I/P Extension Harness Routing (SLT except Y91/MEX) 1 - JX223 (U2K/UK6/UE1) 2 - X203 (UE1/U3U/UVB) 3 - X204 (U42) 4 - X212 5 - X206 (U42) 6 X213 (COAX) 7 - Vehicle Communication Interface Module (VCIM) (UE1) 8 - X301 (UQA/D07) 9 Floor Panel Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Page 14844 Communications Control Module: Diagrams Component Connector End Views Vehicle Communication Interface Module (VCIM) X1 (UE1) Vehicle Communication Interface Module (VCIM) X2 (UE1) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Page 14845 Vehicle Communication Interface Module (VCIM) X3 (UE1 with UUL or UUK) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Page 14846 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Service and Repair > Communication Interface Module Replacement (with RPO SLT) Communications Control Module: Service and Repair Communication Interface Module Replacement (with RPO SLT) Communication Interface Module Replacement (with RPO SLT) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Service and Repair > Communication Interface Module Replacement (with RPO SLT) > Page 14849 Communications Control Module: Service and Repair Communication Interface Module Replacement (without RPO SLT) Communication Interface Module Replacement (without RPO SLT) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: Customer Interest OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 14858 Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 14864 Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Service and Repair Keyless Entry Module: Service and Repair Remote Control Door Lock Receiver Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Diagrams Parking Assist Control Module: Diagrams Component Connector End Views Rear Object Sensor Control Module X1 (UD7) Rear Object Sensor Control Module X2 (UD7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Diagrams > Page 14871 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Diagrams > Page 14872 Parking Assist Control Module: Service and Repair Rear Object Alarm Module Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 14881 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 14882 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 14883 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 14889 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 14890 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 14891 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 14900 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 14901 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 14902 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 14908 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 14909 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 14910 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Relay Module: > 07-08-46-002D > Jul > 09 > Audio System Noise When Using OnStar(R) Electronic Noise Suppressor: All Technical Service Bulletins Audio System - Noise When Using OnStar(R) TECHNICAL Bulletin No.: 07-08-46-002D Date: July 29, 2009 Subject: Audio Whine Noise from Radio Speakers When Using OnStar(R) (Install Noise Suppression Filter) Models: 2007-2010 GM Passenger Cars and Trucks (Including Saturn) 2007-2010 HUMMER H2, H3 2007-2009 Saab 9-7X Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update the Warranty Information. Please discard Corporate Bulletin Number 07-08-46-002C (Section 08 - Body and Accessories). Condition Some customers may comment on an audio whine coming from the radio speakers when using the OnStar(R) system. The amplitude and frequency of the whine will change with an increase or decrease in engine speed. Cause This condition may be caused by electrical noise on the OnStar(R) Vehicle Communication Interface Module (VCIM) battery feed wire being passed to the microphone output pins at the radio. Correction Technicians are to install a noise suppression filter, P/N 1224205, into the OnStar(R) battery voltage circuit, a few centimeters (inches) from the VCIM. The filter package has three attached wires - a single yellow wire at one end with a yellow wire and a black wire at the other. Install the single yellow wire side into the battery voltage circuit towards the VCIM. Install the remaining single yellow wire into the battery voltage circuit toward the fuse and the black wire to ground. Important The noise suppression filter is polarity sensitive. The filter is designed to be most effective when the end with the capacitor ground is connected towards the source of the electrical noise. Install the filter in this polarity first. If the noise level is still not satisfactory, try disconnecting the capacitor ground. In some cases, if the first installation does not correct the noise, try reversing the filter polarity (removing the filter, turning it end for end and then reinstalling it) and grounding the capacitor lead. Parts Information Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table above. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Relay Module: > 07-08-46-002D > Jul > 09 > Audio System Noise When Using OnStar(R) > Page 14916 Warranty Information (Saab U.S. Models) Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Relay Module: > 07-08-46-002D > Jul > 09 > Audio System Noise When Using OnStar(R) > Page 14922 Warranty Information (Saab U.S. Models) Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Diagrams Hood Sensor/Switch (For Alarm): Diagrams Component Connector End Views Hood Ajar Switch (AP3, AP8 or PTO) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams Parking Assist Distance Sensor: Diagrams Component Connector End Views Object Alarm Sensor - Left Rear Corner (UD7) Object Alarm Sensor - Left Rear Middle (UD7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Page 14930 Object Alarm Sensor - Right Rear Corner (UD7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Page 14931 Object Alarm Sensor - Right Rear Middle (UD7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Page 14932 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Service and Repair > Rear Object Sensor Replacement Parking Assist Distance Sensor: Service and Repair Rear Object Sensor Replacement Rear Object Sensor Replacement Removal Procedure 1. Disconnect electrical from the rear object sensor. 2. Lift the locking tabs on the housing and remove the rear object sensor. Installation Procedure Note: Do not refinish previously painted sensors. Excess paint build up will cause the sensor to be inoperative. 1. Paint the rear object sensor. Refer to Basecoat/Clearcoat Paint Systems (See: Body and Frame/Paint, Striping and Decals/Paint/Application and ID/Basecoat/Clearcoat Paint Systems). 2. Ensure the paint does not exceed 6 mils. Use a paint thickness gauge suitable for non-ferrous metals. Refer to Paint Gauges (). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Service and Repair > Rear Object Sensor Replacement > Page 14935 Note: Ensure the silicone decoupling ring is installed on the sensor to avoid sensor failure. 3. Insert the sensor into the housing. 4. Connect the electrical connector to the rear object sensor. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Service and Repair > Rear Object Sensor Replacement > Page 14936 Parking Assist Distance Sensor: Service and Repair Rear Object Sensor Housing Replacement (Sierra/Silverado) Rear Object Sensor Housing Replacement (Sierra/Silverado) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Service and Repair > Rear Object Sensor Replacement > Page 14937 Parking Assist Distance Sensor: Service and Repair Rear Object Sensor Housing Replacement (All Other Vehicles) Rear Object Sensor Housing Replacement (All Other Vehicles) 1. Remove the center rear bumper step pad or the rear bumper impact bar end cap. Refer to Rear Bumper Step Center Pad Replacement () or Rear Bumper Impact Bar End Cap Replacement (). 2. Disconnect the sensor harness. 3. Remove the sensor from the sensor housing. The sensor housing must be painted if replaced. If reinstalled, painting will not be necessary. Important: Do Not grind off alignment tabs. 4. Sand/grind sonic weld plastic residue from the fascia. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Service and Repair > Rear Object Sensor Replacement > Page 14938 5. Apply structural adhesive epoxy, Lord Fusor(TM) 127EZ or equivalent, to fascia at mating surface. 6. Using the alignment tabs, install the sensor housing to the fascia. 7. Allow adhesive to cure according to manufacturer's directions. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Service and Repair > Rear Object Sensor Replacement > Page 14939 8. Install the sensor to the sensor housing. 9. Connect the electrical harness. 10. Install the center rear bumper step pad or the rear bumper impact bar end cap. Refer to Rear Bumper Step Center Pad Replacement () or Rear Bumper Impact Bar End Cap Replacement (). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Sensor > Component Information > Service and Repair Pedal Positioning Sensor: Service and Repair Brake and Accelerator Pedal Adjuster Position Sensor Replacement (With Memory Seats) Removal Procedure 1. Turn the ignition switch to the OFF position. 2. Remove the driver knee bolster. Refer to Knee Bolster Replacement (With SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (With SLT))Knee Bolster Replacement (Without SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (Without SLT)). 3. Disconnect the adjustable pedal position sensor jumper harness electrical connector (1). 4. Remove the adjustable pedal position sensor bolts (1). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Sensor > Component Information > Service and Repair > Page 14943 5. Remove the brake and accelerator pedal adjuster position sensor (1). Installation Procedure 1. Install the brake and accelerator pedal adjuster position sensor (1). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Sensor > Component Information > Service and Repair > Page 14944 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the adjustable pedal position sensor bolts (1) and tighten to 2 Nm (18 lb in). 3. Connect the adjustable pedal position sensor jumper harness electrical connector (1). 4. Install the driver knee bolster. Refer to Knee Bolster Replacement (With SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (With SLT))Knee Bolster Replacement (Without SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (Without SLT)). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Diagrams Remote Switch: Diagrams Component Connector End Views Rear Seat Audio (RSA) Control X1 (UK6) Rear Seat Audio (RSA) Control X2 (UK6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Diagrams > Page 14948 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Shock Sensor, Antitheft > Component Information > Diagrams Shock Sensor: Diagrams Component Connector End Views Vehicle Shock Sensor (SPO Alarm) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Steering Mounted Controls Assembly > Component Information > Service and Repair Steering Mounted Controls Assembly: Service and Repair Steering Wheel Control Switch Assembly Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Tow Sensor, Antitheft > Component Information > Diagrams Tow Sensor: Diagrams Component Connector End Views Vehicle Inclination Sensor (SPO Alarm) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Assembly > Component Information > Service and Repair Steering Mounted Controls Assembly: Service and Repair Steering Wheel Control Switch Assembly Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams Steering Mounted Controls Transmitter: Diagrams Component Connector End Views Steering Wheel Control Switch - Left (K34 or KA9) Steering Wheel Control Switch - Right (UK3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Page 14964 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Hook / Bracket > Component Information > Service and Repair Towing Hook / Bracket: Service and Repair Tow Hook Replacement (2500HD/3500 Series) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Accessories - Aftermarket Trailer Brake Controller Trailer Brake Control Module: Technical Service Bulletins Accessories - Aftermarket Trailer Brake Controller INFORMATION Bulletin No.: 07-08-45-001F Date: November 09, 2010 Subject: Procedure for Installation of an Aftermarket Trailer Brake Controller Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2010 HUMMER H2 with Integrated Trailer Brake Controller Supercede: This bulletin is being revised to combine information from bulletins 06-08-45-008D and 07-08-45-001E. Please discard Corporate Bulletin Numbers 07-08-45-001E and 06-08-45-008D (Section 08 - Body and Accessories). Important Installation of an electric brake controller and the wiring connections outlined in this bulletin are the responsibility of the dealership or customer. These repairs should never be charged to warranty. If you have any questions, please consult with your District Service Manager. Some customers may request to have an aftermarket trailer brake controller added to their vehicle, OR in lieu of the factory integrated trailer brake controller (ITBC) (RPO JL1). Installation Instructions Starting with the new 2007 full-size utilities and pickups and 2008 HUMMER H2, there is no longer an electric trailer brake controller pigtail harness. To install an aftermarket trailer brake controller, use the four blunt cut wires located near the data link connector. The following steps should be used to complete the installation. Important Ensure that the ringlets are not interfering with the UBEC cover. 1. Place the terminal on the larger of the two studs at the front of the electrical center and secure with an M8 nut. This is circuit #242 to stud #2, to power the aftermarket trailer brake controller. Important The fuse is already present in the vehicle to power the electrical trailer brake controller system. 2. ONLY For Vehicles Equipped with JL1 - Locate connector X126 or X115 (varies with vehicle build; refer to SI) near the underhood fuse block. Refer to SI Document ID# 1849049 - I/P Harness-Engine Compartment. Circuit 47 from the blunt cut wires near the data link connector will end Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Accessories - Aftermarket Trailer Brake Controller > Page 14973 at connector X126 terminal "G" or X115 terminal "B5." Obtain enough Dark Blue 12 gauge wire to run from X126/X115 to the 7-way trailer connector at the bumper. On one end of the Dark Blue wire attach terminal part number 15304732, located in Delphi Tray 8 and insert into X126 "G" or terminal part number 15304720 located in Delphi Tray 19 and insert into X115 "B5." Run the Dark Blue wire in its own conduit along the frame to the 7-way trailer connector at the bumper. Remove circuit 47 from the 7-way trailer connector terminal "C" and tape the bare terminal and attach to the harness. Attach terminal part number 12110853, located in Delphi Tray 4, to the other end of the Dark Blue wire and insert it into the 7-way trailer connector terminal "C." 3. ONLY For Vehicles Equipped with JL1 - The Red/Black wire, circuit 242, must be connected to stud #2 of the 30 Amp fuse of the underhood fuse block. This wire is located between the left fender and the underhood fuse block. Important This procedure will not result in any trailer brake related display messages to be set. However, ITBC diagnostics will continue to function. If an ITBC fault is detected, a "Service Trailer Brake System" message will be displayed on the driver information center (DIC) and an appropriate DTC will be stored in the ITBC module. The operator will still be able to adjust gain and access the "Trailer Gain / Output" display page in the DIC. However, the factory installed ITBC system will not sense a trailer connection and will not provide output to the trailer. 4. Locate the trailer brake control circuits that are looped and taped to the main harness under the instrument panel. 5. Pull the trailering wire harness down. 6. Match the vehicle harness label circuit functions to the trailer brake controller jumper harness functions. Important The color or wires to be joined together may not match. - Dark Blue Wire: switched power from controller to trailer brakes - Red with Black Stripe: fused vehicle power to electrical brake controller Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Accessories - Aftermarket Trailer Brake Controller > Page 14974 - Light Blue with White Stripe: Brake switch input to power electric brake controller - White: ground - Orange: CHMSL (Center High Mounted Stop Lamp) - not required with most systems 7. After completing the under dash connections to the electric brake controller, open the hood and locate the red wire that is taped to the harness between the underhood electrical center and the driver side front fender. 8. Break the tape on the red/black wire and pull it toward the front of vehicle. 9. Remove the lid from the electrical center. Auxiliary Power (Applies to All LD and 2007-2009 HD's Only) Without JL1 Circuit #742 for Auxiliary Power at the 7-way trailer connector is no longer connected by the GM Assembly Plant. If the customer desires auxiliary power at the trailer connector location (i.e. refrigeration, battery charger or interior light in the trailer), complete the following steps to connect circuit #742: 1. Locate the red/black wire, looped and taped to the chassis harness, below the brake master cylinder. 2. Break the tape and route the wire to the front of the underhood electrical center. Important Ensure that the ringlets are not interfering with the UBEC cover. 3. Place the terminal on the smaller of the two studs on the electrical center and secure with an M6 fastener. This is circuit #742 to stud #1 for auxiliary power to the 7-way trailer connector. 4. ONLY for vehicles without RPO TP2 - Auxiliary Battery, install a 40 amp fuse to power the circuit. Important For vehicles equipped with RPO TP2 - Devices powered by this fuse will drain the vehicle battery if left connected with the vehicle not running. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Accessories - Aftermarket Trailer Brake Controller > Page 14975 Warranty Information This installation procedure is to be performed at the customer's request and at their expense. It is not a warranty repair and a claim should not be submitted for reimbursement. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Accessories - Aftermarket Trailer Brake Controller > Page 14976 Trailer Brake Control Module: Technical Service Bulletins Brakes - Aftermarket Trailer Brake Controllers INFORMATION Bulletin No.: 06-08-45-008D Date: July 12, 2010 Subject: Information on Auxiliary Power Wire at Trailer and Installation of Aftermarket Trailer Brake Controller - Towing, Tow Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2011 HUMMER H2 Supercede: This bulletin is being revised to add the 2011 model year and information about the orientation of the ringlet. Please discard Corporate Bulletin Number 06-08-45-008C (Section 08 Body and Accessories). Important Installation of an electric brake controller and the wiring connections outlined in this bulletin are the responsibility of the dealership or customer. These repairs should never be charged to warranty. If you have any questions, please consult with your District Service Manager. Some customers may have questions on how to connect an electric trailer brake controller or where the brake controller pigtail harness is located. Starting with the new 2007 full-size utilities and pickups and 2008 HUMMER H2, there is no longer an electric trailer brake controller pigtail harness. An aftermarket brake controller will need to be installed/connected to the blunt wires under the left side of the IP for vehicles built without JL1 - Integrated Brake Controller (full-size utilities and pickups). The following steps should be used to complete the installation. 1. Locate the trailer brake control circuits that are looped and taped to the main harness under the instrument panel. 2. Pull the trailering wire harness down. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Accessories - Aftermarket Trailer Brake Controller > Page 14977 3. Match the vehicle harness label circuit functions to the trailer brake controller jumper harness functions. Important The color or wires to be joined together may not match. - Dark Blue Wire: switched power from controller to trailer brakes - Red with Black Stripe: fused vehicle power to electrical brake controller - Light Blue with White Stripe: Brake switch input to power electric brake controller - White: ground - Orange: CHMSL (Center High Mounted Stop Lamp) - not required with most systems 4. After completing the under dash connections to the electric brake controller, open the hood and locate the red wire that is taped to the harness between the underhood electrical center and the driver side front fender. 5. Break the tape on the red/black wire and pull it toward the front of vehicle. 6. Remove the lid from the electrical center. Important Ensure that the ringlets are not interfering with the UBEC cover. 7. Place the terminal on the larger of the two studs at the front of the electrical center and secure with an M8 nut. This is circuit #242 to stud #2, to power the aftermarket trailer brake controller. Important The fuse is already present in the vehicle to power the electrical trailer brake controller system. Auxiliary Power (Applies to All LD & 07-09 HD's Only) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Accessories - Aftermarket Trailer Brake Controller > Page 14978 Circuit #742 for Auxiliary Power at the 7-way trailer connector is no longer connected by the GM Assembly Plant. If the customer desires auxiliary power at the trailer connector location (i.e. refrigeration, battery charger or interior light in the trailer), complete the following steps to connect circuit #742: 1. Locate the red/black wire, looped and taped to the chassis harness, below the brake master cylinder. 2. Break the tape and route the wire to the front of the underhood electrical center. Important Ensure that the ringlets are not interfering with the UBEC cover. 3. Place the terminal on the smaller of the two studs on the electrical center and secure with an M6 fastener. This is circuit #742 to stud #1 for auxiliary power to the 7-way trailer connector. 4. ONLY for vehicles without RPO TP2 - Auxiliary Battery, install a 40 amp fuse to power the circuit. Important For vehicles equipped with RPO TP2 - Devices powered by this fuse will drain the vehicle battery if left connected with the vehicle not running. Warranty Information This installation procedure is to be performed at the customer's request and at their expense. It is not a warranty repair and a claim should not be submitted for reimbursement. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Page 14979 Trailer Brake Control Module: Diagrams Component Connector End Views Trailer Brake Control Module (JL1 except 31 Series) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Page 14980 Trailer Brake Control Module (JL1 with 31 Series) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Page 14981 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Page 14982 Fuel Pump/Trailer Brake Control Module (Gas with JL1 and except LU3, LY6 or LY6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Page 14983 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Brake Control Module > Component Information > Technical Service Bulletins > Page 14984 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Brake Control Module > Component Information > Service and Repair > Trailer Brake Control Switch Replacement Trailer Brake Control Module: Service and Repair Trailer Brake Control Switch Replacement Trailer Brake Control Switch Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Brake Control Module > Component Information > Service and Repair > Trailer Brake Control Switch Replacement > Page 14987 Trailer Brake Control Module: Service and Repair Trailer Brake Control Module Replacement Trailer Brake Control Module Replacement (2500, 3500) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Technical Service Bulletins > Brakes - Aftermarket Trailer Brake Controllers Trailer Connector: Technical Service Bulletins Brakes - Aftermarket Trailer Brake Controllers INFORMATION Bulletin No.: 06-08-45-008D Date: July 12, 2010 Subject: Information on Auxiliary Power Wire at Trailer and Installation of Aftermarket Trailer Brake Controller - Towing, Tow Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2011 HUMMER H2 Supercede: This bulletin is being revised to add the 2011 model year and information about the orientation of the ringlet. Please discard Corporate Bulletin Number 06-08-45-008C (Section 08 Body and Accessories). Important Installation of an electric brake controller and the wiring connections outlined in this bulletin are the responsibility of the dealership or customer. These repairs should never be charged to warranty. If you have any questions, please consult with your District Service Manager. Some customers may have questions on how to connect an electric trailer brake controller or where the brake controller pigtail harness is located. Starting with the new 2007 full-size utilities and pickups and 2008 HUMMER H2, there is no longer an electric trailer brake controller pigtail harness. An aftermarket brake controller will need to be installed/connected to the blunt wires under the left side of the IP for vehicles built without JL1 - Integrated Brake Controller (full-size utilities and pickups). The following steps should be used to complete the installation. 1. Locate the trailer brake control circuits that are looped and taped to the main harness under the instrument panel. 2. Pull the trailering wire harness down. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Technical Service Bulletins > Brakes - Aftermarket Trailer Brake Controllers > Page 14992 3. Match the vehicle harness label circuit functions to the trailer brake controller jumper harness functions. Important The color or wires to be joined together may not match. - Dark Blue Wire: switched power from controller to trailer brakes - Red with Black Stripe: fused vehicle power to electrical brake controller - Light Blue with White Stripe: Brake switch input to power electric brake controller - White: ground - Orange: CHMSL (Center High Mounted Stop Lamp) - not required with most systems 4. After completing the under dash connections to the electric brake controller, open the hood and locate the red wire that is taped to the harness between the underhood electrical center and the driver side front fender. 5. Break the tape on the red/black wire and pull it toward the front of vehicle. 6. Remove the lid from the electrical center. Important Ensure that the ringlets are not interfering with the UBEC cover. 7. Place the terminal on the larger of the two studs at the front of the electrical center and secure with an M8 nut. This is circuit #242 to stud #2, to power the aftermarket trailer brake controller. Important The fuse is already present in the vehicle to power the electrical trailer brake controller system. Auxiliary Power (Applies to All LD & 07-09 HD's Only) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Technical Service Bulletins > Brakes - Aftermarket Trailer Brake Controllers > Page 14993 Circuit #742 for Auxiliary Power at the 7-way trailer connector is no longer connected by the GM Assembly Plant. If the customer desires auxiliary power at the trailer connector location (i.e. refrigeration, battery charger or interior light in the trailer), complete the following steps to connect circuit #742: 1. Locate the red/black wire, looped and taped to the chassis harness, below the brake master cylinder. 2. Break the tape and route the wire to the front of the underhood electrical center. Important Ensure that the ringlets are not interfering with the UBEC cover. 3. Place the terminal on the smaller of the two studs on the electrical center and secure with an M6 fastener. This is circuit #742 to stud #1 for auxiliary power to the 7-way trailer connector. 4. ONLY for vehicles without RPO TP2 - Auxiliary Battery, install a 40 amp fuse to power the circuit. Important For vehicles equipped with RPO TP2 - Devices powered by this fuse will drain the vehicle battery if left connected with the vehicle not running. Warranty Information This installation procedure is to be performed at the customer's request and at their expense. It is not a warranty repair and a claim should not be submitted for reimbursement. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Technical Service Bulletins > Page 14994 Trailer Connector: Diagrams Component Connector End Views Trailer Connector (except MEX or EXP) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Service and Repair > Trailer Hitch Replacement (Light Duty) Trailer Hitch: Service and Repair Trailer Hitch Replacement (Light Duty) Trailer Hitch Replacement (Light Duty) Removal Procedure 1. Disconnect the trailer wiring harness connector (3) from the trailer wiring receptacle (4). 2. Remove the retainers (1) securing the trailer wiring harness (2) to the hitch platform. 3. Remove the hitch platform bolts (5) from the bumper weld nuts (4). 4. Remove the nuts (7) and bolts (1) securing the hitch platform to the frame rails. 5. Remove the hitch platform bolts (6) from the frame weld nuts (2). 6. Remove the hitch platform from the vehicle. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Service and Repair > Trailer Hitch Replacement (Light Duty) > Page 14999 1. Position the hitch platform to the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the hitch platform bolts (6) to the frame weld nuts (2). Tighten the bolts to 100 Nm (74 lb ft). 3. Install the bolts (1) and nuts (7) securing the hitch platform to the frame rails. Tighten the nuts to 113 Nm (83 lb ft). 4. Install the hitch platform bolts (5) to the bumper weld nuts (4). Tighten the bolts to 100 Nm (74 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Service and Repair > Trailer Hitch Replacement (Light Duty) > Page 15000 5. Install the retainers (1) securing the trailer wiring harness (2) to the hitch platform. 6. Connect the trailer wiring harness connector (3) to the trailer wiring receptacle (4). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Service and Repair > Trailer Hitch Replacement (Light Duty) > Page 15001 Trailer Hitch: Service and Repair Trailer Hitch Replacement (Heavy Duty) Trailer Hitch Replacement (Heavy Duty) Removal Procedure 1. Remove the hitch platform bolts (5) from the bumper weld nuts (4). 2. Remove the nuts (7) and bolts (1) securing the hitch platform to the frame rails. 3. Remove the hitch platform bolts (6) from the frame weld nuts (2). 4. Remove the hitch platform from the vehicle. Installation Procedure 1. Position the hitch platform to the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Service and Repair > Trailer Hitch Replacement (Light Duty) > Page 15002 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the hitch platform bolts (6) to the frame weld nuts (2). Tighten the bolts to 100 Nm (74 lb ft). 3. Install the bolts (1) and nuts (7) securing the hitch platform to the frame rails. Tighten the nuts to 113 Nm (83 lb ft). 4. Install the hitch platform bolts (5) to the bumper weld nuts (4). Tighten the bolts to 100 Nm (74 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Locations Trailer Lighting Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Locations > Page 15006 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Locations > Page 15007 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Locations > Page 15008 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Locations > Page 15009 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Locations > Page 15010 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Locations > Page 15011 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Locations > Page 15012 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Locations > Page 15013 Trailer Lighting Relay: Diagrams Component Connector End Views Trailer Stop/Turn Relay (TZ0) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Towing Relay > Component Information > Diagrams Trailer Towing Relay: Diagrams Component Connector End Views Trailer Brake Control Relay (JL1) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Towing Relay > Component Information > Diagrams > Page 15017 Trailer Towing Relay: Service and Repair Trailer Brake Control Relay Replacement (2500, 3500) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Technical Service Bulletins > Brakes - Aftermarket Trailer Brake Controllers Trailer Connector: Technical Service Bulletins Brakes - Aftermarket Trailer Brake Controllers INFORMATION Bulletin No.: 06-08-45-008D Date: July 12, 2010 Subject: Information on Auxiliary Power Wire at Trailer and Installation of Aftermarket Trailer Brake Controller - Towing, Tow Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2011 HUMMER H2 Supercede: This bulletin is being revised to add the 2011 model year and information about the orientation of the ringlet. Please discard Corporate Bulletin Number 06-08-45-008C (Section 08 Body and Accessories). Important Installation of an electric brake controller and the wiring connections outlined in this bulletin are the responsibility of the dealership or customer. These repairs should never be charged to warranty. If you have any questions, please consult with your District Service Manager. Some customers may have questions on how to connect an electric trailer brake controller or where the brake controller pigtail harness is located. Starting with the new 2007 full-size utilities and pickups and 2008 HUMMER H2, there is no longer an electric trailer brake controller pigtail harness. An aftermarket brake controller will need to be installed/connected to the blunt wires under the left side of the IP for vehicles built without JL1 - Integrated Brake Controller (full-size utilities and pickups). The following steps should be used to complete the installation. 1. Locate the trailer brake control circuits that are looped and taped to the main harness under the instrument panel. 2. Pull the trailering wire harness down. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Technical Service Bulletins > Brakes - Aftermarket Trailer Brake Controllers > Page 15022 3. Match the vehicle harness label circuit functions to the trailer brake controller jumper harness functions. Important The color or wires to be joined together may not match. - Dark Blue Wire: switched power from controller to trailer brakes - Red with Black Stripe: fused vehicle power to electrical brake controller - Light Blue with White Stripe: Brake switch input to power electric brake controller - White: ground - Orange: CHMSL (Center High Mounted Stop Lamp) - not required with most systems 4. After completing the under dash connections to the electric brake controller, open the hood and locate the red wire that is taped to the harness between the underhood electrical center and the driver side front fender. 5. Break the tape on the red/black wire and pull it toward the front of vehicle. 6. Remove the lid from the electrical center. Important Ensure that the ringlets are not interfering with the UBEC cover. 7. Place the terminal on the larger of the two studs at the front of the electrical center and secure with an M8 nut. This is circuit #242 to stud #2, to power the aftermarket trailer brake controller. Important The fuse is already present in the vehicle to power the electrical trailer brake controller system. Auxiliary Power (Applies to All LD & 07-09 HD's Only) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Technical Service Bulletins > Brakes - Aftermarket Trailer Brake Controllers > Page 15023 Circuit #742 for Auxiliary Power at the 7-way trailer connector is no longer connected by the GM Assembly Plant. If the customer desires auxiliary power at the trailer connector location (i.e. refrigeration, battery charger or interior light in the trailer), complete the following steps to connect circuit #742: 1. Locate the red/black wire, looped and taped to the chassis harness, below the brake master cylinder. 2. Break the tape and route the wire to the front of the underhood electrical center. Important Ensure that the ringlets are not interfering with the UBEC cover. 3. Place the terminal on the smaller of the two studs on the electrical center and secure with an M6 fastener. This is circuit #742 to stud #1 for auxiliary power to the 7-way trailer connector. 4. ONLY for vehicles without RPO TP2 - Auxiliary Battery, install a 40 amp fuse to power the circuit. Important For vehicles equipped with RPO TP2 - Devices powered by this fuse will drain the vehicle battery if left connected with the vehicle not running. Warranty Information This installation procedure is to be performed at the customer's request and at their expense. It is not a warranty repair and a claim should not be submitted for reimbursement. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Technical Service Bulletins > Page 15024 Trailer Connector: Diagrams Component Connector End Views Trailer Connector (except MEX or EXP) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 07-08-42-006E > Nov > 10 > Instruments - Bulb Outage Detection Restoration Body Control Module: Customer Interest Instruments - Bulb Outage Detection Restoration INFORMATION Bulletin No.: 07-08-42-006E Date: November 11, 2010 Subject: Information on BCM Calibrations Available to Restore Bulb Outage Detection on Vehicles Produced by a Second Stage Manufacturer, Turn Signals Flash Fast after Factory Box Removed (Upfitter) Models: 2007-2011 Chevrolet Silverado 2007-2011 GMC Sierra Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 07-08-42-006D (Section 08 - Body and Accessories). The information contained in this bulletin applies to vehicles that are to be completed by a second stage manufacturer (upfitter) and may need to have the Body Control Module (BCM) rear turn signal bulb outage detection capability changed. All production vehicles will be manufactured with one of the following BCM rear turn signal bulb outage detection software options: 1. A standard production vehicle will have BCM software that checks for two bulbs functioning in each rear turn signal bulb circuit. If one or more bulbs are inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 2. Certain 2500 and 3500 models can be ordered with a new option (RPO 9U5) where the BCM checks for one bulb functioning in each rear turn signal bulb circuit. If the bulb goes inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 3. A vehicle built with a pickup box delete or chassis cab option (RPO ZW9) will be produced with a BCM program that has no turn signal bulb outage detection capability (LED compatible). The IPC turn signal indicator will flash at the same rate no matter how many turn signal bulbs are inoperative. In some cases, the upfitter may wish to change the turn signal bulb outage detection capability so that the turn signals work correctly with their upfit or to meet certain requirements. This will require contacting the Techline Customer Support Center (TCSC) to open a case and obtain a Vehicle Configuration Index (VCI) number. Advise the TCSC consultant which turn signal bulb outage detection capability is needed: 1. Factory standard production TWO bulb outage detection. 2. Optional (RPO 9U5) ONE bulb outage detection. NOTE: ONLY AVAILABLE ON CERTAIN 2007-2011 MODEL 2500 AND 3500 VEHICLES. 3. NO bulb outage detection (LED compatible). The BCM can then be reprogrammed with the correct software. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 07-08-42-006E > Nov > 10 > Instruments - Bulb Outage Detection Restoration Body Control Module: All Technical Service Bulletins Instruments - Bulb Outage Detection Restoration INFORMATION Bulletin No.: 07-08-42-006E Date: November 11, 2010 Subject: Information on BCM Calibrations Available to Restore Bulb Outage Detection on Vehicles Produced by a Second Stage Manufacturer, Turn Signals Flash Fast after Factory Box Removed (Upfitter) Models: 2007-2011 Chevrolet Silverado 2007-2011 GMC Sierra Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 07-08-42-006D (Section 08 - Body and Accessories). The information contained in this bulletin applies to vehicles that are to be completed by a second stage manufacturer (upfitter) and may need to have the Body Control Module (BCM) rear turn signal bulb outage detection capability changed. All production vehicles will be manufactured with one of the following BCM rear turn signal bulb outage detection software options: 1. A standard production vehicle will have BCM software that checks for two bulbs functioning in each rear turn signal bulb circuit. If one or more bulbs are inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 2. Certain 2500 and 3500 models can be ordered with a new option (RPO 9U5) where the BCM checks for one bulb functioning in each rear turn signal bulb circuit. If the bulb goes inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 3. A vehicle built with a pickup box delete or chassis cab option (RPO ZW9) will be produced with a BCM program that has no turn signal bulb outage detection capability (LED compatible). The IPC turn signal indicator will flash at the same rate no matter how many turn signal bulbs are inoperative. In some cases, the upfitter may wish to change the turn signal bulb outage detection capability so that the turn signals work correctly with their upfit or to meet certain requirements. This will require contacting the Techline Customer Support Center (TCSC) to open a case and obtain a Vehicle Configuration Index (VCI) number. Advise the TCSC consultant which turn signal bulb outage detection capability is needed: 1. Factory standard production TWO bulb outage detection. 2. Optional (RPO 9U5) ONE bulb outage detection. NOTE: ONLY AVAILABLE ON CERTAIN 2007-2011 MODEL 2500 AND 3500 VEHICLES. 3. NO bulb outage detection (LED compatible). The BCM can then be reprogrammed with the correct software. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 09-08-47-001A > Jun > 10 > Body Controls - Unable To Reprogram Body Control Module Body Control Module: All Technical Service Bulletins Body Controls - Unable To Reprogram Body Control Module INFORMATION Bulletin No.: 09-08-47-001A Date: June 14, 2010 Subject: Unable to Reprogram Body Control Module (BCM), BCM Reprogramming Did Not Complete - Revised Reprogramming Instructions Models: 2006-2010 Buick Lucerne 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX 2008-2010 Cadillac CTS 2010 Cadillac CTS Wagon 2010 Chevrolet Camaro 2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Impala 2007-2010 Chevrolet Avalanche, Equinox, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet Traverse 2007-2010 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2008-2010 GMC Savana 2010 GMC Terrain 2007-2009 Pontiac Torrent 2008-2009 Pontiac G8 2008-2009 HUMMER H2 2007-2009 Saturn OUTLOOK 2008-2009 Saturn VUE Refer to GMVIS Supercede: This bulletin is being revised to update the models and the model years. Please discard Corporate Bulletin Number 09-08-47-001 (Section 08 - Body and Accessories). Some technicians may experience an unsuccessful body control module (BCM) reprogramming event, when choosing the Reprogram ECU selection on the Service Programming System (SPS). The technician may also notice that when attempting to reprogram the BCM again after this incident has occurred, the BCM may not complete the programming event. This condition may be caused by the following: - A reprogramming event that was interrupted due to a lack of communication between the vehicle and the TIS2WEB terminal. - The vehicle experienced low system voltage during the reprogramming event. Important Do not replace the BCM for this condition. SPS Programming Process Selection Perform this procedure first. 1. If reprogramming has failed during the initial reprogramming event, back out of the SPS application completely. 2. Re-select SPS from the TIS2WEB terminal application. 3. When selecting the Programming Process , choose Replace and Program ECU , even though a new BCM is NOT being installed. 4. Reprogram the BCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the SPS procedures in SI. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 09-08-47-001A > Jun > 10 > Body Controls - Unable To Reprogram Body Control Module > Page 15044 During programming, the battery voltage must be maintained within the proper range of 12-15 volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. BCM Still Fails to Reprogram If the BCM still fails to reprogram perform this procedure: 1. Turn OFF the ignition, and remove the key. 2. Remove the fuses that power up the following modules/components for a minimum of 2 minutes: - BCM - EBCM - ECM - IS LPS (located in the left IP fusebox) - TCM 3. Open and close the driver door. Allow enough time for the retained accessory power (RAP) to turn OFF. 4. Reinstall the fuses. 5. When selecting the Programming Process , choose Replace and Program ECU , even though a new BCM is NOT being installed. 6. Reprogram the BCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the SPS procedures in SI. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 09-08-47-001A > Jun > 10 > Body Controls - Unable To Reprogram Body Control Module Body Control Module: All Technical Service Bulletins Body Controls - Unable To Reprogram Body Control Module INFORMATION Bulletin No.: 09-08-47-001A Date: June 14, 2010 Subject: Unable to Reprogram Body Control Module (BCM), BCM Reprogramming Did Not Complete - Revised Reprogramming Instructions Models: 2006-2010 Buick Lucerne 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX 2008-2010 Cadillac CTS 2010 Cadillac CTS Wagon 2010 Chevrolet Camaro 2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Impala 2007-2010 Chevrolet Avalanche, Equinox, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet Traverse 2007-2010 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2008-2010 GMC Savana 2010 GMC Terrain 2007-2009 Pontiac Torrent 2008-2009 Pontiac G8 2008-2009 HUMMER H2 2007-2009 Saturn OUTLOOK 2008-2009 Saturn VUE Refer to GMVIS Supercede: This bulletin is being revised to update the models and the model years. Please discard Corporate Bulletin Number 09-08-47-001 (Section 08 - Body and Accessories). Some technicians may experience an unsuccessful body control module (BCM) reprogramming event, when choosing the Reprogram ECU selection on the Service Programming System (SPS). The technician may also notice that when attempting to reprogram the BCM again after this incident has occurred, the BCM may not complete the programming event. This condition may be caused by the following: - A reprogramming event that was interrupted due to a lack of communication between the vehicle and the TIS2WEB terminal. - The vehicle experienced low system voltage during the reprogramming event. Important Do not replace the BCM for this condition. SPS Programming Process Selection Perform this procedure first. 1. If reprogramming has failed during the initial reprogramming event, back out of the SPS application completely. 2. Re-select SPS from the TIS2WEB terminal application. 3. When selecting the Programming Process , choose Replace and Program ECU , even though a new BCM is NOT being installed. 4. Reprogram the BCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the SPS procedures in SI. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 09-08-47-001A > Jun > 10 > Body Controls - Unable To Reprogram Body Control Module > Page 15050 During programming, the battery voltage must be maintained within the proper range of 12-15 volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. BCM Still Fails to Reprogram If the BCM still fails to reprogram perform this procedure: 1. Turn OFF the ignition, and remove the key. 2. Remove the fuses that power up the following modules/components for a minimum of 2 minutes: - BCM - EBCM - ECM - IS LPS (located in the left IP fusebox) - TCM 3. Open and close the driver door. Allow enough time for the retained accessory power (RAP) to turn OFF. 4. Reinstall the fuses. 5. When selecting the Programming Process , choose Replace and Program ECU , even though a new BCM is NOT being installed. 6. Reprogram the BCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the SPS procedures in SI. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 15051 Body Control Module: Diagrams Component Connector End Views Body Control Module (BCM) X1 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 15052 Body Control Module (BCM) X2 Body Control Module (BCM) X3 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 15053 Body Control Module (BCM) X4 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 15054 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 15055 Body Control Module (BCM) X5 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 15056 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 15057 Body Control Module (BCM) X6 Body Control Module (BCM) X7 (except MEX or A52) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 15058 Auxiliary Body Control Module (XBCM) X1 (EXP) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 15059 Auxiliary Body Control Module (XBCM) X2 (EXP) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 15060 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Service and Repair > Auxiliary Body Control Module Replacement Body Control Module: Service and Repair Auxiliary Body Control Module Replacement Auxiliary Body Control Module Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Service and Repair > Auxiliary Body Control Module Replacement > Page 15063 Body Control Module: Service and Repair Body Control Module Replacement Body Control Module Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Service and Repair > Auxiliary Body Control Module Replacement > Page 15064 Body Control Module: Service and Repair Body Control Module Bracket Replacement Body Control Module Bracket Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Service and Repair > Auxiliary Body Control Module Replacement > Page 15065 Body Control Module: Service and Repair Serial Data Gateway Module Replacement Serial Data Gateway Module Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > System Information > Service and Repair Auxiliary Step / Running Board: Service and Repair Assist Step Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Front Bumper Fascia Center Support Bracket Replacement Front Bumper Cover / Fascia: Service and Repair Front Bumper Fascia Center Support Bracket Replacement Front Bumper Fascia Center Support Bracket Replacement (GMC) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Front Bumper Fascia Center Support Bracket Replacement > Page 15075 Front Bumper Cover / Fascia: Service and Repair Front Bumper Fascia Side Bracket Replacement Front Bumper Fascia Side Bracket Replacement (GMC) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Front Bumper Fascia Center Support Bracket Replacement > Page 15076 Front Bumper Cover / Fascia: Service and Repair Front Bumper Fascia Outer Support Replacement Front Bumper Fascia Outer Support Replacement (GMC) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Reinforcement > System Information > Adjustments Front Bumper Reinforcement: Adjustments Front Bumper Impact Bar Adjustment (Chevrolet) 1. Remove the right or left front wheelhouse liners. Refer to Front Wheelhouse Liner Replacement Right Side (Chevrolet) (See: Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side)Front Wheelhouse Liner Replacement - Right Side (GMC) (See: Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side) and Front Wheelhouse Liner Replacement - Left Side (Chevrolet) (See: Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Left Side)Front Wheelhouse Liner Replacement - Left Side (GMC) (See: Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Left Side). 2. Loosen the inner front bumper impact bar support bolts (1). 3. Loosen the outer front bumper impact bar support bolts (2). 4. Position a service jack to the front bumper impact bar support (3) to raise the front bumper impact bar if needed. 5. Push downward on the end of the front bumper impact bar (4) to lower if needed. 6. Align the front bumper impact bar (4) in order to achieve and equal gap to the lower edge of the headlamp and fender. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 7. Tighten the inner front bumper impact bar support bolts (1) to 55 Nm (40 lb ft). 8. Tighten the outer front bumper impact bar support bolts (1) to 55 Nm (40 lb ft). 9. Install the right or left front wheelhouse liners. Refer to Front Wheelhouse Liner Replacement - Right Side (Chevrolet) (See: Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side)Front Wheelhouse Liner Replacement - Right Side (GMC) (See: Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Right Side) and Front Wheelhouse Liner Replacement - Left Side (Chevrolet) (See: Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Left Side)Front Wheelhouse Liner Replacement - Left Side (GMC) (See: Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Left Side). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Reinforcement > System Information > Service and Repair > Front Bumper Impact Bar Replacement Front Bumper Reinforcement: Service and Repair Front Bumper Impact Bar Replacement Front Bumper Impact Bar Replacement (Chevrolet) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Reinforcement > System Information > Service and Repair > Front Bumper Impact Bar Replacement > Page 15082 Front Bumper Reinforcement: Service and Repair Front Bumper Impact Bar Outer Bracket Replacement Front Bumper Impact Bar Outer Bracket Replacement (Chevrolet) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Reinforcement > System Information > Service and Repair > Front Bumper Impact Bar Replacement > Page 15083 Front Bumper Reinforcement: Service and Repair Front Bumper Impact Bar Extension Replacement (Chevrolet) Front Bumper Impact Bar Extension Replacement (Chevrolet) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Reinforcement > System Information > Service and Repair > Front Bumper Impact Bar Replacement > Page 15084 Front Bumper Reinforcement: Service and Repair Front Bumper Impact Bar Extension Replacement Front Bumper Impact Bar Extension Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Reinforcement > System Information > Service and Repair > Front Bumper Impact Bar Replacement > Page 15085 Front Bumper Reinforcement: Service and Repair Front Bumper Impact Bar Brace Replacement Front Bumper Impact Bar Brace Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Reinforcement > System Information > Service and Repair > Rear Bumper Impact Bar Replacement Rear Bumper Reinforcement: Service and Repair Rear Bumper Impact Bar Replacement Rear Bumper Impact Bar Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Reinforcement > System Information > Service and Repair > Rear Bumper Impact Bar Replacement > Page 15091 Rear Bumper Reinforcement: Service and Repair Rear Bumper Impact Bar Brace Replacement Rear Bumper Impact Bar Brace Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Cabin Ventilation Grille > Component Information > Service and Repair Cabin Ventilation Grille: Service and Repair Pressure Relief Valve Replacement Removal Procedure 1. Remove the rear window lower garnish molding. Refer to Rear Window Lower Garnish Molding Replacement (Ext Cab/Crew Cab w/A48) (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Rear Window Lower Garnish Molding Replacement (Ext Cab/Crew Cab w/A48))Rear Window Lower Garnish Molding Replacement (Ext Cab/Crew Cab w/o A48) (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Rear Window Lower Garnish Molding Replacement (Ext Cab/Crew Cab w/o A48))Rear Window Lower Garnish Molding Replacement (Regular Cab) (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Rear Window Lower Garnish Molding Replacement (Regular Cab)) 2. Remove the body lock pillar trim. Refer to Body Lock Pillar Trim Replacement (Crew Cab) (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Body Lock Pillar Trim Replacement (Crew Cab))Body Lock Pillar Trim Replacement (Extended Cab) (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Body Lock Pillar Trim Replacement (Extended Cab))Body Lock Pillar Trim Replacement (Regular Cab) ( See: Interior Moulding / Trim/Trim Panel/Service and Repair/Body Lock Pillar Trim Replacement (Regular Cab)) 3. Pull back carpeting on the rear wall of the cab exposing the pressure relief valve. 4. Press on the retaining tab on the top downward to release the valve from the cab back panel. 5. Remove the pressure relief valve from the vehicle. Installation Procedure 1. Align the pressure relief valve into the opening of the rear cab. 2. Press the pressure relief valve into the cab back panel until the locking tabs are fully seated. 3. Realign carpeting on the rear wall of the cab to lay flat. 4. Install the body lock pillar trim. Refer to Body Lock Pillar Trim Replacement (Crew Cab) (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Body Lock Pillar Trim Replacement (Crew Cab))Body Lock Pillar Trim Replacement (Extended Cab) (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Body Lock Pillar Trim Replacement (Extended Cab))Body Lock Pillar Trim Replacement (Regular Cab) ( See: Interior Moulding / Trim/Trim Panel/Service and Repair/Body Lock Pillar Trim Replacement (Regular Cab)) 5. Install the rear window lower garnish molding. Refer to Rear Window Lower Garnish Molding Replacement (Ext Cab/Crew Cab w/A48) (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Rear Window Lower Garnish Molding Replacement (Ext Cab/Crew Cab w/A48))Rear Window Lower Garnish Molding Replacement (Ext Cab/Crew Cab w/o A48) (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Rear Window Lower Garnish Molding Replacement (Ext Cab/Crew Cab w/o A48))Rear Window Lower Garnish Molding Replacement (Regular Cab) (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Rear Window Lower Garnish Molding Replacement (Regular Cab)) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Cowl > Cowl Moulding / Trim > System Information > Service and Repair Cowl Moulding / Trim: Service and Repair Air Inlet Grille Panel Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Exterior Handle: > 09-08-64-032A > Apr > 11 > Body - Chrome Outside Door Handle Loose/Cracked Front Door Exterior Handle: All Technical Service Bulletins Body - Chrome Outside Door Handle Loose/Cracked TECHNICAL Bulletin No.: 09-08-64-032A Date: April 18, 2011 Subject: Chrome Outside Door Handle Loose/Cracked at Attachment Screw (Replace Handle) Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add model years, update the Parts Information and add a Caution. Please discard Corporate Bulletin Number 09-08-64-032 (Section 08 - Body and Accessories). Condition Some customers may comment that a chrome outside door handle is loose or cracked in the area of the attachment screws. Cause For 2007 and 2008 models, this condition may be caused by grease used on the attachment screws during the assembly process, which can migrate into the handle screw bosses and cause degradation. Among other contributing factors to this condition is that the initial assembly torque of the attachment screws was too high, which may have helped initiate cracks in the screw bosses. Correction Important When replacing a chrome outside door handle for this condition, be sure to address the following: - Ensure that the attachment screws are free from grease before installing the new handle. Clean the screws with Kent Automotive Acrysol(TM) P/N 20005, or an equivalent grease removing body solvent. - Torque the screws to 6 Nm (53 lb in). Caution Exceeding the recommended screw torque of 6 Nm (53 lb in) could result in the thread insert pulling out of the handle base, as shown in the graphic above. Replace the affected chrome outside door handle. Refer to Front Side Door Outside Handle Replacement, Rear Side Door Outside Handle Replacement, or Rear Side Door Outside Handle Replacement (Crew Cab) in SI. Parts Information Acrysol(TM) is available from Kent Automotive at 1-888-YES-KENT or online at www.kent-automotive.com. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Exterior Handle: > 09-08-64-032A > Apr > 11 > Body - Chrome Outside Door Handle Loose/Cracked > Page 15111 Warranty Information For vehicles repaired under warranty, use the appropriate labor operation found in the Labor Time Guide (LTG). Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Technical Service Bulletins > Customer Interest for Front Door Exterior Handle: > 09-08-64-032A > Apr > 11 > Body - Chrome Outside Door Handle Loose/Cracked Front Door Exterior Handle: Customer Interest Body - Chrome Outside Door Handle Loose/Cracked TECHNICAL Bulletin No.: 09-08-64-032A Date: April 18, 2011 Subject: Chrome Outside Door Handle Loose/Cracked at Attachment Screw (Replace Handle) Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add model years, update the Parts Information and add a Caution. Please discard Corporate Bulletin Number 09-08-64-032 (Section 08 - Body and Accessories). Condition Some customers may comment that a chrome outside door handle is loose or cracked in the area of the attachment screws. Cause For 2007 and 2008 models, this condition may be caused by grease used on the attachment screws during the assembly process, which can migrate into the handle screw bosses and cause degradation. Among other contributing factors to this condition is that the initial assembly torque of the attachment screws was too high, which may have helped initiate cracks in the screw bosses. Correction Important When replacing a chrome outside door handle for this condition, be sure to address the following: - Ensure that the attachment screws are free from grease before installing the new handle. Clean the screws with Kent Automotive Acrysol(TM) P/N 20005, or an equivalent grease removing body solvent. - Torque the screws to 6 Nm (53 lb in). Caution Exceeding the recommended screw torque of 6 Nm (53 lb in) could result in the thread insert pulling out of the handle base, as shown in the graphic above. Replace the affected chrome outside door handle. Refer to Front Side Door Outside Handle Replacement, Rear Side Door Outside Handle Replacement, or Rear Side Door Outside Handle Replacement (Crew Cab) in SI. Parts Information Acrysol(TM) is available from Kent Automotive at 1-888-YES-KENT or online at www.kent-automotive.com. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Technical Service Bulletins > Customer Interest for Front Door Exterior Handle: > 09-08-64-032A > Apr > 11 > Body - Chrome Outside Door Handle Loose/Cracked > Page 15117 Warranty Information For vehicles repaired under warranty, use the appropriate labor operation found in the Labor Time Guide (LTG). Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Technical Service Bulletins > Customer Interest for Front Door Exterior Handle: > Page 15118 Front Door Exterior Handle: By Symptom Technical Service Bulletin # 09-08-64-032A Date: 110418 Body - Chrome Outside Door Handle Loose/Cracked TECHNICAL Bulletin No.: 09-08-64-032A Date: April 18, 2011 Subject: Chrome Outside Door Handle Loose/Cracked at Attachment Screw (Replace Handle) Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add model years, update the Parts Information and add a Caution. Please discard Corporate Bulletin Number 09-08-64-032 (Section 08 - Body and Accessories). Condition Some customers may comment that a chrome outside door handle is loose or cracked in the area of the attachment screws. Cause For 2007 and 2008 models, this condition may be caused by grease used on the attachment screws during the assembly process, which can migrate into the handle screw bosses and cause degradation. Among other contributing factors to this condition is that the initial assembly torque of the attachment screws was too high, which may have helped initiate cracks in the screw bosses. Correction Important When replacing a chrome outside door handle for this condition, be sure to address the following: - Ensure that the attachment screws are free from grease before installing the new handle. Clean the screws with Kent Automotive Acrysol(TM) P/N 20005, or an equivalent grease removing body solvent. - Torque the screws to 6 Nm (53 lb in). Caution Exceeding the recommended screw torque of 6 Nm (53 lb in) could result in the thread insert pulling out of the handle base, as shown in the graphic above. Replace the affected chrome outside door handle. Refer to Front Side Door Outside Handle Replacement, Rear Side Door Outside Handle Replacement, or Rear Side Door Outside Handle Replacement (Crew Cab) in SI. Parts Information Acrysol(TM) is available from Kent Automotive at 1-888-YES-KENT or online at www.kent-automotive.com. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Technical Service Bulletins > Customer Interest for Front Door Exterior Handle: > Page 15119 Warranty Information For vehicles repaired under warranty, use the appropriate labor operation found in the Labor Time Guide (LTG). Disclaimer Technical Service Bulletin # 09-08-64-032A Date: 110418 Body - Chrome Outside Door Handle Loose/Cracked TECHNICAL Bulletin No.: 09-08-64-032A Date: April 18, 2011 Subject: Chrome Outside Door Handle Loose/Cracked at Attachment Screw (Replace Handle) Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add model years, update the Parts Information and add a Caution. Please discard Corporate Bulletin Number 09-08-64-032 (Section 08 - Body and Accessories). Condition Some customers may comment that a chrome outside door handle is loose or cracked in the area of the attachment screws. Cause For 2007 and 2008 models, this condition may be caused by grease used on the attachment screws during the assembly process, which can migrate into the handle screw bosses and cause degradation. Among other contributing factors to this condition is that the initial assembly torque of the attachment screws was too high, which may have helped initiate cracks in the screw bosses. Correction Important When replacing a chrome outside door handle for this condition, be sure to address the following: - Ensure that the attachment screws are free from grease before installing the new handle. Clean the screws with Kent Automotive Acrysol(TM) P/N 20005, or an equivalent grease removing body solvent. - Torque the screws to 6 Nm (53 lb in). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Technical Service Bulletins > Customer Interest for Front Door Exterior Handle: > Page 15120 Caution Exceeding the recommended screw torque of 6 Nm (53 lb in) could result in the thread insert pulling out of the handle base, as shown in the graphic above. Replace the affected chrome outside door handle. Refer to Front Side Door Outside Handle Replacement, Rear Side Door Outside Handle Replacement, or Rear Side Door Outside Handle Replacement (Crew Cab) in SI. Parts Information Acrysol(TM) is available from Kent Automotive at 1-888-YES-KENT or online at www.kent-automotive.com. Warranty Information For vehicles repaired under warranty, use the appropriate labor operation found in the Labor Time Guide (LTG). Disclaimer Technical Service Bulletin # 09-08-64-032A Date: 110418 Body - Chrome Outside Door Handle Loose/Cracked TECHNICAL Bulletin No.: 09-08-64-032A Date: April 18, 2011 Subject: Chrome Outside Door Handle Loose/Cracked at Attachment Screw (Replace Handle) Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add model years, update the Parts Information and add a Caution. Please discard Corporate Bulletin Number 09-08-64-032 (Section 08 - Body and Accessories). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Technical Service Bulletins > Customer Interest for Front Door Exterior Handle: > Page 15121 Condition Some customers may comment that a chrome outside door handle is loose or cracked in the area of the attachment screws. Cause For 2007 and 2008 models, this condition may be caused by grease used on the attachment screws during the assembly process, which can migrate into the handle screw bosses and cause degradation. Among other contributing factors to this condition is that the initial assembly torque of the attachment screws was too high, which may have helped initiate cracks in the screw bosses. Correction Important When replacing a chrome outside door handle for this condition, be sure to address the following: - Ensure that the attachment screws are free from grease before installing the new handle. Clean the screws with Kent Automotive Acrysol(TM) P/N 20005, or an equivalent grease removing body solvent. - Torque the screws to 6 Nm (53 lb in). Caution Exceeding the recommended screw torque of 6 Nm (53 lb in) could result in the thread insert pulling out of the handle base, as shown in the graphic above. Replace the affected chrome outside door handle. Refer to Front Side Door Outside Handle Replacement, Rear Side Door Outside Handle Replacement, or Rear Side Door Outside Handle Replacement (Crew Cab) in SI. Parts Information Acrysol(TM) is available from Kent Automotive at 1-888-YES-KENT or online at www.kent-automotive.com. Warranty Information For vehicles repaired under warranty, use the appropriate labor operation found in the Labor Time Guide (LTG). Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Technical Service Bulletins > Page 15122 Front Door Exterior Handle: Service and Repair Front Side Door Outside Handle Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Service and Repair > Front Side Door Inside Handle Replacement (with SLT) Front Door Interior Handle: Service and Repair Front Side Door Inside Handle Replacement (with SLT) Front Side Door Inside Handle Replacement (with SLT) Removal Procedure 1. Remove door upper trim panel. Refer to Upper Extension Trim Panel Replacement (See: Front Door Panel/Service and Repair). 2. Pull the door trim panel away from the door and support the bottom of the trim panel on the door panel hooks. Refer to Front Side Door Trim Panel Replacement (SLT, A95) (See: Front Door Panel/Service and Repair)Front Side Door Trim Panel Replacement (Except YE9 or SLT) ( See: Front Door Panel/Service and Repair). 3. Remove the front side door inside handle fasteners (1). 4. Remove the front side door inside handle assembly (2). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Service and Repair > Front Side Door Inside Handle Replacement (with SLT) > Page 15127 1. Disconnect the electrical connector. 2. If replacing the door handle, transfer the heated seat switch or seat adjuster memory switch, if equipped. Refer to Front Seat Heater Switch Replacement (See: Seats/Seat Heater Switch/Service and Repair/Front Seat Heater Switch Replacement) or Driver Seat Adjuster Memory Switch Replacement (Crew Cab) (See: Mirrors/Memory Positioning Systems/Seat Memory Switch/Service and Repair). 3. Depress both tabs to remove the front side door cable and pull the cable rearward out of the handle assembly. Installation Procedure 1. Connect the front side door cable. Ensure the cable is fully seated past the guide tab. 2. Slide the front side door inside handle assembly into place (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the front side door inside handle fasteners and tighten to 2 Nm (18 lb in). 4. Install the door trim panel. Refer to Front Side Door Trim Panel Replacement (SLT, A95) (See: Front Door Panel/Service and Repair)Front Side Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Service and Repair > Front Side Door Inside Handle Replacement (with SLT) > Page 15128 Door Trim Panel Replacement (Except YE9 or SLT) (See: Front Door Panel/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Service and Repair > Front Side Door Inside Handle Replacement (with SLT) > Page 15129 Front Door Interior Handle: Service and Repair Front Side Door Inside Handle Replacement (without SLT) Front Side Door Inside Handle Replacement (without SLT) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Service and Repair Front Door Hinge: Service and Repair Front Side Door Upper Hinge and Lower Hinge Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Service and Repair > Page 15133 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Diagrams Front Door Latch: Diagrams Component Connector End Views Door Latch - Driver (AU3) Door Latch - Driver (except AU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Diagrams > Page 15137 Door Latch - Left Rear (Crew Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Diagrams > Page 15138 Door Latch - Passenger Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Diagrams > Page 15139 Door Latch - Right Rear (Crew Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Diagrams > Page 15140 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Side Door Window Switch Bezel Replacement Front Door Panel: Service and Repair Front Side Door Window Switch Bezel Replacement Front Side Door Window Switch Bezel Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Side Door Window Switch Bezel Replacement > Page 15145 Front Door Panel: Service and Repair Front Side Door Pull Handle Replacement Front Side Door Pull Handle Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Side Door Window Switch Bezel Replacement > Page 15146 Front Door Panel: Service and Repair Front Side Door Trim Panel Replacement (Slt, A95) Front Side Door Trim Panel Replacement (SLT, A95) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Side Door Window Switch Bezel Replacement > Page 15147 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Side Door Window Switch Bezel Replacement > Page 15148 Front Door Panel: Service and Repair Front Side Door Trim Panel Replacement (Except YE9 or Slt) Front Side Door Trim Panel Replacement (Except YE9 or SLT) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Side Door Window Switch Bezel Replacement > Page 15149 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Side Door Window Switch Bezel Replacement > Page 15150 Front Door Panel: Service and Repair Front Side Door Window Switch Bezel Replacement Front Side Door Window Switch Bezel Replacement Front Side Door Pull Handle Replacement Front Side Door Pull Handle Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Side Door Window Switch Bezel Replacement > Page 15151 Front Side Door Trim Panel Replacement (Slt, A95) Front Side Door Trim Panel Replacement (SLT, A95) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Side Door Window Switch Bezel Replacement > Page 15152 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Side Door Window Switch Bezel Replacement > Page 15153 Front Side Door Trim Panel Replacement (Except YE9 or Slt) Front Side Door Trim Panel Replacement (Except YE9 or SLT) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Side Door Window Switch Bezel Replacement > Page 15154 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Side Door Window Switch Bezel Replacement > Page 15155 Upper Extension Trim Panel Replacement Upper Extension Trim Panel Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Side Door Window Switch Bezel Replacement > Page 15156 Front Side Door Water Deflector Replacement Front Side Door Water Deflector Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Side Door Window Switch Bezel Replacement > Page 15157 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Striker > System Information > Adjustments Front Door Striker: Adjustments Door Lock Striker Adjustment To determine if striker adjustment is required, proceed as follows: 1. Make certain the door is properly aligned within the door opening before proceeding with the striker adjustment. 2. Close the door onto the striker and note if the door drags on the striker causing the door to move upward or downward upon contact with the striker. Also note the closing effort to fully engage the latch. 3. Using a soft marker, mark around the striker for reference of the original position. Loosen the striker. 4. Move the striker to eliminate drag on the striker and door latch and to achieve the proper door position within the door opening. Start with the up/down position, then position the striker to achieve proper alignment to the door opening. Set the in/out adjustment for the proper door seal engagement making sure the door closing efforts are correct. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Tighten the striker-to-body bolts to 27 Nm (20 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Striker > System Information > Service and Repair > Door Striker Replacement (Crew Cab) Front Door Striker: Service and Repair Door Striker Replacement (Crew Cab) Door Striker Replacement (Crew Cab) Removal Procedure Note: If both of the door striker bolts are removed at the same time, the striker backing plate will fall into the body. This will result in additional time to perform the repair. 1. Remove the lower striker bolt. 2. Loosen the upper striker bolt enough in order to rotate the striker and the spacer, if equipped, away from the lower bolt hole. 3. Install the lower striker bolt. Tighten the lower striker bolt sufficiently in order to hold the striker backing plate in place. 4. Remove the upper striker bolt (1). 5. Remove the spacer, if equipped. 6. Remove the striker (2). Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Striker > System Information > Service and Repair > Door Striker Replacement (Crew Cab) > Page 15163 1. Install the striker. 2. Install the spacer, if equipped. 3. Install the upper striker bolt (1). 4. If the striker backing plate has moved, rotate the lower striker bolt until the upper threaded hole is properly aligned. 5. Remove the lower bolt. 6. Rotate the striker (2) and the spacer, if equipped, in order to align the lower threaded hole in the striker backing plate. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 7. Tighten the striker bolts. Tighten the door striker bolts to 24 Nm (18 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Striker > System Information > Service and Repair > Door Striker Replacement (Crew Cab) > Page 15164 Front Door Striker: Service and Repair Door Striker Replacement (Extended Cab, Lower) Door Striker Replacement (Extended Cab Lower) Removal Procedure Note: If both of the door striker bolts are removed at the same time, the striker backing plate will fall into the body. This will result in additional time to perform the repair. 1. Remove the door lower striker bolts (1). 2. Remove the spacer, if equipped. 3. Remove the door lower striker (2). Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Striker > System Information > Service and Repair > Door Striker Replacement (Crew Cab) > Page 15165 1. Install the door lower striker (2). 2. Install the spacer, if equipped. 3. Install the door lower striker bolt (1). 4. If the striker backing plate has moved, rotate the lower striker bolt until the upper threaded hole is properly aligned. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Tighten the lower striker bolts. Tighten the door lower striker bolts to 24 Nm (18 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Striker > System Information > Service and Repair > Door Striker Replacement (Crew Cab) > Page 15166 Front Door Striker: Service and Repair Door Striker Replacement (Extended Cab, Upper) Door Striker Replacement (Extended Cab Upper) Removal Procedure Note: If both of the door striker bolts are removed at the same time, the striker backing plate will fall into the body. This will result in additional time to perform the repair. 1. Remove the upper trim door upper striker cover (2). Pull straight downward for the trim cover to release, retained by retainer clips (1). 2. Remove the door upper striker bolts (3). 3. Remove the spacer, if equipped. 4. Remove the door upper striker (4). Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Striker > System Information > Service and Repair > Door Striker Replacement (Crew Cab) > Page 15167 1. Install the door upper striker (4). 2. Install the spacer, if equipped. 3. Install the door upper striker bolt (3). 4. If the striker backing plate has moved, rotate the lower striker bolt until the upper threaded hole is properly aligned. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Tighten the upper striker bolts. Tighten the door upper striker bolts to 24 Nm (18 lb ft). 6. Install the upper trim door upper striker cover. Ensure that the retainer clips were Not damaged when removed. Push upward into locator holes. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Front Door Weatherstrip: > 09-08-64-012C > Nov > 10 > Body - Side Door Body Mounted Weatherstrip Replacement Front Door Weatherstrip: Customer Interest Body - Side Door Body Mounted Weatherstrip Replacement INFORMATION Bulletin No.: 09-08-64-012C Date: November 22, 2010 Subject: Information on Side Door Body Mounted Primary Weatherstrip Replacement Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to communicate feedback received from engineering information and add the 2011 model year. Please discard Corporate Bulletin Number 09-08-64-012B (Section 08 - Body and Accessories). Some customers may comment about side door wind noise, water leaks or door fit concerns. These concerns may appear to be related to the body mounted primary door opening weatherstrips. As a result of feedback received from engineering information, we have found that many replacements of the primary door opening weatherstrip are for issues not related to the primary door opening weatherstrip. The instructions below are a guide to help "root cause" the customer's concern and obtain the proper direction for repair. Recommendation Note: If the seal is properly installed, it will not cause a Windnoise. If mis-installed, the seal could create a Windnoise that can be corrected by re-installing the seal. If the condition is for Windnoise, please view the training courses on this subject and follow the proper diagnostics outlined in courses 10210.01D 2010 SKH Seminar Jan Emerging Issues,.02D (Feb),.03D (March) (3 Parts) (Emerging Issues programs available to U.S. dealers only). If the condition is specific to an itch noise, refer to Corporate Bulletin Number 06-08-64-035F to correct that concern. If diagnosing a water leak, please follow information supplied in Corporate Bulletin Number 09-08-57-002B. For door fit concerns, or if the seal is loose or exhibits a poor appearance, inspect for even retention around the door. If the seal pulls off too easily, the channel crimp may be wide/loose as shown between the dashed lines in the graphic above. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Front Door Weatherstrip: > 09-08-64-012C > Nov > 10 > Body - Side Door Body Mounted Weatherstrip Replacement > Page 15176 Remove the seal only in the affected area. Inspect the seal's channel crimp and adjust accordingly by pinching the channel together for a tighter retention. Reinstall the portion of the seal that was removed. Warranty Information For vehicles repaired under warranty, use the appropriate labor operation found in the Labor Time Guide (LTG). Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Front Door Weatherstrip: > 06-08-64-035G > Jun > 10 > Body - Squeak/Itching Noise in Upper Door Area Front Door Weatherstrip: Customer Interest Body - Squeak/Itching Noise in Upper Door Area TECHNICAL Bulletin No.: 06-08-64-035G Date: June 01, 2010 Subject: Squeak/Itching Noise in Upper Door Area (Replace Weatherstrip Assembly) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to update parts description information. Please discard Corporate Bulletin Number 06-08-64-035F (Section 08 - Body and Accessories). Condition Some customers may comment on a squeaking or itching noise in the upper door area when driving. Cause This condition may be caused by the roof drip weatherstrip to door frame contact. This could occur at any or all of the doors. Correction Replace the weatherstrip assembly. Refer to Door Opening Weatherstrip Replacement in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the appropriate labor operation from the Labor Time Guide. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Weatherstrip: > 09-08-64-012C > Nov > 10 > Body - Side Door Body Mounted Weatherstrip Replacement Front Door Weatherstrip: All Technical Service Bulletins Body - Side Door Body Mounted Weatherstrip Replacement INFORMATION Bulletin No.: 09-08-64-012C Date: November 22, 2010 Subject: Information on Side Door Body Mounted Primary Weatherstrip Replacement Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to communicate feedback received from engineering information and add the 2011 model year. Please discard Corporate Bulletin Number 09-08-64-012B (Section 08 - Body and Accessories). Some customers may comment about side door wind noise, water leaks or door fit concerns. These concerns may appear to be related to the body mounted primary door opening weatherstrips. As a result of feedback received from engineering information, we have found that many replacements of the primary door opening weatherstrip are for issues not related to the primary door opening weatherstrip. The instructions below are a guide to help "root cause" the customer's concern and obtain the proper direction for repair. Recommendation Note: If the seal is properly installed, it will not cause a Windnoise. If mis-installed, the seal could create a Windnoise that can be corrected by re-installing the seal. If the condition is for Windnoise, please view the training courses on this subject and follow the proper diagnostics outlined in courses 10210.01D 2010 SKH Seminar Jan Emerging Issues,.02D (Feb),.03D (March) (3 Parts) (Emerging Issues programs available to U.S. dealers only). If the condition is specific to an itch noise, refer to Corporate Bulletin Number 06-08-64-035F to correct that concern. If diagnosing a water leak, please follow information supplied in Corporate Bulletin Number 09-08-57-002B. For door fit concerns, or if the seal is loose or exhibits a poor appearance, inspect for even retention around the door. If the seal pulls off too easily, the channel crimp may be wide/loose as shown between the dashed lines in the graphic above. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Weatherstrip: > 09-08-64-012C > Nov > 10 > Body - Side Door Body Mounted Weatherstrip Replacement > Page 15186 Remove the seal only in the affected area. Inspect the seal's channel crimp and adjust accordingly by pinching the channel together for a tighter retention. Reinstall the portion of the seal that was removed. Warranty Information For vehicles repaired under warranty, use the appropriate labor operation found in the Labor Time Guide (LTG). Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Weatherstrip: > 06-08-64-035G > Jun > 10 > Body - Squeak/Itching Noise in Upper Door Area Front Door Weatherstrip: All Technical Service Bulletins Body - Squeak/Itching Noise in Upper Door Area TECHNICAL Bulletin No.: 06-08-64-035G Date: June 01, 2010 Subject: Squeak/Itching Noise in Upper Door Area (Replace Weatherstrip Assembly) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to update parts description information. Please discard Corporate Bulletin Number 06-08-64-035F (Section 08 - Body and Accessories). Condition Some customers may comment on a squeaking or itching noise in the upper door area when driving. Cause This condition may be caused by the roof drip weatherstrip to door frame contact. This could occur at any or all of the doors. Correction Replace the weatherstrip assembly. Refer to Door Opening Weatherstrip Replacement in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the appropriate labor operation from the Labor Time Guide. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Front Side Door Window Weatherstrip Replacement Front Door Weatherstrip: Service and Repair Front Side Door Window Weatherstrip Replacement Front Side Door Window Weatherstrip Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Front Side Door Window Weatherstrip Replacement > Page 15193 Front Door Weatherstrip: Service and Repair Front Side Door Roof Drip Weatherstrip Replacement Front Side Door Roof Drip Weatherstrip Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Front Side Door Window Weatherstrip Replacement > Page 15194 Front Door Weatherstrip: Service and Repair Front Door Opening Weatherstrip Replacement (Regular Cab) Front Door Opening Weatherstrip Replacement (Regular Cab) Removal Procedure 1. Remove the front door sill plate. Refer to Front Side Door Sill Trim Plate Replacement (Extended Cab) (See: Interior Moulding / Trim/Scuff Plate/Service and Repair/Front Side Door Sill Trim Plate Replacement (Extended Cab))Front Side Door Sill Trim Plate Replacement (Regular Cab/Crew Cab) (See: Interior Moulding / Trim/Scuff Plate/Service and Repair/Front Side Door Sill Trim Plate Replacement (Regular Cab/Crew Cab)). 2. Remove the weatherstrip from the pinch-weld flange. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Front Side Door Window Weatherstrip Replacement > Page 15195 1. Align the weatherstrip to the door opening with the 2 dots positioned on the upper right and left side. 2. Align the weatherstrip to the door opening with the bond joint positioned at the lower center of the door opening. 3. Install the weatherstrip to the pinch-weld flange. Ensure that the weatherstrip is fully seated. 4. Install the front door sill plate. Refer to Front Side Door Sill Trim Plate Replacement (Extended Cab) (See: Interior Moulding / Trim/Scuff Plate/Service and Repair/Front Side Door Sill Trim Plate Replacement (Extended Cab))Front Side Door Sill Trim Plate Replacement (Regular Cab/Crew Cab) (See: Interior Moulding / Trim/Scuff Plate/Service and Repair/Front Side Door Sill Trim Plate Replacement (Regular Cab/Crew Cab)). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Front Side Door Window Weatherstrip Replacement > Page 15196 Front Door Weatherstrip: Service and Repair Front Door Opening Weatherstrip Replacement (Extended Cab) Front Door Opening Weatherstrip Replacement (Extended Cab) Removal Procedure 1. Open both doors. 2. Remove the front and rear door sill plate. Refer to Front Side Door Sill Trim Plate Replacement (Extended Cab) (See: Interior Moulding / Trim/Scuff Plate/Service and Repair/Front Side Door Sill Trim Plate Replacement (Extended Cab))Front Side Door Sill Trim Plate Replacement (Regular Cab/Crew Cab) (See: Interior Moulding / Trim/Scuff Plate/Service and Repair/Front Side Door Sill Trim Plate Replacement (Regular Cab/Crew Cab)) or Rear Side Door Sill Trim Plate Replacement (Crew Cab) (See: Interior Moulding / Trim/Scuff Plate/Service and Repair/Rear Side Door Sill Trim Plate Replacement (Crew Cab))Rear Side Door Sill Trim Plate Replacement (Extended Cab) (See: Interior Moulding / Trim/Scuff Plate/Service and Repair/Rear Side Door Sill Trim Plate Replacement (Extended Cab)). 3. Remove the hinge pillar trim. Refer to Body Hinge Pillar Trim Panel Replacement (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Body Hinge Pillar Trim Panel Replacement). 4. Remove the body lock pillar trim. Refer to Body Lock Pillar Trim Replacement (Crew Cab) (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Body Lock Pillar Trim Replacement (Crew Cab))Body Lock Pillar Trim Replacement (Extended Cab) (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Body Lock Pillar Trim Replacement (Extended Cab))Body Lock Pillar Trim Replacement (Regular Cab) ( See: Interior Moulding / Trim/Trim Panel/Service and Repair/Body Lock Pillar Trim Replacement (Regular Cab)). 5. Remove the windshield pillar molding. Refer to Windshield Pillar Garnish Molding Replacement (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Windshield Pillar Garnish Molding Replacement). 6. Remove the weatherstrip (1) from the pinch-weld flange (2). Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Front Side Door Window Weatherstrip Replacement > Page 15197 1. Align the weatherstrip to the door opening with the 2 dots positioned on the upper right and left side. 2. Install the weatherstrip (1) to the pinch-weld flange (2). Ensure that the weatherstrip is fully seated around the door opening. 3. Install the windshield pillar molding. Refer to Windshield Pillar Garnish Molding Replacement (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Windshield Pillar Garnish Molding Replacement). 4. Install the body lock pillar trim. Refer to Body Lock Pillar Trim Replacement (Crew Cab) (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Body Lock Pillar Trim Replacement (Crew Cab))Body Lock Pillar Trim Replacement (Extended Cab) (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Body Lock Pillar Trim Replacement (Extended Cab))Body Lock Pillar Trim Replacement (Regular Cab) ( See: Interior Moulding / Trim/Trim Panel/Service and Repair/Body Lock Pillar Trim Replacement (Regular Cab)). 5. Install the hinge pillar trim. Refer to Body Hinge Pillar Trim Panel Replacement (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Body Hinge Pillar Trim Panel Replacement). 6. Install the sill plate. Refer to Front Side Door Sill Trim Plate Replacement (Extended Cab) (See: Interior Moulding / Trim/Scuff Plate/Service and Repair/Front Side Door Sill Trim Plate Replacement (Extended Cab))Front Side Door Sill Trim Plate Replacement (Regular Cab/Crew Cab) (See: Interior Moulding / Trim/Scuff Plate/Service and Repair/Front Side Door Sill Trim Plate Replacement (Regular Cab/Crew Cab)) or Rear Side Door Sill Trim Plate Replacement (Crew Cab) (See: Interior Moulding / Trim/Scuff Plate/Service and Repair/Rear Side Door Sill Trim Plate Replacement (Crew Cab))Rear Side Door Sill Trim Plate Replacement (Extended Cab) (See: Interior Moulding / Trim/Scuff Plate/Service and Repair/Rear Side Door Sill Trim Plate Replacement (Extended Cab)). 7. Inspect the door closing effort and seal to door fit. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Front Side Door Window Weatherstrip Replacement > Page 15198 Front Door Weatherstrip: Service and Repair Front Side Door Bottom Auxiliary Sealing Strip Replacement Front Side Door Bottom Auxiliary Sealing Strip Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Technical Service Bulletins > Customer Interest: > 07-08-64-019C > Apr > 11 > Body - Front Door Window Regulator Squeak Noise Front Door Window Glass: Customer Interest Body - Front Door Window Regulator Squeak Noise TECHNICAL Bulletin No.: 07-08-64-019C Date: April 08, 2011 Subject: Front Door Window Regulator Squeak Noise When Operated (Apply Lubricant) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add the 2011 and 2012 model years. Please discard Corporate Bulletin Number 07-08-64-019B (Section 08 - Body and Accessories). Condition Some customers may comment on a front door glass squeak when operated up or down. Cause There may be insufficient lubrication on the regulator rails. Correction Lubricate BOTH front door regulators at time of repair using the following procedure. 1. Remove the regulator following SI procedures. 2. Brush a small amount of lubricant on the entire length of both regulator rails. Refer to the illustration for lubricant location. 3. Cycle the door glass to verify that the noise is gone. 4. Reinstall the regulator following SI procedures. Parts Information Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Technical Service Bulletins > Customer Interest: > 07-08-64-019C > Apr > 11 > Body - Front Door Window Regulator Squeak Noise > Page 15207 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass: > 07-08-64-019C > Apr > 11 > Body - Front Door Window Regulator Squeak Noise Front Door Window Glass: All Technical Service Bulletins Body - Front Door Window Regulator Squeak Noise TECHNICAL Bulletin No.: 07-08-64-019C Date: April 08, 2011 Subject: Front Door Window Regulator Squeak Noise When Operated (Apply Lubricant) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add the 2011 and 2012 model years. Please discard Corporate Bulletin Number 07-08-64-019B (Section 08 - Body and Accessories). Condition Some customers may comment on a front door glass squeak when operated up or down. Cause There may be insufficient lubrication on the regulator rails. Correction Lubricate BOTH front door regulators at time of repair using the following procedure. 1. Remove the regulator following SI procedures. 2. Brush a small amount of lubricant on the entire length of both regulator rails. Refer to the illustration for lubricant location. 3. Cycle the door glass to verify that the noise is gone. 4. Reinstall the regulator following SI procedures. Parts Information Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass: > 07-08-64-019C > Apr > 11 > Body - Front Door Window Regulator Squeak Noise > Page 15213 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass: > 00-08-48-005D > Sep > 10 > Body - Vehicle Glass Distortion Information Front Door Window Glass: All Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass: > 06-08-64-001B > Oct > 09 > Body - Side Window Chipping Information Front Door Window Glass: All Technical Service Bulletins Body - Side Window Chipping Information INFORMATION Bulletin No.: 06-08-64-001B Date: October 20, 2009 Subject: Information on Side Door Window Glass Chipping Caused by Hanging Vehicle Key Lock Box Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add vehicles and model years and to include all types of door window glass. Please discard Corporate Bulletin Number 06-08-64-001A (Section 08 - Body & Accessories). - In several warranty parts review cases, side door window glass was observed with a chip or chips on the top side of the window glass. Dealer contacts confirmed that they use a vehicle key lock box on the front side door window glass. - A random selection of side door glass returns will be conducted to confirm adherence. If a side door glass is discovered with a chip or chips in the location previously described, the side door glass will be returned to the dealership for debit. Example of Side Door Glass - DO NOT place a vehicle key lock box on a side door window glass. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass: > 06-08-64-001B > Oct > 09 > Body - Side Window Chipping Information > Page 15222 Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Window Glass: > 00-08-48-005D > Sep > 10 > Body - Vehicle Glass Distortion Information Front Door Window Glass: All Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Window Glass: > 06-08-64-001B > Oct > 09 > Body - Side Window Chipping Information Front Door Window Glass: All Technical Service Bulletins Body - Side Window Chipping Information INFORMATION Bulletin No.: 06-08-64-001B Date: October 20, 2009 Subject: Information on Side Door Window Glass Chipping Caused by Hanging Vehicle Key Lock Box Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add vehicles and model years and to include all types of door window glass. Please discard Corporate Bulletin Number 06-08-64-001A (Section 08 - Body & Accessories). - In several warranty parts review cases, side door window glass was observed with a chip or chips on the top side of the window glass. Dealer contacts confirmed that they use a vehicle key lock box on the front side door window glass. - A random selection of side door glass returns will be conducted to confirm adherence. If a side door glass is discovered with a chip or chips in the location previously described, the side door glass will be returned to the dealership for debit. Example of Side Door Glass - DO NOT place a vehicle key lock box on a side door window glass. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Window Glass: > 06-08-64-001B > Oct > 09 > Body - Side Window Chipping Information > Page 15232 Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Window Glass: > Page 15233 Front Door Window Glass: By Symptom Technical Service Bulletin # 07-08-64-019C Date: 110408 Body - Front Door Window Regulator Squeak Noise TECHNICAL Bulletin No.: 07-08-64-019C Date: April 08, 2011 Subject: Front Door Window Regulator Squeak Noise When Operated (Apply Lubricant) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add the 2011 and 2012 model years. Please discard Corporate Bulletin Number 07-08-64-019B (Section 08 - Body and Accessories). Condition Some customers may comment on a front door glass squeak when operated up or down. Cause There may be insufficient lubrication on the regulator rails. Correction Lubricate BOTH front door regulators at time of repair using the following procedure. 1. Remove the regulator following SI procedures. 2. Brush a small amount of lubricant on the entire length of both regulator rails. Refer to the illustration for lubricant location. 3. Cycle the door glass to verify that the noise is gone. 4. Reinstall the regulator following SI procedures. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Window Glass: > Page 15234 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 07-08-64-019C Date: 110408 Body - Front Door Window Regulator Squeak Noise TECHNICAL Bulletin No.: 07-08-64-019C Date: April 08, 2011 Subject: Front Door Window Regulator Squeak Noise When Operated (Apply Lubricant) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add the 2011 and 2012 model years. Please discard Corporate Bulletin Number 07-08-64-019B (Section 08 - Body and Accessories). Condition Some customers may comment on a front door glass squeak when operated up or down. Cause There may be insufficient lubrication on the regulator rails. Correction Lubricate BOTH front door regulators at time of repair using the following procedure. 1. Remove the regulator following SI procedures. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Window Glass: > Page 15235 2. Brush a small amount of lubricant on the entire length of both regulator rails. Refer to the illustration for lubricant location. 3. Cycle the door glass to verify that the noise is gone. 4. Reinstall the regulator following SI procedures. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Technical Service Bulletins > Page 15236 Front Door Window Glass: Service and Repair Front Side Door Window Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor > Component Information > Diagrams Front Door Window Motor: Diagrams Component Connector End Views Window Motor - Driver (A31) Window Motor - Passenger (A31) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor > Component Information > Diagrams > Page 15240 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor > Component Information > Diagrams > Page 15241 Front Door Window Motor: Service and Repair Front Side Door Window Regulator Motor Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Technical Service Bulletins > Customer Interest for Front Door Window Regulator: > 07-08-64-019C > Apr > 11 > Body - Front Door Window Regulator Squeak Noise Front Door Window Regulator: Customer Interest Body - Front Door Window Regulator Squeak Noise TECHNICAL Bulletin No.: 07-08-64-019C Date: April 08, 2011 Subject: Front Door Window Regulator Squeak Noise When Operated (Apply Lubricant) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add the 2011 and 2012 model years. Please discard Corporate Bulletin Number 07-08-64-019B (Section 08 - Body and Accessories). Condition Some customers may comment on a front door glass squeak when operated up or down. Cause There may be insufficient lubrication on the regulator rails. Correction Lubricate BOTH front door regulators at time of repair using the following procedure. 1. Remove the regulator following SI procedures. 2. Brush a small amount of lubricant on the entire length of both regulator rails. Refer to the illustration for lubricant location. 3. Cycle the door glass to verify that the noise is gone. 4. Reinstall the regulator following SI procedures. Parts Information Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Technical Service Bulletins > Customer Interest for Front Door Window Regulator: > 07-08-64-019C > Apr > 11 > Body - Front Door Window Regulator Squeak Noise > Page 15250 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Regulator: > 07-08-64-019C > Apr > 11 > Body - Front Door Window Regulator Squeak Noise Front Door Window Regulator: All Technical Service Bulletins Body - Front Door Window Regulator Squeak Noise TECHNICAL Bulletin No.: 07-08-64-019C Date: April 08, 2011 Subject: Front Door Window Regulator Squeak Noise When Operated (Apply Lubricant) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add the 2011 and 2012 model years. Please discard Corporate Bulletin Number 07-08-64-019B (Section 08 - Body and Accessories). Condition Some customers may comment on a front door glass squeak when operated up or down. Cause There may be insufficient lubrication on the regulator rails. Correction Lubricate BOTH front door regulators at time of repair using the following procedure. 1. Remove the regulator following SI procedures. 2. Brush a small amount of lubricant on the entire length of both regulator rails. Refer to the illustration for lubricant location. 3. Cycle the door glass to verify that the noise is gone. 4. Reinstall the regulator following SI procedures. Parts Information Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Regulator: > 07-08-64-019C > Apr > 11 > Body - Front Door Window Regulator Squeak Noise > Page 15256 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Regulator: > Page 15257 Front Door Window Regulator: By Symptom Technical Service Bulletin # 07-08-64-019C Date: 110408 Body - Front Door Window Regulator Squeak Noise TECHNICAL Bulletin No.: 07-08-64-019C Date: April 08, 2011 Subject: Front Door Window Regulator Squeak Noise When Operated (Apply Lubricant) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add the 2011 and 2012 model years. Please discard Corporate Bulletin Number 07-08-64-019B (Section 08 - Body and Accessories). Condition Some customers may comment on a front door glass squeak when operated up or down. Cause There may be insufficient lubrication on the regulator rails. Correction Lubricate BOTH front door regulators at time of repair using the following procedure. 1. Remove the regulator following SI procedures. 2. Brush a small amount of lubricant on the entire length of both regulator rails. Refer to the illustration for lubricant location. 3. Cycle the door glass to verify that the noise is gone. 4. Reinstall the regulator following SI procedures. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Regulator: > Page 15258 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 07-08-64-019C Date: 110408 Body - Front Door Window Regulator Squeak Noise TECHNICAL Bulletin No.: 07-08-64-019C Date: April 08, 2011 Subject: Front Door Window Regulator Squeak Noise When Operated (Apply Lubricant) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add the 2011 and 2012 model years. Please discard Corporate Bulletin Number 07-08-64-019B (Section 08 - Body and Accessories). Condition Some customers may comment on a front door glass squeak when operated up or down. Cause There may be insufficient lubrication on the regulator rails. Correction Lubricate BOTH front door regulators at time of repair using the following procedure. 1. Remove the regulator following SI procedures. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Regulator: > Page 15259 2. Brush a small amount of lubricant on the entire length of both regulator rails. Refer to the illustration for lubricant location. 3. Cycle the door glass to verify that the noise is gone. 4. Reinstall the regulator following SI procedures. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Door Window Regulator Handle Replacement Front Door Window Regulator: Service and Repair Door Window Regulator Handle Replacement Door Window Regulator Handle Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Door Window Regulator Handle Replacement > Page 15262 Front Door Window Regulator: Service and Repair Front Side Door Window Regulator Replacement (Manual) Front Side Door Window Regulator Replacement (Manual) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Door Window Regulator Handle Replacement > Page 15263 Front Door Window Regulator: Service and Repair Front Side Door Window Regulator Replacement (Power) Front Side Door Window Regulator Replacement (Power) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Exterior Handle: > 09-08-64-032A > Apr > 11 > Body - Chrome Outside Door Handle Loose/Cracked Rear Door Exterior Handle: All Technical Service Bulletins Body - Chrome Outside Door Handle Loose/Cracked TECHNICAL Bulletin No.: 09-08-64-032A Date: April 18, 2011 Subject: Chrome Outside Door Handle Loose/Cracked at Attachment Screw (Replace Handle) Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add model years, update the Parts Information and add a Caution. Please discard Corporate Bulletin Number 09-08-64-032 (Section 08 - Body and Accessories). Condition Some customers may comment that a chrome outside door handle is loose or cracked in the area of the attachment screws. Cause For 2007 and 2008 models, this condition may be caused by grease used on the attachment screws during the assembly process, which can migrate into the handle screw bosses and cause degradation. Among other contributing factors to this condition is that the initial assembly torque of the attachment screws was too high, which may have helped initiate cracks in the screw bosses. Correction Important When replacing a chrome outside door handle for this condition, be sure to address the following: - Ensure that the attachment screws are free from grease before installing the new handle. Clean the screws with Kent Automotive Acrysol(TM) P/N 20005, or an equivalent grease removing body solvent. - Torque the screws to 6 Nm (53 lb in). Caution Exceeding the recommended screw torque of 6 Nm (53 lb in) could result in the thread insert pulling out of the handle base, as shown in the graphic above. Replace the affected chrome outside door handle. Refer to Front Side Door Outside Handle Replacement, Rear Side Door Outside Handle Replacement, or Rear Side Door Outside Handle Replacement (Crew Cab) in SI. Parts Information Acrysol(TM) is available from Kent Automotive at 1-888-YES-KENT or online at www.kent-automotive.com. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Exterior Handle: > 09-08-64-032A > Apr > 11 > Body - Chrome Outside Door Handle Loose/Cracked > Page 15274 Warranty Information For vehicles repaired under warranty, use the appropriate labor operation found in the Labor Time Guide (LTG). Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Technical Service Bulletins > Customer Interest: > 09-08-64-032A > Apr > 11 > Body - Chrome Outside Door Handle Loose/Cracked Rear Door Exterior Handle: Customer Interest Body - Chrome Outside Door Handle Loose/Cracked TECHNICAL Bulletin No.: 09-08-64-032A Date: April 18, 2011 Subject: Chrome Outside Door Handle Loose/Cracked at Attachment Screw (Replace Handle) Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add model years, update the Parts Information and add a Caution. Please discard Corporate Bulletin Number 09-08-64-032 (Section 08 - Body and Accessories). Condition Some customers may comment that a chrome outside door handle is loose or cracked in the area of the attachment screws. Cause For 2007 and 2008 models, this condition may be caused by grease used on the attachment screws during the assembly process, which can migrate into the handle screw bosses and cause degradation. Among other contributing factors to this condition is that the initial assembly torque of the attachment screws was too high, which may have helped initiate cracks in the screw bosses. Correction Important When replacing a chrome outside door handle for this condition, be sure to address the following: - Ensure that the attachment screws are free from grease before installing the new handle. Clean the screws with Kent Automotive Acrysol(TM) P/N 20005, or an equivalent grease removing body solvent. - Torque the screws to 6 Nm (53 lb in). Caution Exceeding the recommended screw torque of 6 Nm (53 lb in) could result in the thread insert pulling out of the handle base, as shown in the graphic above. Replace the affected chrome outside door handle. Refer to Front Side Door Outside Handle Replacement, Rear Side Door Outside Handle Replacement, or Rear Side Door Outside Handle Replacement (Crew Cab) in SI. Parts Information Acrysol(TM) is available from Kent Automotive at 1-888-YES-KENT or online at www.kent-automotive.com. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Technical Service Bulletins > Customer Interest: > 09-08-64-032A > Apr > 11 > Body - Chrome Outside Door Handle Loose/Cracked > Page 15280 Warranty Information For vehicles repaired under warranty, use the appropriate labor operation found in the Labor Time Guide (LTG). Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Technical Service Bulletins > Customer Interest: > Page 15281 Rear Door Exterior Handle: By Symptom Technical Service Bulletin # 09-08-64-032A Date: 110418 Body - Chrome Outside Door Handle Loose/Cracked TECHNICAL Bulletin No.: 09-08-64-032A Date: April 18, 2011 Subject: Chrome Outside Door Handle Loose/Cracked at Attachment Screw (Replace Handle) Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add model years, update the Parts Information and add a Caution. Please discard Corporate Bulletin Number 09-08-64-032 (Section 08 - Body and Accessories). Condition Some customers may comment that a chrome outside door handle is loose or cracked in the area of the attachment screws. Cause For 2007 and 2008 models, this condition may be caused by grease used on the attachment screws during the assembly process, which can migrate into the handle screw bosses and cause degradation. Among other contributing factors to this condition is that the initial assembly torque of the attachment screws was too high, which may have helped initiate cracks in the screw bosses. Correction Important When replacing a chrome outside door handle for this condition, be sure to address the following: - Ensure that the attachment screws are free from grease before installing the new handle. Clean the screws with Kent Automotive Acrysol(TM) P/N 20005, or an equivalent grease removing body solvent. - Torque the screws to 6 Nm (53 lb in). Caution Exceeding the recommended screw torque of 6 Nm (53 lb in) could result in the thread insert pulling out of the handle base, as shown in the graphic above. Replace the affected chrome outside door handle. Refer to Front Side Door Outside Handle Replacement, Rear Side Door Outside Handle Replacement, or Rear Side Door Outside Handle Replacement (Crew Cab) in SI. Parts Information Acrysol(TM) is available from Kent Automotive at 1-888-YES-KENT or online at www.kent-automotive.com. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Technical Service Bulletins > Customer Interest: > Page 15282 Warranty Information For vehicles repaired under warranty, use the appropriate labor operation found in the Labor Time Guide (LTG). Disclaimer Technical Service Bulletin # 09-08-64-032A Date: 110418 Body - Chrome Outside Door Handle Loose/Cracked TECHNICAL Bulletin No.: 09-08-64-032A Date: April 18, 2011 Subject: Chrome Outside Door Handle Loose/Cracked at Attachment Screw (Replace Handle) Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add model years, update the Parts Information and add a Caution. Please discard Corporate Bulletin Number 09-08-64-032 (Section 08 - Body and Accessories). Condition Some customers may comment that a chrome outside door handle is loose or cracked in the area of the attachment screws. Cause For 2007 and 2008 models, this condition may be caused by grease used on the attachment screws during the assembly process, which can migrate into the handle screw bosses and cause degradation. Among other contributing factors to this condition is that the initial assembly torque of the attachment screws was too high, which may have helped initiate cracks in the screw bosses. Correction Important When replacing a chrome outside door handle for this condition, be sure to address the following: - Ensure that the attachment screws are free from grease before installing the new handle. Clean the screws with Kent Automotive Acrysol(TM) P/N 20005, or an equivalent grease removing body solvent. - Torque the screws to 6 Nm (53 lb in). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Technical Service Bulletins > Customer Interest: > Page 15283 Caution Exceeding the recommended screw torque of 6 Nm (53 lb in) could result in the thread insert pulling out of the handle base, as shown in the graphic above. Replace the affected chrome outside door handle. Refer to Front Side Door Outside Handle Replacement, Rear Side Door Outside Handle Replacement, or Rear Side Door Outside Handle Replacement (Crew Cab) in SI. Parts Information Acrysol(TM) is available from Kent Automotive at 1-888-YES-KENT or online at www.kent-automotive.com. Warranty Information For vehicles repaired under warranty, use the appropriate labor operation found in the Labor Time Guide (LTG). Disclaimer Technical Service Bulletin # 09-08-64-032A Date: 110418 Body - Chrome Outside Door Handle Loose/Cracked TECHNICAL Bulletin No.: 09-08-64-032A Date: April 18, 2011 Subject: Chrome Outside Door Handle Loose/Cracked at Attachment Screw (Replace Handle) Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add model years, update the Parts Information and add a Caution. Please discard Corporate Bulletin Number 09-08-64-032 (Section 08 - Body and Accessories). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Technical Service Bulletins > Customer Interest: > Page 15284 Condition Some customers may comment that a chrome outside door handle is loose or cracked in the area of the attachment screws. Cause For 2007 and 2008 models, this condition may be caused by grease used on the attachment screws during the assembly process, which can migrate into the handle screw bosses and cause degradation. Among other contributing factors to this condition is that the initial assembly torque of the attachment screws was too high, which may have helped initiate cracks in the screw bosses. Correction Important When replacing a chrome outside door handle for this condition, be sure to address the following: - Ensure that the attachment screws are free from grease before installing the new handle. Clean the screws with Kent Automotive Acrysol(TM) P/N 20005, or an equivalent grease removing body solvent. - Torque the screws to 6 Nm (53 lb in). Caution Exceeding the recommended screw torque of 6 Nm (53 lb in) could result in the thread insert pulling out of the handle base, as shown in the graphic above. Replace the affected chrome outside door handle. Refer to Front Side Door Outside Handle Replacement, Rear Side Door Outside Handle Replacement, or Rear Side Door Outside Handle Replacement (Crew Cab) in SI. Parts Information Acrysol(TM) is available from Kent Automotive at 1-888-YES-KENT or online at www.kent-automotive.com. Warranty Information For vehicles repaired under warranty, use the appropriate labor operation found in the Labor Time Guide (LTG). Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Technical Service Bulletins > All Other Service Bulletins for Rear Door Exterior Handle: > 08-08-67-006B > Apr > 11 > Body - Headliner Wet/Water Leak Into Cab Past Sunroof Sunroof / Moonroof Weatherstrip: All Technical Service Bulletins Body - Headliner Wet/Water Leak Into Cab Past Sunroof TECHNICAL Bulletin No.: 08-08-67-006B Date: April 11, 2011 Subject: Headliner Wet, Water Leak into Cab, Water Leak Past Sunroof Glass Weatherstrip/Seal (Inspect Sunroof Weatherstrip/Seal and Replace if Necessary) Models: 2007-2012 Chevrolet Silverado Crew Cab Models 2007-2012 GMC Sierra Crew Cab Models with Sunroof (RPO CF5) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 08-08-67-006A (Section 08 - Body and Accessories). Condition Some customers may comment on the headliner being wet or water leaking into the cab. Cause The sunroof glass weatherstrip/seal may not be completely water tight. The weatherstrip/seal may not be properly secured to the glass panel. Correction Important DO NOT replace the sunroof glass panel. Technicians are to inspect the glass panel seal appearance at the corners and around the glass panel. If the weatherstrip/seal looks depressed or concave in the middle, as shown above, replace the seal. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Technical Service Bulletins > All Other Service Bulletins for Rear Door Exterior Handle: > 08-08-67-006B > Apr > 11 > Body - Headliner Wet/Water Leak Into Cab Past Sunroof > Page 15290 Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Service and Repair > Rear Side Door Outside Handle Replacement (Crew Cab) Rear Door Exterior Handle: Service and Repair Rear Side Door Outside Handle Replacement (Crew Cab) Rear Side Door Outside Handle Replacement (Crew Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Service and Repair > Rear Side Door Outside Handle Replacement (Crew Cab) > Page 15293 Rear Door Exterior Handle: Service and Repair Rear Side Door Outside Handle Replacement (Extended Cab) Rear Side Door Outside Handle Replacement (Extended Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Service and Repair > Rear Side Door Inside Handle Replacement (with SLT) Rear Door Interior Handle: Service and Repair Rear Side Door Inside Handle Replacement (with SLT) Rear Side Door Inside Handle Replacement (with SLT) Removal Procedure 1. Pull the door trim panel away from the door and support the bottom of the trim panel on the door panel hooks. Refer to Rear Side Door Trim Panel Replacement (SLT) (See: Rear Door Panel/Service and Repair/Rear Side Door Trim Panel Replacement (SLT))Rear Side Door Trim Panel Replacement (YE9) (See: Rear Door Panel/Service and Repair/Rear Side Door Trim Panel Replacement (YE9)). 2. Remove the rear side door inside handle fasteners (1). 3. Remove the rear side door inside handle fasteners assembly (2). 1. Disconnect the electrical connector. 2. Depress both tabs to remove the rear side door cable and pull the cable rearward out of the handle assembly. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Service and Repair > Rear Side Door Inside Handle Replacement (with SLT) > Page 15298 Installation Procedure 1. Connect the rear side door cable. Ensure the cable is fully seated past the guide tab. 2. Slide the rear side door inside handle assembly into place (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the rear side door inside handle fasteners and tighten to 2 Nm (18 lb in). 4. Install the door trim panel. Refer to Rear Side Door Trim Panel Replacement (SLT) (See: Rear Door Panel/Service and Repair/Rear Side Door Trim Panel Replacement (SLT))Rear Side Door Trim Panel Replacement (YE9) (See: Rear Door Panel/Service and Repair/Rear Side Door Trim Panel Replacement (YE9)). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Service and Repair > Rear Side Door Inside Handle Replacement (with SLT) > Page 15299 Rear Door Interior Handle: Service and Repair Rear Side Door Inside Handle Replacement (without SLT) Rear Side Door Inside Handle Replacement (without SLT) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Service and Repair > Rear Side Door Hinge Cover Replacement Rear Door Hinge: Service and Repair Rear Side Door Hinge Cover Replacement Rear Side Door Hinge Cover Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Service and Repair > Rear Side Door Hinge Cover Replacement > Page 15304 Rear Door Hinge: Service and Repair Rear Side Door Upper Hinge and Lower Hinge Replacement (Crew Cab) Rear Side Door Upper Hinge and Lower Hinge Replacement (Crew Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Service and Repair > Rear Side Door Hinge Cover Replacement > Page 15305 Rear Door Hinge: Service and Repair Rear Side Door Upper Hinge and Lower Hinge Replacement (Extended Cab) Rear Side Door Upper Hinge and Lower Hinge Replacement (Extended Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Service and Repair > Rear Side Door Hinge Cover Replacement > Page 15306 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Diagrams Rear Door Latch: Diagrams Component Connector End Views Door Latch - Driver (AU3) Door Latch - Driver (except AU3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Diagrams > Page 15310 Door Latch - Left Rear (Crew Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Diagrams > Page 15311 Door Latch - Passenger Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Diagrams > Page 15312 Door Latch - Right Rear (Crew Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Diagrams > Page 15313 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Rear Side Door Window Switch Bezel Replacement (Crew Cab) Rear Door Panel: Service and Repair Rear Side Door Window Switch Bezel Replacement (Crew Cab) Rear Side Door Window Switch Bezel Replacement (Crew Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Rear Side Door Window Switch Bezel Replacement (Crew Cab) > Page 15318 Rear Door Panel: Service and Repair Rear Side Door Window Switch Bezel Replacement (Extended Cab) Rear Side Door Window Switch Bezel Replacement (Extended Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Rear Side Door Window Switch Bezel Replacement (Crew Cab) > Page 15319 Rear Door Panel: Service and Repair Rear Side Door Trim Panel Replacement (SLT) Rear Side Door Trim Panel Replacement (SLT) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Rear Side Door Window Switch Bezel Replacement (Crew Cab) > Page 15320 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Rear Side Door Window Switch Bezel Replacement (Crew Cab) > Page 15321 Rear Door Panel: Service and Repair Rear Side Door Trim Panel Replacement (YE9) Rear Side Door Trim Panel Replacement (YE9) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Rear Side Door Window Switch Bezel Replacement (Crew Cab) > Page 15322 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Rear Side Door Window Switch Bezel Replacement (Crew Cab) > Page 15323 Rear Door Panel: Service and Repair Rear Side Door Window Switch Bezel Replacement (Crew Cab) Rear Side Door Window Switch Bezel Replacement (Crew Cab) Rear Side Door Window Switch Bezel Replacement (Extended Cab) Rear Side Door Window Switch Bezel Replacement (Extended Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Rear Side Door Window Switch Bezel Replacement (Crew Cab) > Page 15324 Rear Side Door Trim Panel Replacement (SLT) Rear Side Door Trim Panel Replacement (SLT) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Rear Side Door Window Switch Bezel Replacement (Crew Cab) > Page 15325 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Rear Side Door Window Switch Bezel Replacement (Crew Cab) > Page 15326 Rear Side Door Trim Panel Replacement (YE9) Rear Side Door Trim Panel Replacement (YE9) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Rear Side Door Window Switch Bezel Replacement (Crew Cab) > Page 15327 Rear Side Access Door Trim Panel Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Rear Side Door Window Switch Bezel Replacement (Crew Cab) > Page 15328 Rear Side Access Door Trim Panel Replacement Rear Side Door Water Deflector Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Rear Side Door Window Switch Bezel Replacement (Crew Cab) > Page 15329 Rear Side Door Water Deflector Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Striker > System Information > Adjustments Rear Door Striker: Adjustments Door Lock Striker Adjustment To determine if striker adjustment is required, proceed as follows: 1. Make certain the door is properly aligned within the door opening before proceeding with the striker adjustment. 2. Close the door onto the striker and note if the door drags on the striker causing the door to move upward or downward upon contact with the striker. Also note the closing effort to fully engage the latch. 3. Using a soft marker, mark around the striker for reference of the original position. Loosen the striker. 4. Move the striker to eliminate drag on the striker and door latch and to achieve the proper door position within the door opening. Start with the up/down position, then position the striker to achieve proper alignment to the door opening. Set the in/out adjustment for the proper door seal engagement making sure the door closing efforts are correct. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Tighten the striker-to-body bolts to 27 Nm (20 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Striker > System Information > Adjustments > Page 15333 Rear Door Striker: Service and Repair Door Striker Replacement (Crew Cab) Removal Procedure Note: If both of the door striker bolts are removed at the same time, the striker backing plate will fall into the body. This will result in additional time to perform the repair. 1. Remove the lower striker bolt. 2. Loosen the upper striker bolt enough in order to rotate the striker and the spacer, if equipped, away from the lower bolt hole. 3. Install the lower striker bolt. Tighten the lower striker bolt sufficiently in order to hold the striker backing plate in place. 4. Remove the upper striker bolt (1). 5. Remove the spacer, if equipped. 6. Remove the striker (2). Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Striker > System Information > Adjustments > Page 15334 1. Install the striker. 2. Install the spacer, if equipped. 3. Install the upper striker bolt (1). 4. If the striker backing plate has moved, rotate the lower striker bolt until the upper threaded hole is properly aligned. 5. Remove the lower bolt. 6. Rotate the striker (2) and the spacer, if equipped, in order to align the lower threaded hole in the striker backing plate. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 7. Tighten the striker bolts. Tighten the door striker bolts to 24 Nm (18 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Weatherstrip: > 09-08-64-012C > Nov > 10 > Body - Side Door Body Mounted Weatherstrip Replacement Rear Door Weatherstrip: All Technical Service Bulletins Body - Side Door Body Mounted Weatherstrip Replacement INFORMATION Bulletin No.: 09-08-64-012C Date: November 22, 2010 Subject: Information on Side Door Body Mounted Primary Weatherstrip Replacement Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to communicate feedback received from engineering information and add the 2011 model year. Please discard Corporate Bulletin Number 09-08-64-012B (Section 08 - Body and Accessories). Some customers may comment about side door wind noise, water leaks or door fit concerns. These concerns may appear to be related to the body mounted primary door opening weatherstrips. As a result of feedback received from engineering information, we have found that many replacements of the primary door opening weatherstrip are for issues not related to the primary door opening weatherstrip. The instructions below are a guide to help "root cause" the customer's concern and obtain the proper direction for repair. Recommendation Note: If the seal is properly installed, it will not cause a Windnoise. If mis-installed, the seal could create a Windnoise that can be corrected by re-installing the seal. If the condition is for Windnoise, please view the training courses on this subject and follow the proper diagnostics outlined in courses 10210.01D 2010 SKH Seminar Jan Emerging Issues,.02D (Feb),.03D (March) (3 Parts) (Emerging Issues programs available to U.S. dealers only). If the condition is specific to an itch noise, refer to Corporate Bulletin Number 06-08-64-035F to correct that concern. If diagnosing a water leak, please follow information supplied in Corporate Bulletin Number 09-08-57-002B. For door fit concerns, or if the seal is loose or exhibits a poor appearance, inspect for even retention around the door. If the seal pulls off too easily, the channel crimp may be wide/loose as shown between the dashed lines in the graphic above. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Weatherstrip: > 09-08-64-012C > Nov > 10 > Body - Side Door Body Mounted Weatherstrip Replacement > Page 15343 Remove the seal only in the affected area. Inspect the seal's channel crimp and adjust accordingly by pinching the channel together for a tighter retention. Reinstall the portion of the seal that was removed. Warranty Information For vehicles repaired under warranty, use the appropriate labor operation found in the Labor Time Guide (LTG). Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Weatherstrip: > 06-08-64-035G > Jun > 10 > Body - Squeak/Itching Noise in Upper Door Area Rear Door Weatherstrip: All Technical Service Bulletins Body - Squeak/Itching Noise in Upper Door Area TECHNICAL Bulletin No.: 06-08-64-035G Date: June 01, 2010 Subject: Squeak/Itching Noise in Upper Door Area (Replace Weatherstrip Assembly) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to update parts description information. Please discard Corporate Bulletin Number 06-08-64-035F (Section 08 - Body and Accessories). Condition Some customers may comment on a squeaking or itching noise in the upper door area when driving. Cause This condition may be caused by the roof drip weatherstrip to door frame contact. This could occur at any or all of the doors. Correction Replace the weatherstrip assembly. Refer to Door Opening Weatherstrip Replacement in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the appropriate labor operation from the Labor Time Guide. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Rear Door Weatherstrip: > 09-08-64-012C > Nov > 10 > Body - Side Door Body Mounted Weatherstrip Replacement Rear Door Weatherstrip: Customer Interest Body - Side Door Body Mounted Weatherstrip Replacement INFORMATION Bulletin No.: 09-08-64-012C Date: November 22, 2010 Subject: Information on Side Door Body Mounted Primary Weatherstrip Replacement Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to communicate feedback received from engineering information and add the 2011 model year. Please discard Corporate Bulletin Number 09-08-64-012B (Section 08 - Body and Accessories). Some customers may comment about side door wind noise, water leaks or door fit concerns. These concerns may appear to be related to the body mounted primary door opening weatherstrips. As a result of feedback received from engineering information, we have found that many replacements of the primary door opening weatherstrip are for issues not related to the primary door opening weatherstrip. The instructions below are a guide to help "root cause" the customer's concern and obtain the proper direction for repair. Recommendation Note: If the seal is properly installed, it will not cause a Windnoise. If mis-installed, the seal could create a Windnoise that can be corrected by re-installing the seal. If the condition is for Windnoise, please view the training courses on this subject and follow the proper diagnostics outlined in courses 10210.01D 2010 SKH Seminar Jan Emerging Issues,.02D (Feb),.03D (March) (3 Parts) (Emerging Issues programs available to U.S. dealers only). If the condition is specific to an itch noise, refer to Corporate Bulletin Number 06-08-64-035F to correct that concern. If diagnosing a water leak, please follow information supplied in Corporate Bulletin Number 09-08-57-002B. For door fit concerns, or if the seal is loose or exhibits a poor appearance, inspect for even retention around the door. If the seal pulls off too easily, the channel crimp may be wide/loose as shown between the dashed lines in the graphic above. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Rear Door Weatherstrip: > 09-08-64-012C > Nov > 10 > Body - Side Door Body Mounted Weatherstrip Replacement > Page 15353 Remove the seal only in the affected area. Inspect the seal's channel crimp and adjust accordingly by pinching the channel together for a tighter retention. Reinstall the portion of the seal that was removed. Warranty Information For vehicles repaired under warranty, use the appropriate labor operation found in the Labor Time Guide (LTG). Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Rear Door Weatherstrip: > 06-08-64-035G > Jun > 10 > Body - Squeak/Itching Noise in Upper Door Area Rear Door Weatherstrip: Customer Interest Body - Squeak/Itching Noise in Upper Door Area TECHNICAL Bulletin No.: 06-08-64-035G Date: June 01, 2010 Subject: Squeak/Itching Noise in Upper Door Area (Replace Weatherstrip Assembly) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to update parts description information. Please discard Corporate Bulletin Number 06-08-64-035F (Section 08 - Body and Accessories). Condition Some customers may comment on a squeaking or itching noise in the upper door area when driving. Cause This condition may be caused by the roof drip weatherstrip to door frame contact. This could occur at any or all of the doors. Correction Replace the weatherstrip assembly. Refer to Door Opening Weatherstrip Replacement in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the appropriate labor operation from the Labor Time Guide. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement (Crew Cab) Rear Door Weatherstrip: Service and Repair Rear Door Opening Weatherstrip Replacement (Crew Cab) Rear Door Opening Weatherstrip Replacement (Crew Cab) Removal Procedure 1. Remove the rear door sill plate. Refer to Rear Side Door Sill Trim Plate Replacement (Crew Cab) (See: Interior Moulding / Trim/Scuff Plate/Service and Repair/Rear Side Door Sill Trim Plate Replacement (Crew Cab))Rear Side Door Sill Trim Plate Replacement (Extended Cab) ( See: Interior Moulding / Trim/Scuff Plate/Service and Repair/Rear Side Door Sill Trim Plate Replacement (Extended Cab)). 2. Remove the weatherstrip from the pinch-weld flange. Installation Procedure 1. Align the weatherstrip to the door opening with the 2 dots positioned on the upper right and left side. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement (Crew Cab) > Page 15360 2. Align the weatherstrip to the door opening with the bond joint positioned at the lower center of the door opening. 3. Install the weatherstrip to the pinch-weld flange. Ensure that the weatherstrip is fully seated. 4. Install the rear door sill plate. Refer to Rear Side Door Sill Trim Plate Replacement (Crew Cab) (See: Interior Moulding / Trim/Scuff Plate/Service and Repair/Rear Side Door Sill Trim Plate Replacement (Crew Cab))Rear Side Door Sill Trim Plate Replacement (Extended Cab) ( See: Interior Moulding / Trim/Scuff Plate/Service and Repair/Rear Side Door Sill Trim Plate Replacement (Extended Cab)). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement (Crew Cab) > Page 15361 Rear Door Weatherstrip: Service and Repair Rear Side Door Bottom Auxiliary Sealing Strip Replacement (Crew Cab) Rear Side Door Bottom Auxiliary Sealing Strip Replacement (Crew Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement (Crew Cab) > Page 15362 Rear Door Weatherstrip: Service and Repair Rear Side Door Bottom Auxiliary Sealing Strip Replacement (Extended Cab) Rear Side Door Bottom Auxiliary Sealing Strip Replacement (Extended Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement (Crew Cab) > Page 15363 Rear Door Weatherstrip: Service and Repair Rear Side Door Front Auxiliary Weatherstrip Replacement (Crew Cab) Rear Side Door Front Auxiliary Weatherstrip Replacement (Crew Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement (Crew Cab) > Page 15364 Rear Door Weatherstrip: Service and Repair Rear Door Opening Weatherstrip Replacement (Crew Cab) Rear Door Opening Weatherstrip Replacement (Crew Cab) Removal Procedure 1. Remove the rear door sill plate. Refer to Rear Side Door Sill Trim Plate Replacement (Crew Cab) (See: Interior Moulding / Trim/Scuff Plate/Service and Repair/Rear Side Door Sill Trim Plate Replacement (Crew Cab))Rear Side Door Sill Trim Plate Replacement (Extended Cab) ( See: Interior Moulding / Trim/Scuff Plate/Service and Repair/Rear Side Door Sill Trim Plate Replacement (Extended Cab)). 2. Remove the weatherstrip from the pinch-weld flange. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement (Crew Cab) > Page 15365 1. Align the weatherstrip to the door opening with the 2 dots positioned on the upper right and left side. 2. Align the weatherstrip to the door opening with the bond joint positioned at the lower center of the door opening. 3. Install the weatherstrip to the pinch-weld flange. Ensure that the weatherstrip is fully seated. 4. Install the rear door sill plate. Refer to Rear Side Door Sill Trim Plate Replacement (Crew Cab) (See: Interior Moulding / Trim/Scuff Plate/Service and Repair/Rear Side Door Sill Trim Plate Replacement (Crew Cab))Rear Side Door Sill Trim Plate Replacement (Extended Cab) ( See: Interior Moulding / Trim/Scuff Plate/Service and Repair/Rear Side Door Sill Trim Plate Replacement (Extended Cab)). Rear Side Door Bottom Auxiliary Sealing Strip Replacement (Crew Cab) Rear Side Door Bottom Auxiliary Sealing Strip Replacement (Crew Cab) Rear Side Door Bottom Auxiliary Sealing Strip Replacement (Extended Cab) Rear Side Door Bottom Auxiliary Sealing Strip Replacement (Extended Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement (Crew Cab) > Page 15366 Rear Side Door Front Auxiliary Weatherstrip Replacement (Crew Cab) Rear Side Door Front Auxiliary Weatherstrip Replacement (Crew Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement (Crew Cab) > Page 15367 Rear Side Door Front Auxiliary Weatherstrip Replacement (Extended Cab) Rear Side Door Front Auxiliary Weatherstrip Replacement (Extended Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement (Crew Cab) > Page 15368 Rear Side Door Window Weatherstrip Replacement (Crew Cab) Rear Side Door Window Weatherstrip Replacement (Crew Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement (Crew Cab) > Page 15369 Rear Side Door Window Weatherstrip Replacement (Extended Cab) Rear Side Door Window Weatherstrip Replacement (Extended Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement (Crew Cab) > Page 15370 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > System Information > Service and Repair > Rear Side Door Window Replacement (Crew Cab) Rear Door Window Glass: Service and Repair Rear Side Door Window Replacement (Crew Cab) Rear Side Door Window Replacement (Crew Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > System Information > Service and Repair > Rear Side Door Window Replacement (Crew Cab) > Page 15375 Rear Door Window Glass: Service and Repair Rear Side Door Window Replacement (Extended Cab) Rear Side Door Window Replacement (Extended Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor > Component Information > Diagrams Rear Door Window Motor: Diagrams Component Connector End Views Window Motor - Left Rear (Crew Cab with A31 or Extended Cab with ABV) Window Motor - Right Rear (Crew Cab with A31 or Extended Cab with ABV) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor > Component Information > Diagrams > Page 15379 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor > Component Information > Service and Repair > Rear Side Door Window Regulator Motor Replacement (Crew Cab) Rear Door Window Motor: Service and Repair Rear Side Door Window Regulator Motor Replacement (Crew Cab) Rear Side Door Window Regulator Motor Replacement (Crew Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor > Component Information > Service and Repair > Rear Side Door Window Regulator Motor Replacement (Crew Cab) > Page 15382 Rear Door Window Motor: Service and Repair Rear Side Door Window Regulator Motor Replacement (Extended Cab) Rear Side Door Window Regulator Motor Replacement (Extended Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair > Rear Side Door Window Regulator Replacement (Crew Cab, Manual) Rear Door Window Regulator: Service and Repair Rear Side Door Window Regulator Replacement (Crew Cab, Manual) Rear Side Door Window Regulator Replacement (Crew Cab, Manual) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair > Rear Side Door Window Regulator Replacement (Crew Cab, Manual) > Page 15387 Rear Door Window Regulator: Service and Repair Rear Side Door Window Regulator Replacement (Crew Cab, Power) Rear Side Door Window Regulator Replacement (Crew Cab, Power) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair > Rear Side Door Window Regulator Replacement (Crew Cab, Manual) > Page 15388 Rear Door Window Regulator: Service and Repair Rear Side Door Window Regulator Replacement (Extended Cab, Power) Rear Side Door Window Regulator Replacement (Extended Cab, Power) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Component Information > Service and Repair Fuel Door: Service and Repair Fuel Tank Filler Door Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Hinge > Component Information > Service and Repair > Hood Link Replacement Hood Hinge: Service and Repair Hood Link Replacement Hood Link Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Hinge > Component Information > Service and Repair > Hood Link Replacement > Page 15397 Hood Hinge: Service and Repair Hood Hinge Replacement Hood Hinge Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Hinge > Component Information > Service and Repair > Hood Link Replacement > Page 15398 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Insulator / Pad > Component Information > Service and Repair Hood Insulator / Pad: Service and Repair Hood Insulator Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Service and Repair Hood Latch: Service and Repair Hood Primary and Secondary Latch Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release Cable > Component Information > Service and Repair > Hood Primary Latch Release Cable Replacement Hood Latch Release Cable: Service and Repair Hood Primary Latch Release Cable Replacement Hood Primary Latch Release Cable Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release Cable > Component Information > Service and Repair > Hood Primary Latch Release Cable Replacement > Page 15409 Hood Latch Release Cable: Service and Repair Hood Primary Latch Release Cable Handle Replacement Hood Primary Latch Release Cable Handle Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Shock / Support > Component Information > Service and Repair > Hood Open Assist Spring Replacement Hood Shock / Support: Service and Repair Hood Open Assist Spring Replacement Hood Open Assist Spring Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Shock / Support > Component Information > Service and Repair > Hood Open Assist Spring Replacement > Page 15414 Hood Shock / Support: Service and Repair Hood Strut Replacement Hood Strut Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Stop > Component Information > Service and Repair > Hood Stop Bracket Replacement Hood Stop: Service and Repair Hood Stop Bracket Replacement Hood Stop Bracket Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Stop > Component Information > Service and Repair > Hood Stop Bracket Replacement > Page 15419 Hood Stop: Service and Repair Hood Stop Bumper Bracket Replacement Hood Stop Bumper Bracket Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Stop > Component Information > Service and Repair > Hood Stop Bracket Replacement > Page 15420 Hood Stop: Service and Repair Hood Bumper Replacement Hood Bumper Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Diagrams Hood Sensor/Switch (For Alarm): Diagrams Component Connector End Views Hood Ajar Switch (AP3, AP8 or PTO) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Weatherstrip > Component Information > Service and Repair > Hood Front Seal Replacement Hood Weatherstrip: Service and Repair Hood Front Seal Replacement Hood Front Seal Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Weatherstrip > Component Information > Service and Repair > Hood Front Seal Replacement > Page 15429 Hood Weatherstrip: Service and Repair Hood Rear Seal Replacement Hood Rear Seal Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Service and Repair Trunk / Liftgate Lock Cylinder: Service and Repair Lock Cylinder Binding In many cases, applying the proper lubrication can correct the following conditions: * Binding or sticking door lock cylinders * Difficulty in inserting and removing the keys For lubricating the above components, use lubricant GM P/N 12346241 or equivalent. Do not use penetrating lubricants such as GM P/N 1052949 or WD-40(R). Penetrating lubricants wash out the original lubrication. Penetrating lubricants eventually evaporate, leaving little or no lubricating material. However, when using penetrating lubricants in order to thaw or in order to loosen the lock cylinder components, refer to steps 2-4 in the procedure below for the proper methods of lubrication. Repair lock cylinders frozen in cold weather by using the following procedure: 1. While carefully avoiding damage to the painted surfaces, apply heat to the cylinder with a heat gun. 2. Using a paper clip or a similar item, hold the door shutter open. Force air into the cylinders using compressed air through a blow gun attachment. 3. While holding the shutter door open, inject small amounts of a recommended lubricant into the cylinder. 4. Work the key into the cylinder repeatedly. Wipe away any excess lubrication from the key. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Endgate Emblem/Nameplate Replacement (L71) Body Emblem: Service and Repair Endgate Emblem/Nameplate Replacement (L71) Endgate Emblem/Nameplate Replacement (Z71) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Endgate Emblem/Nameplate Replacement (L71) > Page 15439 Body Emblem: Service and Repair Endgate Emblem/Nameplate Replacement (Silverado) Endgate Emblem/Nameplate Replacement (Silverado) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Endgate Emblem/Nameplate Replacement (L71) > Page 15440 Body Emblem: Service and Repair Endgate Emblem/Nameplate Replacement (LT LS) Endgate Emblem/Nameplate Replacement (LT LS) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Endgate Emblem/Nameplate Replacement (L71) > Page 15441 Body Emblem: Service and Repair Front Side Door Emblem/Nameplate Replacement (GMC Allison Duramax) Front Side Door Emblem/Nameplate Replacement (GMC Allison Duramax) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Endgate Emblem/Nameplate Replacement (L71) > Page 15442 Body Emblem: Service and Repair Endgate Emblem/Nameplate Replacement (L71) Endgate Emblem/Nameplate Replacement (Z71) Endgate Emblem/Nameplate Replacement (Silverado) Endgate Emblem/Nameplate Replacement (Silverado) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Endgate Emblem/Nameplate Replacement (L71) > Page 15443 Endgate Emblem/Nameplate Replacement (LT LS) Endgate Emblem/Nameplate Replacement (LT LS) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Endgate Emblem/Nameplate Replacement (L71) > Page 15444 Front Side Door Emblem/Nameplate Replacement (GMC Allison Duramax) Front Side Door Emblem/Nameplate Replacement (GMC Allison Duramax) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Endgate Emblem/Nameplate Replacement (L71) > Page 15445 Hood Emblem/Nameplate Replacement (Vortec) Hood Emblem/Nameplate Replacement (Vortec) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Endgate Emblem/Nameplate Replacement (L71) > Page 15446 Front Side Door Emblem/Nameplate Replacement (Chevrolet Silverado) Front Side Door Emblem/Nameplate Replacement (Chevrolet Silverado) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Endgate Emblem/Nameplate Replacement (L71) > Page 15447 Endgate Emblem/Nameplate Replacement (Chevrolet) Endgate Emblem/Nameplate Replacement (Chevrolet) Endgate Emblem/Nameplate Replacement (TUF) Endgate Emblem/Nameplate Replacement (TUF) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Endgate Emblem/Nameplate Replacement (L71) > Page 15448 Radiator Grille Emblem/Nameplate Replacement (HD) Radiator Grille Emblem/Nameplate Replacement (Chevrolet HD) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Endgate Emblem/Nameplate Replacement (L71) > Page 15449 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Cowl Moulding / Trim > System Information > Service and Repair Cowl Moulding / Trim: Service and Repair Air Inlet Grille Panel Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Upper Side Moulding / Trim > Component Information > Service and Repair Upper Side Moulding / Trim: Service and Repair Body Panel Paint Protector Replacement (VGC) 1. The paint protective film and vehicle surface temperature should be 13-32°C (55-90°F) for best results. 2. Automatic car washes should be avoided for at least 24 hours after the paint protective film application. 3. Wipe the vehicle surface with isopropyl alcohol or flash naptha at the application area. 4. Dry the surface with a clean lint-free cloth. 5. Create a mixture of 25 percent isopropyl alcohol and 75 percent water and two drops of baby shampoo per 16 oz of fluid mixture. 6. Remove the backing liner from the protective film patch. 7. Use the solution to liberally spray the adhesive side of the protective patch, the mounting location along with your hands. 8. Position the paint protective film patch to the desired location on the vehicle. 9. Spray the surface of the film with the alcohol, water and soap solution. 10. Using a dampened squeegee, start at the center of the protective patch, working outward in order to remove the air and solution from under the protective patch. 11. Release any air bubbles with a pin. 12. Dry the surface with a clean, lint-free cotton cloth. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Windshield Moulding / Trim > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield Moulding / Trim: > 08-08-48-003F > Apr > 11 > Body - Tapping/Clicking/Ticking Noise at Windshield Area Windshield Moulding / Trim: All Technical Service Bulletins Body - Tapping/Clicking/Ticking Noise at Windshield Area TECHNICAL Bulletin No.: 08-08-48-003F Date: April 06, 2011 Subject: Tapping, Clicking or Ticking Noise at Windshield Area (R&R; Right and Left Windshield Side Reveal Moldings to Add Double Sided Tape) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Sierra Denali, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 08-08-48-003E (Section 08 - Body and Accessories). Condition Some customers may comment on hearing a tapping, clicking or ticking noise at the windshield area. This condition occurs more frequently while driving at highway speeds and could be exaggerated on vehicles with front bug guard deflectors. Cause This condition may be caused by air/wind causing the windshield side reveal moldings to move, generating a noise. Correction Remove both windshield reveal moldings, add double-sided tape and re-install the moldings following the steps below: 1. Using tape (1) or a grease pencil, mark the position of the inboard edge (2) of both left and right reveal moldings onto the windshield, following the contour of the molding. 2. Remove the left and right windshield side reveal moldings. Refer to Windshield Side Reveal Molding Replacement in SI. 3. Being careful not to affect the tape or grease pencil marks, clean and prep the glass at the seal interface with Glass Adhesion Promoter, P/N 12378555 (in Canada, use 88901239). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Windshield Moulding / Trim > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield Moulding / Trim: > 08-08-48-003F > Apr > 11 > Body - Tapping/Clicking/Ticking Noise at Windshield Area > Page 15464 4. Apply 3M Automotive Adhesion Promoter 06396, or equivalent, to the underside of the reveal molding seals. Tip An approximate 600 mm (24 in) length of tape should allow for overlap at the top to be trimmed back leaving a tail of release liner (1) and, at minimum, should reach the fender cut line at the bottom. 5. Apply a 600 mm (24 in) length of 3M Automotive Acrylic Plus Attachment Tape 06386 (1.14 mm (0.045 in) thick x 6.35 mm (0.25 in) wide), or equivalent, to both sides of the windshield. Ensure the tape (1) position is centered between the windshield edge (2) and the tape/grease pencil line (3). Do not remove the release lining from the tape yet. 6. Reinstall the reveal molding to one side by sliding the molding downward and ensuring that the top lip is engaged at the upper edge of the windshield. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Windshield Moulding / Trim > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield Moulding / Trim: > 08-08-48-003F > Apr > 11 > Body - Tapping/Clicking/Ticking Noise at Windshield Area > Page 15465 7. Install the fasteners to the reveal molding, starting from the top. Refer to Windshield Side Reveal Molding Replacement in SI. 8. Lifting the top edge of the reveal molding, grab the tail of the release lining and pull downward removing the lining. 9. Press or roll the reveal molding against the windshield ensuring adhesion of the tape to the glass. 10. Repeat steps 6-9 on the opposite side. 11. Remove tape or clean the grease pencil marks from the windshield. 12. If positioned correctly, trimming of the double sided tape should not be necessary, however inspect the reveal moldings for any tape not covered and trim off any exposed tape. Important After taping the windshield reveal moldings, avoid washing the vehicle as well as excessive contact with the windshield reveal moldings for a minimum of 72 hours. Parts Information 3M(TM) products may be purchased through your local distributor. Information about 3M product retailers in your area may be obtained by calling 1-866-364-3577 (U.S. and Canada). Warranty Information Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Windshield Moulding / Trim > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield Moulding / Trim: > 08-08-48-003F > Apr > 11 > Body - Tapping/Clicking/Ticking Noise at Windshield Area > Page 15466 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Windshield Moulding / Trim > Component Information > Technical Service Bulletins > Customer Interest for Windshield Moulding / Trim: > 08-08-48-003F > Apr > 11 > Body - Tapping/Clicking/Ticking Noise at Windshield Area Windshield Moulding / Trim: Customer Interest Body - Tapping/Clicking/Ticking Noise at Windshield Area TECHNICAL Bulletin No.: 08-08-48-003F Date: April 06, 2011 Subject: Tapping, Clicking or Ticking Noise at Windshield Area (R&R; Right and Left Windshield Side Reveal Moldings to Add Double Sided Tape) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Sierra Denali, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 08-08-48-003E (Section 08 - Body and Accessories). Condition Some customers may comment on hearing a tapping, clicking or ticking noise at the windshield area. This condition occurs more frequently while driving at highway speeds and could be exaggerated on vehicles with front bug guard deflectors. Cause This condition may be caused by air/wind causing the windshield side reveal moldings to move, generating a noise. Correction Remove both windshield reveal moldings, add double-sided tape and re-install the moldings following the steps below: 1. Using tape (1) or a grease pencil, mark the position of the inboard edge (2) of both left and right reveal moldings onto the windshield, following the contour of the molding. 2. Remove the left and right windshield side reveal moldings. Refer to Windshield Side Reveal Molding Replacement in SI. 3. Being careful not to affect the tape or grease pencil marks, clean and prep the glass at the seal interface with Glass Adhesion Promoter, P/N 12378555 (in Canada, use 88901239). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Windshield Moulding / Trim > Component Information > Technical Service Bulletins > Customer Interest for Windshield Moulding / Trim: > 08-08-48-003F > Apr > 11 > Body - Tapping/Clicking/Ticking Noise at Windshield Area > Page 15472 4. Apply 3M Automotive Adhesion Promoter 06396, or equivalent, to the underside of the reveal molding seals. Tip An approximate 600 mm (24 in) length of tape should allow for overlap at the top to be trimmed back leaving a tail of release liner (1) and, at minimum, should reach the fender cut line at the bottom. 5. Apply a 600 mm (24 in) length of 3M Automotive Acrylic Plus Attachment Tape 06386 (1.14 mm (0.045 in) thick x 6.35 mm (0.25 in) wide), or equivalent, to both sides of the windshield. Ensure the tape (1) position is centered between the windshield edge (2) and the tape/grease pencil line (3). Do not remove the release lining from the tape yet. 6. Reinstall the reveal molding to one side by sliding the molding downward and ensuring that the top lip is engaged at the upper edge of the windshield. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Windshield Moulding / Trim > Component Information > Technical Service Bulletins > Customer Interest for Windshield Moulding / Trim: > 08-08-48-003F > Apr > 11 > Body - Tapping/Clicking/Ticking Noise at Windshield Area > Page 15473 7. Install the fasteners to the reveal molding, starting from the top. Refer to Windshield Side Reveal Molding Replacement in SI. 8. Lifting the top edge of the reveal molding, grab the tail of the release lining and pull downward removing the lining. 9. Press or roll the reveal molding against the windshield ensuring adhesion of the tape to the glass. 10. Repeat steps 6-9 on the opposite side. 11. Remove tape or clean the grease pencil marks from the windshield. 12. If positioned correctly, trimming of the double sided tape should not be necessary, however inspect the reveal moldings for any tape not covered and trim off any exposed tape. Important After taping the windshield reveal moldings, avoid washing the vehicle as well as excessive contact with the windshield reveal moldings for a minimum of 72 hours. Parts Information 3M(TM) products may be purchased through your local distributor. Information about 3M product retailers in your area may be obtained by calling 1-866-364-3577 (U.S. and Canada). Warranty Information Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Windshield Moulding / Trim > Component Information > Technical Service Bulletins > Customer Interest for Windshield Moulding / Trim: > 08-08-48-003F > Apr > 11 > Body - Tapping/Clicking/Ticking Noise at Windshield Area > Page 15474 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Fender > Front Fender > Front Fender Liner > System Information > Service and Repair > Front Wheelhouse Liner Replacement - Right Side Front Fender Liner: Service and Repair Front Wheelhouse Liner Replacement - Right Side Front Wheelhouse Liner Replacement - Right Side (Chevrolet) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Fender > Front Fender > Front Fender Liner > System Information > Service and Repair > Front Wheelhouse Liner Replacement - Right Side > Page 15481 Front Fender Liner: Service and Repair Front Wheelhouse Liner Replacement - Left Side Front Wheelhouse Liner Replacement - Left Side (Chevrolet) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body / Frame Mount Bushing: > 06-08-61-003F > Apr > 11 > Body/Frame - Underbody Pop/Clunk When Turning Body / Frame Mount Bushing: All Technical Service Bulletins Body/Frame - Underbody Pop/Clunk When Turning TECHNICAL Bulletin No.: 06-08-61-003F Date: April 12, 2011 Subject: Underbody Pop or Clunk Type Noise While Turning or Driving on Uneven Road Surfaces (Install Body Mount Insulator) Models: 2004-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2004-2012 Chevrolet Avalanche, Silverado (Classic), Silverado, Suburban, Tahoe 2004-2012 GMC Sierra (Classic), Sierra Denali (Classic), Sierra, Sierra Denali, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-08-61-003E (Section 08 - Body and Accessories). Condition Some customers may comment on a pop or clunk type noise while turning or driving on uneven road surfaces. This noise can be heard and/or felt at either the driver's or front passenger floor pan area. Cause Under certain conditions, normal movement between the frame and the #1, #2 or #3 body mounts may cause this noise to occur. Diagnosis 1. If the vehicle is equipped with aftermarket (non-GM Accessory) running boards or the running board is mounted using the body mount bolt, remove the running boards prior to test driving the vehicle. This will eliminate the running boards as the possible cause of the noise. 2. Install the J-39570 Chassis Ears to the frame rail at or near the body mounts. 3. Test drive the vehicle to identify which mount is suspect. Correction Install an insulator at the suspect mount(s). The insulator should be installed between the upper portion of the body mount and the frame bracket. The #1 mount is the mount located just under the A-pillar. The #2 mount is the mount located just under the B-pillar. The #3 mount is the mount located just under the C-pillar. Use the procedure listed below. 1. Raise the vehicle on the hoist. It is recommended to use a four-post lift or strap the vehicle frame to the hoist arms. 2. For the left side mounts only, remove the intermediate park brake cable. Perform the following steps: 1. Remove the nut from the park brake equalizer. 2. Remove the intermediate cable from the equalizer. 3. Depress the retaining tabs that secure the park brake cable to the frame. 4. Pull slightly on the cable from the mounting area in order to provide slack for body movement without binding the cable. 3. Remove all of the body mount bolts on the side being repaired. 4. Properly support the body at the body mount area. Caution When you remove the body mount, do NOT separate the frame from the body more than is necessary. Possible personal injury and damage to multiple parts may result. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body / Frame Mount Bushing: > 06-08-61-003F > Apr > 11 > Body/Frame - Underbody Pop/Clunk When Turning > Page 15491 5. Lower the chassis accordingly in order to remove the upper portion of the body mount. 6. Install the new insulator to the bottom of the top portion of the body mount. The picture shows the insulator (1) location after the body mount is reassembled. 7. Install the body mount to the frame bracket. 8. Perform the following procedure before installing the bolts. 1. Clean the bolt threads of all the original thread locking compound. 2. Clean the threads of the bolt with denatured alcohol or equivalent and allow to dry. 3. Apply Threadlocker, GM P/N 89021297 (In Canada, use P/N 10953488). 9. Install the body mount bolts. Tighten For 2003, 2004 and 2005 model year, tighten the bolts to 85 Nm (63 lb ft). Tighten For 2006-2012 model year, tighten the bolts to 100 Nm (74 lb ft). 10. Reinstall the intermediate park brake cable (left side only). Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body / Frame Mount Bushing: > 10-08-61-001A > Feb > 11 > Body - Body Mount Bolt Stripped or Will Not Loosen Body / Frame Mount Bushing: All Technical Service Bulletins Body - Body Mount Bolt Stripped or Will Not Loosen INFORMATION Bulletin No.: 10-08-61-001A Date: February 16, 2011 Subject: Information on Body Mount Bolt Stripped or Will Not Loosen Models: 2010-2011 Chevrolet Silverado 2010-2011 GMC Sierra Supercede: This bulletin is being revised to add Warranty Information. Please discard Corporate Bulletin Number 10-08-61-001 (Section 08 - Body and Accessories). The purpose of this bulletin is to provide guidance to GM dealers when performing repairs that involve the removal of the body mount bolts. Technicians may discover that one of the cab mount bolts won't loosen from the vehicle. The bolt may act like the nut is cross-threaded or no longer secured to the floorpan of the vehicle. The cab mounted cage nut may have bent or broken loose allowing the nut to spin. If the nut is allowed to spin, it may prevent the bolt from loosening. The front cab mount nuts are welded to the body structure and are not involved with this bulletin. The cage nut assembly must be accessed from inside of the vehicle if this condition occurs. Some of the cage nuts have rectangular access plates in the floor of the passenger compartment. These plates are located above the affected bolt. On extended cab vehicles it is necessary to create access holes in the rear floor area to reach the rear cage nut. Creating Access Hole (Extended Cab Vehicles Only) Use the following steps to create an access hole in the rear floor area of extended cab vehicles. This procedure only applies to the rear set of mounting bolts. Note This procedure below is for the left side of the vehicle. The procedure and measurements are the same for both the left and right side procedures. 1. Remove the seat located above the affected bolt. Refer to Rear Seat Replacement in SI. 2. Partially remove (pull back) the floor covering (carpet) to expose the seat mounting stud area of the floor. 3. Apply masking tape to the repair area as shown. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body / Frame Mount Bushing: > 10-08-61-001A > Feb > 11 > Body - Body Mount Bolt Stripped or Will Not Loosen > Page 15496 4. Using a straight edge, create a line along the inboard side of the seat mounting studs as shown. 5. Measure and mark as shown (A), 10 mm (3/8 in). 6. Find the center point between the two mounting studs as shown. Create a second mark as shown. 7. Use a center punch to create a mark in the sheet metal. 8. Using a 1-1/2 in. hole saw, create an access hole as shown. 9. Service the cab mounting bolt and nut as required. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body / Frame Mount Bushing: > 10-08-61-001A > Feb > 11 > Body - Body Mount Bolt Stripped or Will Not Loosen > Page 15497 10. Coat the perimeter of the access hole with RTV Silicone Sealant, GM P/N 12378521 (in Canada, 88901148) or equivalent, to seal the bare edge of the metal. 11. Install the round body plug, GM P/N 15908858. Ensure that the plug is sealed with the silicone sealant. 12. Reinstall the floor covering and seat. Cage Nut Access Using Rectangular Service Plug Rectangular service holes have been provided in the floor of the cab to access the cage nut in all other cab mounting bolt locations. The service hole is directly above the cab mount bolt. Use the following steps to remove and replace the service plugs that cover the service hole. 1. Remove the seat located above the affected bolt. Refer to SI for the applicable seat removal steps. 2. Remove the sill trim plate. Refer to Front Side Door Sill Trim Plate Replacement in SI. 3. Partially remove (pull back) the floor covering (carpet) to expose the rectangular service plug. 4. Using a gasket scraper or similar tool, pry off and discard the rectangular floor plug. 5. Service the cab mounting bolt and nut as required. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body / Frame Mount Bushing: > 10-08-61-001A > Feb > 11 > Body - Body Mount Bolt Stripped or Will Not Loosen > Page 15498 6. Coat the perimeter of the access hole with RTV Silicone Sealant, GM P/N 12378521 (in Canada, 88901148) or equivalent, to seal the bare edge of the metal. 7. Install the rectangular body plug, GM P/N 15040085. Ensure that the plug is sealed with the silicone sealant. 8. Reinstall the floor covering, sill trim and seat. Parts Information Warranty Information In most cases, this bulletin information will be used when replacing a body mount and should be claimed under labor code E1095 Drivetrain and Front Suspension Frame Insulator Replacement. If this repair is performed while repairing something different, use the labor code associated with that repair. - Incremental time for this repair should be claimed using Other Labor Hours (OLH). - The recommended OLH for this repair is 0.3-0.5 hr per bolt. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Technical Service Bulletins > Customer Interest for Body / Frame Mount Bushing: > 06-08-61-003F > Apr > 11 > Body/Frame - Underbody Pop/Clunk When Turning Body / Frame Mount Bushing: Customer Interest Body/Frame - Underbody Pop/Clunk When Turning TECHNICAL Bulletin No.: 06-08-61-003F Date: April 12, 2011 Subject: Underbody Pop or Clunk Type Noise While Turning or Driving on Uneven Road Surfaces (Install Body Mount Insulator) Models: 2004-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2004-2012 Chevrolet Avalanche, Silverado (Classic), Silverado, Suburban, Tahoe 2004-2012 GMC Sierra (Classic), Sierra Denali (Classic), Sierra, Sierra Denali, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-08-61-003E (Section 08 - Body and Accessories). Condition Some customers may comment on a pop or clunk type noise while turning or driving on uneven road surfaces. This noise can be heard and/or felt at either the driver's or front passenger floor pan area. Cause Under certain conditions, normal movement between the frame and the #1, #2 or #3 body mounts may cause this noise to occur. Diagnosis 1. If the vehicle is equipped with aftermarket (non-GM Accessory) running boards or the running board is mounted using the body mount bolt, remove the running boards prior to test driving the vehicle. This will eliminate the running boards as the possible cause of the noise. 2. Install the J-39570 Chassis Ears to the frame rail at or near the body mounts. 3. Test drive the vehicle to identify which mount is suspect. Correction Install an insulator at the suspect mount(s). The insulator should be installed between the upper portion of the body mount and the frame bracket. The #1 mount is the mount located just under the A-pillar. The #2 mount is the mount located just under the B-pillar. The #3 mount is the mount located just under the C-pillar. Use the procedure listed below. 1. Raise the vehicle on the hoist. It is recommended to use a four-post lift or strap the vehicle frame to the hoist arms. 2. For the left side mounts only, remove the intermediate park brake cable. Perform the following steps: 1. Remove the nut from the park brake equalizer. 2. Remove the intermediate cable from the equalizer. 3. Depress the retaining tabs that secure the park brake cable to the frame. 4. Pull slightly on the cable from the mounting area in order to provide slack for body movement without binding the cable. 3. Remove all of the body mount bolts on the side being repaired. 4. Properly support the body at the body mount area. Caution When you remove the body mount, do NOT separate the frame from the body more than is necessary. Possible personal injury and damage to multiple parts may result. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Technical Service Bulletins > Customer Interest for Body / Frame Mount Bushing: > 06-08-61-003F > Apr > 11 > Body/Frame - Underbody Pop/Clunk When Turning > Page 15504 5. Lower the chassis accordingly in order to remove the upper portion of the body mount. 6. Install the new insulator to the bottom of the top portion of the body mount. The picture shows the insulator (1) location after the body mount is reassembled. 7. Install the body mount to the frame bracket. 8. Perform the following procedure before installing the bolts. 1. Clean the bolt threads of all the original thread locking compound. 2. Clean the threads of the bolt with denatured alcohol or equivalent and allow to dry. 3. Apply Threadlocker, GM P/N 89021297 (In Canada, use P/N 10953488). 9. Install the body mount bolts. Tighten For 2003, 2004 and 2005 model year, tighten the bolts to 85 Nm (63 lb ft). Tighten For 2006-2012 model year, tighten the bolts to 100 Nm (74 lb ft). 10. Reinstall the intermediate park brake cable (left side only). Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Technical Service Bulletins > Customer Interest for Body / Frame Mount Bushing: > 10-08-61-001A > Feb > 11 > Body Body Mount Bolt Stripped or Will Not Loosen Body / Frame Mount Bushing: Customer Interest Body - Body Mount Bolt Stripped or Will Not Loosen INFORMATION Bulletin No.: 10-08-61-001A Date: February 16, 2011 Subject: Information on Body Mount Bolt Stripped or Will Not Loosen Models: 2010-2011 Chevrolet Silverado 2010-2011 GMC Sierra Supercede: This bulletin is being revised to add Warranty Information. Please discard Corporate Bulletin Number 10-08-61-001 (Section 08 - Body and Accessories). The purpose of this bulletin is to provide guidance to GM dealers when performing repairs that involve the removal of the body mount bolts. Technicians may discover that one of the cab mount bolts won't loosen from the vehicle. The bolt may act like the nut is cross-threaded or no longer secured to the floorpan of the vehicle. The cab mounted cage nut may have bent or broken loose allowing the nut to spin. If the nut is allowed to spin, it may prevent the bolt from loosening. The front cab mount nuts are welded to the body structure and are not involved with this bulletin. The cage nut assembly must be accessed from inside of the vehicle if this condition occurs. Some of the cage nuts have rectangular access plates in the floor of the passenger compartment. These plates are located above the affected bolt. On extended cab vehicles it is necessary to create access holes in the rear floor area to reach the rear cage nut. Creating Access Hole (Extended Cab Vehicles Only) Use the following steps to create an access hole in the rear floor area of extended cab vehicles. This procedure only applies to the rear set of mounting bolts. Note This procedure below is for the left side of the vehicle. The procedure and measurements are the same for both the left and right side procedures. 1. Remove the seat located above the affected bolt. Refer to Rear Seat Replacement in SI. 2. Partially remove (pull back) the floor covering (carpet) to expose the seat mounting stud area of the floor. 3. Apply masking tape to the repair area as shown. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Technical Service Bulletins > Customer Interest for Body / Frame Mount Bushing: > 10-08-61-001A > Feb > 11 > Body Body Mount Bolt Stripped or Will Not Loosen > Page 15509 4. Using a straight edge, create a line along the inboard side of the seat mounting studs as shown. 5. Measure and mark as shown (A), 10 mm (3/8 in). 6. Find the center point between the two mounting studs as shown. Create a second mark as shown. 7. Use a center punch to create a mark in the sheet metal. 8. Using a 1-1/2 in. hole saw, create an access hole as shown. 9. Service the cab mounting bolt and nut as required. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Technical Service Bulletins > Customer Interest for Body / Frame Mount Bushing: > 10-08-61-001A > Feb > 11 > Body Body Mount Bolt Stripped or Will Not Loosen > Page 15510 10. Coat the perimeter of the access hole with RTV Silicone Sealant, GM P/N 12378521 (in Canada, 88901148) or equivalent, to seal the bare edge of the metal. 11. Install the round body plug, GM P/N 15908858. Ensure that the plug is sealed with the silicone sealant. 12. Reinstall the floor covering and seat. Cage Nut Access Using Rectangular Service Plug Rectangular service holes have been provided in the floor of the cab to access the cage nut in all other cab mounting bolt locations. The service hole is directly above the cab mount bolt. Use the following steps to remove and replace the service plugs that cover the service hole. 1. Remove the seat located above the affected bolt. Refer to SI for the applicable seat removal steps. 2. Remove the sill trim plate. Refer to Front Side Door Sill Trim Plate Replacement in SI. 3. Partially remove (pull back) the floor covering (carpet) to expose the rectangular service plug. 4. Using a gasket scraper or similar tool, pry off and discard the rectangular floor plug. 5. Service the cab mounting bolt and nut as required. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Technical Service Bulletins > Customer Interest for Body / Frame Mount Bushing: > 10-08-61-001A > Feb > 11 > Body Body Mount Bolt Stripped or Will Not Loosen > Page 15511 6. Coat the perimeter of the access hole with RTV Silicone Sealant, GM P/N 12378521 (in Canada, 88901148) or equivalent, to seal the bare edge of the metal. 7. Install the rectangular body plug, GM P/N 15040085. Ensure that the plug is sealed with the silicone sealant. 8. Reinstall the floor covering, sill trim and seat. Parts Information Warranty Information In most cases, this bulletin information will be used when replacing a body mount and should be claimed under labor code E1095 Drivetrain and Front Suspension Frame Insulator Replacement. If this repair is performed while repairing something different, use the labor code associated with that repair. - Incremental time for this repair should be claimed using Other Labor Hours (OLH). - The recommended OLH for this repair is 0.3-0.5 hr per bolt. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service and Repair > Drivetrain and Front Suspension Frame Insulator Replacement (Extended Cab) Body / Frame Mount Bushing: Service and Repair Drivetrain and Front Suspension Frame Insulator Replacement (Extended Cab) Drivetrain and Front Suspension Frame Insulator Replacement (Extended Cab) Removal Procedure Note: Ensure that the vehicle is unloaded prior to body removal. 1. Remove the master cylinder. Perform the following steps: 1. Remove the nuts retaining the master cylinder to the brake booster. 2. Remove the master cylinder from the brake booster. 3. Secure the cylinder away from the booster. 2. Raise the vehicle on the hoist. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 3. Remove the park brake equalizer intermediate cable. Perform the following steps: 1. Remove the nut from the park brake equalizer intermediate cable. 2. Remove the intermediate cable from the equalizer. 3. Depress the retaining tabs that secure the park brake cable to the frame. 4. Pull slightly on the cable from the mounting area in order to provide slack for body movement without binding the cable. 4. Remove the body mount bolts. 5. Properly support the body in the area that the mounts will be replaced. Warning When you remove the body cushions, do NOT separate the frame from the body more than is necessary. Possible personal injury and damage to multiple parts may result if you do not follow the guides outlined below: * Intermediate steering shaft-Do not allow the shaft to extend more than 25 mm (1 in). * Fuel tank filler hose-Do not stretch the hose excessively. * Tail/Turn signal lamp wiring/rear lamps junction block-Leave slack in the wires. * Park brake cable-Leave slack in the cable. * Body ground straps-Leave slack in the wire. 6. Lower the chassis accordingly in order to remove the cushions (1) as necessary. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service and Repair > Drivetrain and Front Suspension Frame Insulator Replacement (Extended Cab) > Page 15514 1. Install the cushions (1) as necessary and raise the chassis accordingly. 2. Perform the following procedure before installing the bolts. 1. Remove all traces of the original adhesive patch. 2. Clean the threads of the bolt with denatured alcohol or equivalent and allow to dry. 3. Apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the body mount bolts and tighten to 60 Nm (44 lb ft) plus 170 degrees. 4. Install the park brake equalizer intermediate cable. Perform the following steps: 1. Pull rearward on the park brake cable to the original position. 2. Secure the cable retaining tabs to the frame. 3. Install the intermediate cable end to the equalizer. 4. Install the nut to the threaded end of the intermediate cable. Tighten the nut to 4 Nm (35 lb in). 5. Lower the vehicle. 6. Install the master cylinder. Perform the following steps: 1. Mount the master cylinder to the brake booster. 2. Install the master cylinder mounting nuts and tighten to 36 Nm (27 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service and Repair > Drivetrain and Front Suspension Frame Insulator Replacement (Extended Cab) > Page 15515 Body / Frame Mount Bushing: Service and Repair Drivetrain and Front Suspension Frame Insulator Replacement (Regular Cab) Drivetrain and Front Suspension Frame Insulator Replacement (Regular Cab) Removal Procedure Note: Ensure that the vehicle is unloaded prior to body removal. 1. Remove the master cylinder. Perform the following steps: 1. Remove the nuts retaining the master cylinder to the brake booster. 2. Remove the master cylinder from the brake booster. 3. Secure the cylinder away from the booster. 2. Raise the vehicle on the hoist. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 3. Remove the park brake equalizer intermediate cable. Perform the following steps: 1. Remove the nut from the park brake equalizer intermediate cable. 2. Remove the intermediate cable from the equalizer. 3. Depress the retaining tabs that secure the park brake cable to the frame. 4. Pull slightly on the cable from the mounting area in order to provide slack for body movement without binding the cable. 4. Remove the body mount bolts. 5. Properly support the body in the area that the mounts will be replaced. Warning When you remove the body cushions, do NOT separate the frame from the body more than is necessary. Possible personal injury and damage to multiple parts may result if you do not follow the guides outlined below: * Intermediate steering shaft-Do not allow the shaft to extend more than 25 mm (1 in). * Fuel tank filler hose-Do not stretch the hose excessively. * Tail/Turn signal lamp wiring/rear lamps junction block-Leave slack in the wires. * Park brake cable-Leave slack in the cable. * Body ground straps-Leave slack in the wire. 6. Lower the chassis accordingly in order to remove the cushions (1) as necessary. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service and Repair > Drivetrain and Front Suspension Frame Insulator Replacement (Extended Cab) > Page 15516 1. Install the cushions (1) as necessary and raise the chassis accordingly. 2. Perform the following procedure before installing the bolts. 1. Remove all traces of the original adhesive patch. 2. Clean the threads of the bolt with denatured alcohol or equivalent and allow to dry. 3. Apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the body mount bolts and tighten to 60 Nm (44 lb ft) plus 170 degrees. 4. Install the park brake equalizer intermediate cable. Perform the following steps: 1. Pull rearward on the park brake cable to the original position. 2. Secure the cable retaining tabs to the frame. 3. Install the intermediate cable end to the equalizer. 4. Install the nut to the threaded end of the intermediate cable. Tighten the nut to 4 Nm (35 lb in). 5. Lower the vehicle. 6. Install the master cylinder. Perform the following steps: 1. Mount the master cylinder to the brake booster. 2. Install the master cylinder mounting nuts and tighten to 36 Nm (27 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Service and Repair > Transmission Support Crossmember Replacement Cross-Member: Service and Repair Transmission Support Crossmember Replacement Transmission Support Crossmember Replacement (4WD 2500 HD/3500) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Service and Repair > Transmission Support Crossmember Replacement > Page 15521 Cross-Member: Service and Repair Drivetrain and Front Suspension Frame Front Crossmember Replacement (HD) Drivetrain and Front Suspension Frame Front Crossmember Replacement (4WD 2500 HD, 3500) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Frame > Skid Plate > Component Information > Service and Repair > Oil Pan Skid Plate Replacement (2500/3500 with RPO NZZ) Skid Plate: Service and Repair Oil Pan Skid Plate Replacement (2500/3500 with RPO NZZ) Oil Pan Skid Plate Replacement (2500/3500 with RPO NZZ) Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the mounting bolts for the oil pan skid plate. 3. Remove the oil pan skid plate. 4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 5. Remove the mounting bolts for the oil pan skid plate. 6. Remove the oil pan skid plate. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Frame > Skid Plate > Component Information > Service and Repair > Oil Pan Skid Plate Replacement (2500/3500 with RPO NZZ) > Page 15526 1. Position the oil skid plate on the frame. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the oil skid plate mounting bolts and tighten to 28 Nm (21 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Frame > Skid Plate > Component Information > Service and Repair > Oil Pan Skid Plate Replacement (2500/3500 with RPO NZZ) > Page 15527 Skid Plate: Service and Repair Engine Shield Replacement Engine Shield Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Frame > Structural Brace > Component Information > Service and Repair Structural Brace: Service and Repair Front End Sheet Metal Diagonal Brace Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Service and Repair > Trailer Hitch Replacement (Light Duty) Trailer Hitch: Service and Repair Trailer Hitch Replacement (Light Duty) Trailer Hitch Replacement (Light Duty) Removal Procedure 1. Disconnect the trailer wiring harness connector (3) from the trailer wiring receptacle (4). 2. Remove the retainers (1) securing the trailer wiring harness (2) to the hitch platform. 3. Remove the hitch platform bolts (5) from the bumper weld nuts (4). 4. Remove the nuts (7) and bolts (1) securing the hitch platform to the frame rails. 5. Remove the hitch platform bolts (6) from the frame weld nuts (2). 6. Remove the hitch platform from the vehicle. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Service and Repair > Trailer Hitch Replacement (Light Duty) > Page 15535 1. Position the hitch platform to the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the hitch platform bolts (6) to the frame weld nuts (2). Tighten the bolts to 100 Nm (74 lb ft). 3. Install the bolts (1) and nuts (7) securing the hitch platform to the frame rails. Tighten the nuts to 113 Nm (83 lb ft). 4. Install the hitch platform bolts (5) to the bumper weld nuts (4). Tighten the bolts to 100 Nm (74 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Service and Repair > Trailer Hitch Replacement (Light Duty) > Page 15536 5. Install the retainers (1) securing the trailer wiring harness (2) to the hitch platform. 6. Connect the trailer wiring harness connector (3) to the trailer wiring receptacle (4). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Service and Repair > Trailer Hitch Replacement (Light Duty) > Page 15537 Trailer Hitch: Service and Repair Trailer Hitch Replacement (Heavy Duty) Trailer Hitch Replacement (Heavy Duty) Removal Procedure 1. Remove the hitch platform bolts (5) from the bumper weld nuts (4). 2. Remove the nuts (7) and bolts (1) securing the hitch platform to the frame rails. 3. Remove the hitch platform bolts (6) from the frame weld nuts (2). 4. Remove the hitch platform from the vehicle. Installation Procedure 1. Position the hitch platform to the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Service and Repair > Trailer Hitch Replacement (Light Duty) > Page 15538 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the hitch platform bolts (6) to the frame weld nuts (2). Tighten the bolts to 100 Nm (74 lb ft). 3. Install the bolts (1) and nuts (7) securing the hitch platform to the frame rails. Tighten the nuts to 113 Nm (83 lb ft). 4. Install the hitch platform bolts (5) to the bumper weld nuts (4). Tighten the bolts to 100 Nm (74 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Frame > Trailer Towing Relay > Component Information > Diagrams Trailer Towing Relay: Diagrams Component Connector End Views Trailer Brake Control Relay (JL1) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Frame > Trailer Towing Relay > Component Information > Diagrams > Page 15542 Trailer Towing Relay: Service and Repair Trailer Brake Control Relay Replacement (2500, 3500) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Grille > Component Information > Service and Repair > Radiator Grille Replacement Grille: Service and Repair Radiator Grille Replacement Radiator Grille Replacement (Chevrolet) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Grille > Component Information > Service and Repair > Radiator Grille Replacement > Page 15547 Grille: Service and Repair Radiator Grille Replacement (Chevrolet HD) Radiator Grille Replacement (Chevrolet HD) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Grille > Component Information > Service and Repair > Radiator Grille Replacement > Page 15548 Grille: Service and Repair Radiator Grille Replacement (GMC HD) Radiator Grille Replacement (GMC HD) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Ash Tray > Component Information > Service and Repair Ash Tray: Service and Repair Ashtray Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > Interior - Cleaning Interior Surfaces of Vehicle Carpet: Technical Service Bulletins Interior - Cleaning Interior Surfaces of Vehicle INFORMATION Bulletin No.: 06-00-89-029F Date: April 27, 2010 Subject: Interior Cleaning - Instrument Panel (IP), Hard or Plastic Surfaces, Seats, Carpet, Leather, Vinyl, Fabric Cleaner, Stain Remover, Restorer - Product Availability Models: 2006-2011 GM Passenger Cars and Trucks including Saturn (EXCLUDES Cadillac DTS Platinum and Escalade Platinum with RPO R9N - Tehama Leather) 2006-2010 HUMMER H2, H3 2006-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-00-89-029E (Section 00 - General Information). To keep the vehicle interior looking the best, it should be cleaned often. It is important to keep the upholstery from becoming heavily soiled. The vehicle's interior can experience extreme heat, which can cause stains to set quickly. Lighter color interiors may require more frequent cleaning. Care should be taken because newspapers and garments may transfer color to the vehicle's interior. Many of today's interiors are made with new low gloss materials. Permanent damage may result from using cleaners on ANY surfaces (interior trim, instrument panel, carpet, leather, vinyl and fabric) for which they are not intended. Using non-approved products can actually set the stain to the point that nothing can remove it. Important Do not use silicone or wax-based products or those containing organic solvents (such as naptha, alcohol, etc.) to clean your vehicle's interior because they can alter the appearance by increasing the gloss in a non-uniform manner. The increase in gloss may cause annoying reflections in the windshield and even make it difficult to see through the windshield under certain conditions. - Never use a STIFF brush or a brush that has been previously used with a harsh chemical. This can cause damage to the vehicle's interior surfaces. - Use only mild, Neutral-pH cleaners. Avoid laundry detergents or dishwashing soaps with degreasers. Using too much soap will leave residue that leaves streaks and attracts dirt. Because it is critical to use only mild, neutral-pH cleaners, General Motors has approved the use of the cleaners and conditioners listed in this bulletin for the cleaning of interiors. These products are in the neutral-pH range and will maintain the best vehicle interior appearance. These products are water-based, biodegradable, and do not contain bleach, solvents or harsh chemicals. Interior trim pieces on new vehicles, as well as service components, arrive with a protective film. When removing the protective film, adhesive residue may be left on the trim panels/components. The cleaner (for leather, vinyl, plastic and interior paint) is an effective cleaner in removing adhesive residue without causing damage to the component. Important - If soapy, alkaline cleaning solutions are used on fabrics, and not thoroughly rinsed out, the residual left in the fabric will attract dirt. Because the recommended cleaners/conditioners are in the pH neutral range, they won't leave behind soapy residue. - On heavily stained or difficult to clean fabric/carpet, it is recommended that the entire surface be treated and cleaned vs. spot cleaning. Refer to Extractor Machine and Concentrate section of this bulletin for more information. Effective cleaning steps for hard and/or plastic surfaces: 1. Using a clean towel, apply/spray cleaner - leather, vinyl, plastic, interior paint, directly onto the towel. 2. Wipe the surface with the towel/cleaner. 3. If necessary, use a soft bristle brush to work cleaner into the crevasses of the area being cleaned. 4. Wipe off any excess cleaner from the surface. 5. Using a clean towel, apply/spray the conditioner (leather, vinyl restorer) directly onto the towel. 6. Wipe the conditioner onto the previously cleaned area to restore the material to it's original luster. Important Today's interiors are developed and intended to have a low-gloss appearance. It is important to use only products which provide a low-gloss finish in order to maintain the interior's integrity, customer appeal and satisfaction. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > Interior - Cleaning Interior Surfaces of Vehicle > Page 15557 Effective cleaning steps for fabric: 1. Remove any residue by lightly rubbing the surface with a clean towel. 2. Choose the appropriate stain remover based on the stain type. 3. Spray and lightly brush the area with a clean, soft bristle brush. 4. Gently blot up the stain. 5. On upholstery/carpet, the use of a fabric protector can help to reduce or eliminate future staining. Upholstery and Carpet Stains When cleaning upholstery and carpet stains ONLY, the following cleaning chart will help you determine which cleaner/formula works best on a particular stain. The chart lists many of the common stains. Some complex stains may require the application of both stain removers, one after the other, to remove both food-based oils and synthetic oils. A soft bristle brush (P/N 88861425) should be used to safely work the cleaner into the leather grain or material. This enables the dirt/stain to be completely removed from the material. Leather Conditioner/Restorer A Leather Conditioner/Restorer is also available. The restorer is safe for all vinyl and leather. It is a water-based product and contains essential emollients to restore suppleness, conditions and adds luster without adding gloss. The restorer will also provide protection against re-staining. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > Interior - Cleaning Interior Surfaces of Vehicle > Page 15558 Dye Transfer: Dye transfer will happen any time a natural fiber like cotton, silk, wool, or suede comes into contact with leather. The lighter the leather color, the more quickly the dye transfer will appear. Leather should be cleaned on a regular basis so that the dirt and grime do not adversely affect the top coat of the leather. After cleaning the leather, it is important to treat the surface with the restorer. Extractor Machine and Concentrate For difficult to clean materials or when cleaning a large area, the best results will be achieved when using an extractor machine and concentrate. General Motors offers the Ruby Extractor (P/N 627-CC-3000AU) through GM Tools and Equipment 1-800-GM-TOOLS, and has recently released a concentrate for use with the extractor machine. Whichever extractor machine is used, it should meet the minimum specifications of the Ruby Extractor: Ruby Extractor Specifications: - Pump PSI: 55 - Water Lift: 85" - Hose Length: 10 ft Important The Ruby Extractor also comes with a 6 year Outer Body and 3 year Parts warranty. Extractor: The Ruby Extractor machine was designed for automotive use and works effectively in the vehicle's interior. The narrow design of the vacuum head allows detail work in tight areas. The water pressure pump is reduced so the fabric surface is not wet more than is necessary. The dry time is greatly reduced due to less water on the fabric surface, the vacuum head making better contact with the surface and the significant water lift capability of the machine. Concentrate: The concentrated extraction cleaner is engineered with lower pH levels to help remove alkaline buildup on fabrics. The concentrate should be mixed according to the instructions listed on the container. The available concentrate helps to break the stain down and then the stain is easily removed with less water. The concentrate used in the Ruby Extractor is slightly acidic to remove soap and alkalinity from the fabric surfaces left behind by using improper, soapy solutions. Dirt, grease and grime are more easily removed when the proper solution is used during the extraction process. Parts Information Products are available in two sizes; 8 oz / 235 ML and 24 oz / 710 ML bottles. Available Equipment Equipment is available by contacting 1-800-GMTOOLS. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > Interior - Cleaning Interior Surfaces of Vehicle > Page 15559 Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > Interior - Cleaning Interior Surfaces of Vehicle > Page 15560 Carpet: Technical Service Bulletins Interior - Proper Use of Floor Mats INFORMATION Bulletin No.: 10-08-110-001 Date: March 30, 2010 Subject: Information on Proper Use of Floor Mats Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3, H3T 2005-2009 Saab 9-7X GM's carpeted and all-weather (rubber) floor mats are especially designed for use in specific GM vehicles. Using floor mats that were not designed for the specific vehicle or using them incorrectly may cause interference with the accelerator or brake pedal. Please review the following safety guidelines regarding proper driver's side floor mat usage with the customer. Warning If a floor mat is the wrong size or is not properly installed, it can interfere with the accelerator pedal and/or brake pedal. Interference with the pedals can cause unintended acceleration and/or increased stopping distance which can cause a crash and injury. Make sure the floor mat does not interfere with the accelerator or brake pedal. - Do not flip the driver's floor mat over (in an effort to keep the floor mat clean) - Do not place anything on top of the driver's floor mat (e.g. carpet remnant, towel) - Do not place another mat on top of the driver's floor mat (e.g. do not place all-weather rubber mats over carpeted floor mats) - Only use floor mats that are designed specifically for your vehicle - When using replacement mats, make certain the mats do not interfere with the accelerator or brake pedal before driving the vehicle If your vehicle is equipped with a floor mat retaining pin(s) or clip(s), make certain the mat is installed correctly and according to the instructions. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > Interior - Cleaning Interior Surfaces of Vehicle > Page 15561 After installing floor mats, make certain they cannot move and do not interfere with the accelerator or brake pedals. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Procedures Carpet: Procedures Eliminating Unwanted Odors in Vehicles Eliminating Unwanted Odors in Vehicles GM Vehicle Care Odor Eliminator, GM P/N 88861431 (Canadian P/N 88861436), may control or eliminate odors in the interior and luggage compartment areas of GM vehicles. This non-toxic, biodegradable, odorless product has been shown to greatly reduce or remove the following types of odor: * Objectionable smells of mold and mildew resulting from vehicle water leaks * Customer created odors, such as smoke You may safely use GM Vehicle Care Odor Eliminator on fabrics, vinyl, leather, carpet, and sound deadening materials. You may also induce this product into HVAC modules and instrument panel ducts for the control of non-bacterial related odors. Important: This product leaves no residual scent and should not be used as an air freshener. This product may result in the permanent elimination of an odor and may be preferable to customers whose allergies make them sensitive to perfumes. This product may effectively remove odors when directly contacting the odor source. In cases such as water leaks, use this product with diagnostic procedures to first eliminate the primary cause of the odor. Then use further applications on the residual odor to permanently correct the vehicle condition. How to Use this Product * Spray GM Vehicle Care Odor Eliminator directly or as an additive with carpet shampoo in steam cleaners. * Do not use on any interior surface that plain water would deteriorate, because this product will have the same effect. Also avoid letting this product come into contact with vinegar or any acidic substance. Acid-based products will hamper the effectiveness of GM Vehicle Care Odor Eliminator. * Complete eight page treatment sheets are enclosed within each case of GM Vehicle Care Odor Eliminator. These treatment instructions range from simple vehicle odor elimination to full step by step procedures for odor removal from water leaks. * Instructions and cautions are printed on the bottle, but additional help is available. Drying Floor Carpet Floor Carpet Drying If the carpet or the pad or insulator is wet, use the following criteria for drying or for replacing the components: * For a 1-piece carpet assembly bonded to a cotton or a fiber padding, replace the entire assembly. * For a 2-piece carpet assembly with a cotton or a fiber padding, replace the padding only. While the carpet is out of the vehicle, dry the carpet using the method described below. * For a 1-piece carpet assembly bonded to a foam padding or attached to a synthetic padding, dry the carpet using the method described below. * For a 2-piece carpet assembly with a synthetic padding, dry the assembly using the method described below. * For a 1-piece carpet assembly with a separate cotton or a fiber padding, replace the cotton or fiber padding. While the carpet is out of the vehicle, dry the carpet using the method described below. Drying Method 1. If you observe puddles of liquid on the carpet face, use a wet vacuum to remove the excess moisture. 2. Blot the face of the carpet with a towel in order to absorb as much moisture as possible. 3. Point a fan at the affected area and air dry the carpet. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Procedures > Page 15564 Carpet: Removal and Replacement Front Floor Panel Carpet Replacement (Regular Cab) Front Floor Panel Carpet Replacement (Regular Cab) Front Floor Panel Carpet Replacement (Extended Cab) Front Floor Panel Carpet Replacement (Extended Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Procedures > Page 15565 Front Floor Panel Carpet Replacement (Crew Cab) Front Floor Panel Carpet Replacement (Crew Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Procedures > Page 15566 Body Rear Inner Panel Carpet Replacement (Regular Cab) Body Rear Inner Panel Carpet Replacement (Regular Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Procedures > Page 15567 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Front Floor Console Compartment Bezel Replacement Console: Service and Repair Front Floor Console Compartment Bezel Replacement Front Floor Console Compartment Bezel Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Front Floor Console Compartment Bezel Replacement > Page 15572 Console: Service and Repair Front Floor Console Compartment Door Latch Replacement (Except Cadillac) Front Floor Console Compartment Door Latch Replacement (Except Cadillac) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Front Floor Console Compartment Bezel Replacement > Page 15573 Console: Service and Repair Front Floor Console Side Trim Panel Replacement - Right Side (with RPO SLT) Front Floor Console Side Trim Panel Replacement - Right Side (with RPO SLT) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Front Floor Console Compartment Bezel Replacement > Page 15574 Console: Service and Repair Front Floor Console Side Trim Panel Replacement - Left Side (with RPO SLT) Front Floor Console Side Trim Panel Replacement - Left Side (with RPO SLT) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Front Floor Console Compartment Bezel Replacement > Page 15575 Console: Service and Repair Front Floor Console Compartment Bezel Replacement Front Floor Console Compartment Bezel Replacement Front Floor Console Compartment Door Latch Replacement (Except Cadillac) Front Floor Console Compartment Door Latch Replacement (Except Cadillac) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Front Floor Console Compartment Bezel Replacement > Page 15576 Front Floor Console Side Trim Panel Replacement - Right Side (with RPO SLT) Front Floor Console Side Trim Panel Replacement - Right Side (with RPO SLT) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Front Floor Console Compartment Bezel Replacement > Page 15577 Front Floor Console Side Trim Panel Replacement - Left Side (with RPO SLT) Front Floor Console Side Trim Panel Replacement - Left Side (with RPO SLT) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Front Floor Console Compartment Bezel Replacement > Page 15578 Floor Console Bezel Replacement Floor Console Bezel Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Front Floor Console Compartment Bezel Replacement > Page 15579 Front Floor Console Compartment Replacement (Except Cadillac) Front Floor Console Compartment Replacement (Except Cadillac) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Front Floor Console Compartment Bezel Replacement > Page 15580 Front Floor Console Replacement (without RPO SLT) Front Floor Console Replacement (without RPO SLT) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Front Floor Console Compartment Bezel Replacement > Page 15581 Front Floor Console Replacement (with RPO SLT) Front Floor Console Replacement (with RPO SLT) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Front Floor Console Compartment Bezel Replacement > Page 15582 Front Floor Console Armrest Replacement Front Floor Console Armrest Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Front Floor Console Compartment Bezel Replacement > Page 15583 Center Console End Panel Replacement Center Console End Panel Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Front Floor Console Compartment Bezel Replacement > Page 15584 Roof Console Replacement Roof Console Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Front Floor Console Compartment Bezel Replacement > Page 15585 Roof Rear Console Replacement (with DVD) Roof Rear Console Replacement (with DVD) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Front Floor Console Compartment Bezel Replacement > Page 15586 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling SIR component location affects how a vehicle should be serviced. There are parts of the SIR system installed in various locations around a vehicle. To find the location of the SIR components refer to SIR Identification Views (See: Restraint Systems/Air Bag Systems/Locations). There are several reasons for disabling the SIR system, such as repairs to the SIR system or servicing a component near or attached to an SIR component. There are several ways to disable the SIR system depending on what type of service is being performed. The following information covers the proper procedures for disabling/enabling the SIR system. SIR Service Precautions Warning When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. The inflatable restraint sensing and diagnostic module (SDM) maintains a reserved energy supply. The reserved energy supply provides deployment power for the air bags if the SDM loses battery power during a collision. Deployment power is available for as much as 1 minute after disconnecting the vehicle power. Waiting 1 minute before working on the system after disabling the SIR system prevents deployment of the air bags from the reserved energy supply. General Service Instructions The following are general service instructions which must be followed in order to properly repair the vehicle and return it to its original integrity: * Do not expose air bags to temperatures above 65°C (149°F). * Verify the correct replacement part number. Do not substitute a component from a different vehicle. * Use only original GM replacement parts available from your authorized GM dealer. Do not use salvaged parts for repairs to the SIR system. Discard any of the following components if it has been dropped from a height of 92 cm (3 feet) or greater: * Inflatable restraint sensing and diagnostic module (SDM) * Any air bag * Driver steering wheel air bag coil * Any impact sensor * Seat belt anchor and/or retractor pretensioners * Passenger presence module and/or occupant sensor Disabling Procedure - Air Bag Fuse 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. Note: The SDM may have more than one fused power input. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove all fuses supplying power to the SDM. With all SDM fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate a SIR system malfunction. 3. Locate and remove the fuse(s) supplying power to the SDM. Refer to SIR Schematics (See: Diagrams/Electrical Diagrams/Air Bag Systems) or Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse/Application and ID). 4. Wait 1 minute before working on the system. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Page 15591 Enabling Procedure - Air Bag Fuse 1. Place the ignition in the OFF position. 2. Install the fuse(s) supplying power to the SDM. Refer to SIR Schematics (See: Diagrams/Electrical Diagrams/Air Bag Systems) or Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse/Application and ID). 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle). Disabling Procedure - Negative Battery Cable 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. 3. Disconnect the negative battery cable from the battery. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 4. Wait 1 minute before working on system. Enabling Procedure - Negative Battery Cable 1. Place the ignition in the OFF position. 2. Connect the negative battery cable to the battery. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Drink Holders > Component Information > Service and Repair Drink Holders: Service and Repair Front Floor Console Cup Holder Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Instrument Panel Storage Compartment Replacement Glove Compartment: Service and Repair Instrument Panel Storage Compartment Replacement Instrument Panel Storage Compartment Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Instrument Panel Storage Compartment Replacement > Page 15599 Glove Compartment: Service and Repair Instrument Panel Compartment Door Lock Striker Replacement (With RPO SLT) Instrument Panel Compartment Door Lock Striker Replacement (With RPO SLT) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Instrument Panel Storage Compartment Replacement > Page 15600 Glove Compartment: Service and Repair Instrument Panel Compartment Door Emblem Replacement (TUF) Instrument Panel Compartment Door Emblem Replacement (TUF) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Instrument Panel Storage Compartment Replacement > Page 15601 Glove Compartment: Service and Repair Instrument Panel Compartment Door Replacement (With RPO SLT) Instrument Panel Compartment Door Replacement (With RPO SLT) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Instrument Panel Storage Compartment Replacement > Page 15602 Glove Compartment: Service and Repair Instrument Panel Storage Compartment Replacement Instrument Panel Storage Compartment Replacement Instrument Panel Compartment Door Lock Striker Replacement (With RPO SLT) Instrument Panel Compartment Door Lock Striker Replacement (With RPO SLT) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Instrument Panel Storage Compartment Replacement > Page 15603 Instrument Panel Compartment Door Emblem Replacement (TUF) Instrument Panel Compartment Door Emblem Replacement (TUF) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Instrument Panel Storage Compartment Replacement > Page 15604 Instrument Panel Compartment Door Replacement (With RPO SLT) Instrument Panel Compartment Door Replacement (With RPO SLT) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Instrument Panel Storage Compartment Replacement > Page 15605 Instrument Panel Compartment Door Assembly Replacement (With RPO SLT) Instrument Panel Compartment Door Assembly Replacement (With RPO SLT) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Instrument Panel Storage Compartment Replacement > Page 15606 Instrument Panel Compartment Door Opening Frame Replacement (without RPO SLT) Instrument Panel Compartment Door Opening Frame Replacement (without RPO SLT) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Instrument Panel Storage Compartment Replacement > Page 15607 Instrument Panel Compartment Door Latch Replacement (With RPO SLT) Instrument Panel Compartment Door Latch Replacement (With RPO SLT) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Instrument Panel Storage Compartment Replacement > Page 15608 Instrument Panel Compartment Door Latch Replacement (Without RPO SLT) Instrument Panel Compartment Door Latch Replacement (Without RPO SLT) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Instrument Panel Storage Compartment Replacement > Page 15609 Instrument Panel Compartment Door Lock Cylinder Replacement Instrument Panel Compartment Door Lock Cylinder Replacement Removal Procedure 1. Remove the instrument panel compartment latch. Refer to Instrument Panel Compartment Door Latch Replacement (With RPO SLT) (See: Instrument Panel Compartment Door Latch Replacement (With RPO SLT))Instrument Panel Compartment Door Latch Replacement (Without RPO SLT) (See: Instrument Panel Compartment Door Latch Replacement (Without RPO SLT)). 2. Position the instrument panel compartment latch fork bolt in the up position. 3. Insert the key into the instrument panel compartment lock cylinder. 4. Rotate the instrument panel compartment lock cylinder clockwise to the 3 o'clock position with the key. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Instrument Panel Storage Compartment Replacement > Page 15610 5. With the key in position, apply a light load and depress the retainer tumbler through the poke hole at the right hand side of the instrument panel compartment latch. 6. Rotate the key until the instrument panel compartment lock cylinder rotates to about the 5 o'clock position. This will line up the notch at the rear of the instrument panel compartment lock cylinder with the tab in the instrument panel compartment latch housing. 7. Remove the instrument panel compartment lock cylinder from the instrument panel compartment latch by pulling on the key. Installation Procedure 1. Position the instrument panel compartment latch fork bolt in the up position. 2. Grasp the instrument panel compartment lock cylinder. Depress the rear-most, light-colored tumbler that is flush with the instrument panel compartment lock cylinder surface. 3. Insert the key. All the tumblers will now stay depressed. 4. Insert the instrument panel compartment lock cylinder, with the key inserted, into the instrument panel compartment latch housing. Ensure that the front projection pin is at the appropriate 8 o'clock position. The instrument panel compartment lock cylinder will drop into place. 5. Rotate the key counterclockwise until the key stops. 6. Remove the key, the tumblers will now release. The instrument panel compartment lock cylinder is now locked into the instrument panel compartment latch housing. 7. Install the instrument panel compartment latch. Refer to Instrument Panel Compartment Door Latch Replacement (With RPO SLT) (See: Instrument Panel Compartment Door Latch Replacement (With RPO SLT))Instrument Panel Compartment Door Latch Replacement (Without RPO SLT) (See: Instrument Panel Compartment Door Latch Replacement (Without RPO SLT)). Instrument Panel Compartment Door Dampener Replacement (With RPO SLT) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Instrument Panel Storage Compartment Replacement > Page 15611 Instrument Panel Compartment Door Dampener Replacement (With RPO SLT) Instrument Panel Compartment Door Dampener Replacement (Without RPO SLT) Instrument Panel Compartment Door Dampener Replacement (Without RPO SLT) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Instrument Panel Storage Compartment Replacement > Page 15612 Instrument Panel Upper Compartment Replacement Instrument Panel Upper Compartment Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Instrument Panel Storage Compartment Replacement > Page 15613 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Headlining Trim Panel Replacement (Regular Cab) Headliner: Service and Repair Headlining Trim Panel Replacement (Regular Cab) Headlining Trim Panel Replacement (Regular Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Headlining Trim Panel Replacement (Regular Cab) > Page 15618 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Headlining Trim Panel Replacement (Regular Cab) > Page 15619 Headliner: Service and Repair Headlining Trim Panel Replacement (Extended Cab) Headlining Trim Panel Replacement (Extended Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Headlining Trim Panel Replacement (Regular Cab) > Page 15620 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Headlining Trim Panel Replacement (Regular Cab) > Page 15621 Headliner: Service and Repair Headlining Trim Panel Replacement (Crew Cab) Headlining Trim Panel Replacement (Crew Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Headlining Trim Panel Replacement (Regular Cab) > Page 15622 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Passenger Assist Handle > Component Information > Service and Repair > Front Assist Handle Replacement Passenger Assist Handle: Service and Repair Front Assist Handle Replacement Front Assist Handle Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Passenger Assist Handle > Component Information > Service and Repair > Front Assist Handle Replacement > Page 15627 Passenger Assist Handle: Service and Repair Center Pillar Assist Handle Replacement Center Pillar Assist Handle Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Passenger Assist Handle > Component Information > Service and Repair > Front Assist Handle Replacement > Page 15628 Passenger Assist Handle: Service and Repair Roof Rail Rear Assist Handle Replacement Roof Rail Rear Assist Handle Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Scuff Plate > Component Information > Service and Repair > Front Side Door Sill Trim Plate Replacement (Extended Cab) Scuff Plate: Service and Repair Front Side Door Sill Trim Plate Replacement (Extended Cab) Front Side Door Sill Trim Plate Replacement (Extended Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Scuff Plate > Component Information > Service and Repair > Front Side Door Sill Trim Plate Replacement (Extended Cab) > Page 15633 Scuff Plate: Service and Repair Front Side Door Sill Trim Plate Replacement (Regular Cab/Crew Cab) Front Side Door Sill Trim Plate Replacement (Regular Cab/Crew Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Scuff Plate > Component Information > Service and Repair > Front Side Door Sill Trim Plate Replacement (Extended Cab) > Page 15634 Scuff Plate: Service and Repair Rear Side Door Sill Trim Plate Replacement (Crew Cab) Rear Side Door Sill Trim Plate Replacement (Crew Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Scuff Plate > Component Information > Service and Repair > Front Side Door Sill Trim Plate Replacement (Extended Cab) > Page 15635 Scuff Plate: Service and Repair Rear Side Door Sill Trim Plate Replacement (Extended Cab) Rear Side Door Sill Trim Plate Replacement (Extended Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Technical Service Bulletins > Customer Interest for Sun Visor: > 09-08-110-013A > Apr > 11 > Interior - Sun Visor Fails to Stay In Up Position Sun Visor: Customer Interest Interior - Sun Visor Fails to Stay In Up Position TECHNICAL Bulletin No.: 09-08-110-013A Date: April 18, 2011 Subject: Sunshade (Sun Visor) Fails to Stay In Position (Re-seat Detent Spring) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon XL Supercede: This bulletin is being revised to include the 2012 model year. Please discard Corporate Bulletin Number 09-08-110-013 (Section 08 - Body and Accessories). Condition Some customers may comment that the front sunshade (sun visor) doesn't stay in position tightly against the headliner when in the up position and clipped into the center mount. Cause The condition may be caused by the sunshade being over extended (forced) along the slide on rod to the end of its travel. This over extension can cause the detent spring to be pulled off of the flat on the slide on rod and can cause the detent function to be inoperative. Correction In many cases, the detent spring can be re-seated into the correct position. Use the following procedure to correct the condition. 1. Position the sunshade in the forward position and engage the sunshade into the center clip. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Technical Service Bulletins > Customer Interest for Sun Visor: > 09-08-110-013A > Apr > 11 > Interior - Sun Visor Fails to Stay In Up Position > Page 15644 2. Cycle the sunshade up and down 15-20 cycles. This should engage the detent spring. 3. Repeat the procedure on the second visor. If the above steps fail to resolve the condition, refer to diagnostic procedures in SI to correct the condition. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sun Visor: > 09-08-110-013A > Apr > 11 > Interior - Sun Visor Fails to Stay In Up Position Sun Visor: All Technical Service Bulletins Interior - Sun Visor Fails to Stay In Up Position TECHNICAL Bulletin No.: 09-08-110-013A Date: April 18, 2011 Subject: Sunshade (Sun Visor) Fails to Stay In Position (Re-seat Detent Spring) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon XL Supercede: This bulletin is being revised to include the 2012 model year. Please discard Corporate Bulletin Number 09-08-110-013 (Section 08 - Body and Accessories). Condition Some customers may comment that the front sunshade (sun visor) doesn't stay in position tightly against the headliner when in the up position and clipped into the center mount. Cause The condition may be caused by the sunshade being over extended (forced) along the slide on rod to the end of its travel. This over extension can cause the detent spring to be pulled off of the flat on the slide on rod and can cause the detent function to be inoperative. Correction In many cases, the detent spring can be re-seated into the correct position. Use the following procedure to correct the condition. 1. Position the sunshade in the forward position and engage the sunshade into the center clip. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sun Visor: > 09-08-110-013A > Apr > 11 > Interior - Sun Visor Fails to Stay In Up Position > Page 15650 2. Cycle the sunshade up and down 15-20 cycles. This should engage the detent spring. 3. Repeat the procedure on the second visor. If the above steps fail to resolve the condition, refer to diagnostic procedures in SI to correct the condition. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Service and Repair > Sunshade Sun Visor: Service and Repair Sunshade Sunshade Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Service and Repair > Sunshade > Page 15653 Sun Visor: Service and Repair Sunshade Anchor Replacement Sunshade Anchor Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Body Hinge Pillar Trim Panel Replacement Trim Panel: Service and Repair Body Hinge Pillar Trim Panel Replacement Body Hinge Pillar Trim Panel Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Body Hinge Pillar Trim Panel Replacement > Page 15658 Trim Panel: Service and Repair Body Lock Pillar Trim Replacement (Crew Cab) Body Lock Pillar Trim Replacement (Crew Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Body Hinge Pillar Trim Panel Replacement > Page 15659 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Body Hinge Pillar Trim Panel Replacement > Page 15660 Trim Panel: Service and Repair Body Lock Pillar Trim Replacement (Extended Cab) Body Lock Pillar Trim Replacement (Extended Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Body Hinge Pillar Trim Panel Replacement > Page 15661 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Body Hinge Pillar Trim Panel Replacement > Page 15662 Trim Panel: Service and Repair Body Lock Pillar Trim Replacement (Regular Cab) Body Lock Pillar Trim Replacement (Regular Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Body Hinge Pillar Trim Panel Replacement > Page 15663 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Body Hinge Pillar Trim Panel Replacement > Page 15664 Trim Panel: Service and Repair Body Hinge Pillar Trim Panel Replacement Body Hinge Pillar Trim Panel Replacement Body Lock Pillar Trim Replacement (Crew Cab) Body Lock Pillar Trim Replacement (Crew Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Body Hinge Pillar Trim Panel Replacement > Page 15665 Body Lock Pillar Trim Replacement (Extended Cab) Body Lock Pillar Trim Replacement (Extended Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Body Hinge Pillar Trim Panel Replacement > Page 15666 Body Lock Pillar Trim Replacement (Regular Cab) Body Lock Pillar Trim Replacement (Regular Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Body Hinge Pillar Trim Panel Replacement > Page 15667 Center Pillar Lower Garnish Molding Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Body Hinge Pillar Trim Panel Replacement > Page 15668 Center Pillar Lower Garnish Molding Replacement Center Pillar Upper Garnish Molding Replacement Center Pillar Upper Garnish Molding Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Body Hinge Pillar Trim Panel Replacement > Page 15669 Body Rear Panel Insulator Replacement (Extended Cab/Crew Cab) Body Rear Panel Insulator Replacement (Extended Cab/Crew Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Body Hinge Pillar Trim Panel Replacement > Page 15670 Jack Stowage Cover Replacement Jack Stowage Cover Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Body Hinge Pillar Trim Panel Replacement > Page 15671 Rear Window Lower Garnish Molding Replacement (Ext Cab/Crew Cab w/A48) Rear Window Lower Garnish Molding Replacement (Ext Cab/Crew Cab w/A48) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Body Hinge Pillar Trim Panel Replacement > Page 15672 Rear Window Lower Garnish Molding Replacement (Ext Cab/Crew Cab w/o A48) Rear Window Lower Garnish Molding Replacement (Ext Cab/Crew Cab w/o A48) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Body Hinge Pillar Trim Panel Replacement > Page 15673 Rear Window Lower Garnish Molding Replacement (Regular Cab) Rear Window Lower Garnish Molding Replacement (Regular Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Body Hinge Pillar Trim Panel Replacement > Page 15674 Windshield Pillar Garnish Molding Replacement Windshield Pillar Garnish Molding Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Body Hinge Pillar Trim Panel Replacement > Page 15675 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Service and Repair > Door Lock Cylinder Replacement Door Lock Cylinder: Service and Repair Door Lock Cylinder Replacement Door Lock Cylinder Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Service and Repair > Door Lock Cylinder Replacement > Page 15682 Door Lock Cylinder: Service and Repair Endgate Lock Cylinder Replacement Endgate Lock Cylinder Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information Key: Technical Service Bulletins Locks - Key Code Security Rules and Information INFORMATION Bulletin No.: 10-00-89-010 Date: May 27, 2010 Subject: Key Code Security Rules and Information on GM KeyCode Look-Up Application (Canada Only) Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saturn and Saab 2002 and Prior Isuzu Attention: This bulletin has been created to address potential issues and questions regarding KeyCode security. This bulletin should be read by all parties involved in KeyCode activity, including dealer operator, partner security coordinator, sales, service and parts departments. A copy of this bulletin should be printed and maintained in the parts department for use as a reference. Important U.S. dealers should refer to Corporate Bulletin Number 10-00-89-009. Where Are Key Codes Located? General Motors provides access to KeyCodes through three sources when a vehicle is delivered to a dealer. Vehicle KeyCodes are located on the original vehicle invoice to the dealership. There is a small white bar coded tag sent with most new vehicles that also has the key code printed on it. Dealerships should make a practice of comparing the tag's keycode numbers to the keycode listed on the invoice. Any discrepancy should be reported immediately to the GM of Canada Key Code Inquiry Desk. Remember to remove the key tag prior to showing vehicles to potential customers. The third source for Key codes is through the GM KeyCode Look-Up feature within the OEConnection D2DLink application. KeyCode Look-Up currently goes back 17 previous model years from the current model year. When a vehicle is received by the dealership, care should be taken to safeguard the original vehicle invoice and KeyCode tag provided with the vehicle. Potential customers should not have access to the invoice or this KeyCode tag prior to the sale being completed. After a sale has been completed, the KeyCode information belongs to the customer and General Motors. Tip Only the original invoice contains key code information, a re-printed invoice does not. GM KeyCode Look-Up Application for GM of Canada Dealers All dealers should review the General Motors of Canada KeyCode Look-Up Policies and Procedures (Service Policy & Procedures Manual Section 3.1.6 "Replacement of VIN plates & keys"). Please note that the KeyCode Access site is restricted. Only authorized users should be using this application. Please see your Parts Manager for site authorized users. KeyCode Look-Up currently goes back 17 years from current model year. Important notes about security: - Users may not access the system from multiple computers simultaneously. - Users may only request one KeyCode at a time. - KeyCode information will only be available on the screen for 2 minutes. - Each user is personally responsible for maintaining and protecting their password. - Never share your password with others. - User Id's are suspended after 6 consecutive failed attempts. - User Id's are disabled if not used for 90 days. - Processes must be in place for regular dealership reviews. - The Parts Manager (or assigned management) must have processes in place for employee termination or life change events. Upon termination individuals access must be turned off immediately and access should be re-evaluated upon any position changes within the dealership. - If you think your password or ID security has been breached, contact Dealer Systems Support at 1-800-265-0573. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information > Page 15687 Each user will be required to accept the following agreement each time the KeyCode application is used. Key Code User Agreement - Key codes are proprietary information belonging to General Motors Corporation and to the vehicle owner. - Unauthorized access to, or use of, key code information is unlawful and may subject the user to criminal and civil penalties. - This information should be treated as strictly confidential and should not be disclosed to anyone unless authorized. I will ensure that the following information is obtained prior to releasing any Key Code information: 1. Government issued picture ID (Drivers License) 2. Registration or other proof of ownership. Registration should have normal markings from the Province that issued the registration and possibly the receipt for payment recorded as well. Important - GM takes this agreement seriously. Each user must be certain of vehicle ownership before giving out key codes. - When the ownership of the vehicle is in doubt, dealership personnel should not provide the information. Key code requests should never be received via a fax or the internet and key codes should never be provided to anyone in this manner. A face to face contact with the owner of the vehicle is the expected manner that dealers will use to release a key code or as otherwise stipulated in this bulletin or other materials. - Key codes should NEVER be sent via a fax or the internet. - Each Dealership should create a permanent file to document all KeyCode Look Up transactions. Requests should be filed by VIN and in each folder retain copies of the following: - Government issued picture ID (Drivers License) - Registration or other proof of ownership. - Copy of the paid customer receipt which has the name of the employee who cut and sold the key to the customer. - Do not put yourself or your Dealership in the position of needing to "explain" a KeyCode Look Up to either GM or law enforcement officials. - Dealership Management has the ability to review all KeyCode Look-Up transactions. - Dealership KeyCode documentation must be retained for two years. Frequently Asked Questions (FAQs) for GM of Canada Dealers How do I request a KeyCode for customer owned vehicle that is not registered? Scrapped, salvaged or stored vehicles that do not have a current registration should still have the ownership verified by requesting the vehicle title, current insurance policy and / or current lien holder information from the customers financing source. If you cannot determine if the customer is the owner of the vehicle, do not provide the key code information. In these cases, a short description of the vehicle (scrapped, salvaged, etc.) and the dealership location should be kept on file. Any clarifying explanation should be entered into the comments field. How do I document a KeyCode request for a vehicle that is being repossessed? The repossessor must document ownership of the vehicle by providing a court ordered repossession order and lien-holder documents prior to providing key code information. Copies of the repossessors Drivers License and a business card should be retained by the dealership for documentation. What do I do if the registration information is locked in the vehicle? Every effort should be made to obtain complete information for each request. Each Dealership will have to decide on a case by case basis if enough information is available to verify the customer's ownership of the vehicle. Other forms of documentation include vehicle title, insurance policy, and or current lien information from the customers financing source. Dealership Management must be involved in any request without complete information. If you cannot determine if the customer is the owner of the vehicle, do not provide the key code information. Can I get a print out of the information on the screen? It is important to note that the Key Code Look Up Search Results contain sensitive and/or proprietary information. For this reason GM recommends against printing it. If the Search Results must be printed, store and/or dispose of the printed copy properly to minimize the risk of improper or illegal use. Who in the dealership has access to the KeyCode application? Dealership Parts Manager (or assigned management) will determine, and control, who is authorized to access the KeyCode Look Up application. However, we anticipate that dealership parts and service management will be the primary users of the application. The KeyCode Look Up application automatically tracks each user activity session. Information tracked by the system includes: User name, User ID, all other entered data and the date/time of access. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information > Page 15688 What if I input the VIN incorrectly? If an incorrect VIN is entered into the system (meaning that the system does not recognize the VIN or that the VIN has been entered incorrectly) the system will return an error message. If I am an authorized user for the KeyCode application, can I access the application from home? Yes. What if I suspect key code misuse? Your dealership should communicate the proper procedures for requesting key codes. Any suspicious activity either within the dealership or externally should be reported to Dealer Systems Support at 1-800-265-0573 or GM of Canada Key Code Inquiry Desk at 1-905-644-4892. Whose key codes can I access through the system? At this time the following Canadian vehicle codes are available through the system: Chevrolet, Cadillac, Buick, Pontiac, GMC, HUMMER (H2 and H3 only), Oldsmobile, Saturn, Saab and Isuzu (up to 2002 model year) for a maximum of 17 model years. What should I do if I enter a valid VIN and the system does not produce any key code information? Occasionally, the KeyCode Look Up application may not produce a key code for a valid VIN. This may be the result of new vehicle information not yet available. In addition, older vehicle information may have been sent to an archive status. If you do not receive a key code returned for valid VIN, you should contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. How do I access KeyCodes if the KeyCode Look-up system is down? If the KeyCode Look-up system is temporarily unavailable, you can contact the original selling dealer who may have it on file or contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. If the customer is dealing with an emergency lock-out situation, you need to have the customer contact Roadside assistance, OnStar if subscribed, or 911. What should I do if the KeyCode from the look-up system does not work on the vehicle? On occasion a dealer may encounter a KeyCode that will not work on the vehicle in question. In cases where the KeyCode won't work you will need to verify with the manufacturer of the cutting equipment that the key has been cut correctly. If the key has been cut correctly you may be able to verify the proper KeyCode was given through the original selling dealer. When unable to verify the KeyCode through the original selling dealer contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. If the key has been cut correctly and the code given does not work, the lock cylinder may have been changed. In these situations following the proper SI document for recoding a key or replacing the lock cylinder may be necessary. How long do I have to keep KeyCode Records? Dealership KeyCode documentation must be retained for two years. Can I get a KeyCode changed in the Look-Up system? Yes, KeyCodes can be changed in the Look-Up system if a lock cylinder has been changed. Contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. What information do I need before I can provide a driver of a company fleet vehicle Keys or KeyCode information? The dealership should have a copy of the individual's driver's license, proof of employment and registration. If there is any question as to the customer's employment by the fleet company, the dealer should attempt to contact the fleet company for verification. If there is not enough information to determine ownership and employment, this information should not be provided. How do I document a request from an Independent Repair facility for a KeyCode or Key? The independent must provide a copy of their driver's license, proof of employment and signed copy of the repair order for that repair facility. The repair order must include customer's name, address, VIN, city, province and license plate number. Copies of this information must be included in your dealer KeyCode file. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information > Page 15689 Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Antenna - Keyless Entry > Component Information > Service and Repair > Keyless Entry Antenna Replacement (Regular Cab) Antenna - Keyless Entry: Service and Repair Keyless Entry Antenna Replacement (Regular Cab) Keyless Entry Antenna Replacement (Regular Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Antenna - Keyless Entry > Component Information > Service and Repair > Keyless Entry Antenna Replacement (Regular Cab) > Page 15695 Antenna - Keyless Entry: Service and Repair Keyless Entry Antenna Replacement (Extended/Crew Cab) Keyless Entry Antenna Replacement (Extended/Crew Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Service and Repair Keyless Entry Module: Service and Repair Remote Control Door Lock Receiver Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Receiver > Component Information > Diagrams Keyless Entry Receiver: Diagrams Component Connector End Views Remote Control Door Lock Receiver (RCDLR) (AP3 or AP8) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Starting System > Keyless Start Transmitter > Component Information > Technical Service Bulletins > Keyless System - Remote Start Transmitter Diagnostic Tip Keyless Start Transmitter: Technical Service Bulletins Keyless System - Remote Start Transmitter Diagnostic Tip INFORMATION Bulletin No.: 09-08-52-004A Date: January 08, 2010 Subject: Diagnostic Tips/Recommendations on GM Accessory 2-Way Remote Start Transmitter When Transmitter Battery is Weak or Dead Models: 2007-2010 Buick Lucerne 2008-2010 Buick Enclave 2007-2010 Cadillac DTS, Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Cobalt, HHR, Impala, Silverado, Tahoe 2009-2010 Chevrolet Malibu, Traverse 2007-2010 GMC Acadia, Sierra, Yukon 2007-2009 Pontiac G5, G6, Solstice, Torrent 2008-2009 Pontiac G8 2007-2010 Saturn AURA, OUTLOOK, SKY, VUE 2007-2010 HUMMER H2 Supercede: This bulletin is being revised to update the models and model years. Please discard Corporate Bulletin Number 09-08-52-004 (Section 08 - Body and Accessories). Follow these procedures if a customer comments that their GM Accessory 2-way transmitter stopped communicating with the vehicle. About GM Accessory 2-Way Remote Start The GM Accessory 2-way transmitter has the ability to operate a second vehicle equipped with a 2-way advanced remote start system, but often the 2-way transmitter may only be coded to one vehicle. If the customer presses the left side button twice within one second, the 2-way transmitter will enter second vehicle mode and will not control the original vehicle until a subsequent double press of the left side button places the transmitter back in first vehicle mode. Each vehicle mode of the 2-way transmitter should be thought of as an individual transmitter with its own unique code. Test the Transmitter Battery Note This test should be performed prior to releasing the vehicle or transmitter to the customer. All transmitter batteries should be tested immediately after installation of a 2-way remote start kit or replacement of a transmitter battery using the following procedure. 1. Press the unlock button on the transmitter eight times consecutively. 2. After the eighth press of the unlock button, observe the battery gauge located in the upper right corner of the LCD display. The gauge should read full (three bars inside the battery icon). If after having a new battery installed, the battery goes dead within five months, the transmitter could have high sleep current, causing the battery to go dead. Replace the transmitter. Please follow this diagnostic or repair process thoroughly and complete each step. If the condition exhibited is resolved without completing every step, the remaining steps do not need to be performed. Determine if Transmitter is in Second Vehicle Mode 1. Press and release any of the face buttons on the 2-way transmitter and observe the display on power-up. 2. If the 2-way transmitter is in second vehicle mode, the second vehicle icon will be displayed on the left side of the transmitter display. Is the 2-way transmitter in second vehicle mode? If Yes, the 2-way transmitter is working properly. - Press and release the left side button twice within one second. The 2-way transmitter should exit second vehicle mode. - Press and release the lock button. Press and release the unlock button. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Starting System > Keyless Start Transmitter > Component Information > Technical Service Bulletins > Keyless System - Remote Start Transmitter Diagnostic Tip > Page 15707 - Confirm that the vehicle responds with the appropriate lock and unlock function. - If Yes , the 2-way transmitter was in mode B. - Press and release the left side button twice within one second. The 2-way transmitter should enter second vehicle mode. - Use the "next available slot" method in the scan tool to program the 2-way transmitter to the 2-way RCDLR. Refer to Remote Control Door Lock Transmitter Programming in SI. - Both vehicle modes of the 2-way transmitter should now be coded to the vehicle. If No: The 2-way transmitter is not exhibiting the failure mode addressed by this bulletin. Refer to normal diagnostic procedures. Parts Information For part numbers, usage and availability of 2-way remote start, refer to the Accessory Parts Catalog or Corporate Bulletin Number 09-00-89-025A. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Starting System > Keyless Start Transmitter > Component Information > Technical Service Bulletins > Keyless System - Remote Start Transmitter Diagnostic Tip > Page 15708 Keyless Start Transmitter: Technical Service Bulletins Keyless Start - 2-Way Advanced Remote Start INFORMATION Bulletin No.: 09-00-89-025A Date: October 26, 2009 Subject: GM Accessories: 2-Way Advanced Remote Start Systems Part Information Models: 2007-2010 Buick Lucerne 2008-2010 Buick Enclave 2007-2010 Cadillac Escalade ESV, EXT 2008-2010 Cadillac DTS 2007-2009 Chevrolet Equinox, HHR 2007-2010 Chevrolet Avalanche, Cobalt, Silverado, Tahoe 2008-2010 Chevrolet Impala, Malibu 2009-2010 Chevrolet Traverse 2007-2010 GMC Acadia, Sierra, Yukon 2008-2010 HUMMER H2 2007-2009 Pontiac Torrent 2007-2010 Pontiac G5, G6 2008-2010 Pontiac G8 2010 Pontiac Solstice 2007-2010 Saturn AURA, OUTLOOK 2009-2010 Saturn VUE 2010 Saturn SKY Attention: This bulletin does not apply to GMODC dealers. Supercede: This bulletin is being revised to add part numbers. Please discard Corporate Bulletin Number 09-00-89-025 (Section 00 - General Information). This bulletin is being published to provide information on locating service part numbers for GM Accessory, 2-Way Advanced Remote Start Systems. Dealers should consult the chart below and use the correct service part. Dealers should not use entire kit for warranty or repair work. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Starting System > Keyless Start Transmitter > Component Information > Technical Service Bulletins > Keyless System - Remote Start Transmitter Diagnostic Tip > Page 15709 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Starting System > Keyless Start Transmitter > Component Information > Technical Service Bulletins > Keyless System - Remote Start Transmitter Diagnostic Tip > Page 15710 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Starting System > Keyless Start Transmitter > Component Information > Technical Service Bulletins > Keyless System - Remote Start Transmitter Diagnostic Tip > Page 15711 Parts Information Service parts common to all 2-Way Advanced Remote Start Systems Transmitter Battery 12493150 Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter: > 08-08-52-001G > Aug > 10 > Keyless Entry - Intermittent/Inoperative Remote Keyless Entry Transmitter: All Technical Service Bulletins Keyless Entry - Intermittent/Inoperative Remote TECHNICAL Bulletin No.: 08-08-52-001G Date: August 24, 2010 Subject: EI08028 - Intermittent, Inoperative Remote Keyless Entry (RKE) (Reprogram Key Fobs) Models: 2008-2011 Buick Enclave 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2009-2011 Chevrolet Traverse 2007-2011 GMC Acadia, Sierra, Sierra Denali, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2007-2010 Saturn OUTLOOK Supercede: This bulletin is being revised to change the labor operation number. Please discard Corporate Bulletin Number 08-08-52-001F (Section 08 - Body and Accessories). Condition Some customers may comment that one or more key fobs are inoperative. A number of warranty claims have been submitted that show relearning the key fobs has corrected this concern. Cause Based on technician feedback, engineering has determined two possible causes for key fob concerns: - The fobs may not be programmed when the vehicles leave the plant. - There may be Issues with the fobs internal components. Correction To correct the customer's concern, reprogram the transmitter (key fob). Refer to the procedure for Transmitter Programming found in Service Information. If reprogramming the transmitter is not successful, it will be necessary to replace the transmitter. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter: > 10-08-52-003 > Jul > 10 > Keyless Entry - Transmitter Button Inop/Won't Program Keyless Entry Transmitter: All Technical Service Bulletins Keyless Entry - Transmitter Button Inop/Won't Program INFORMATION Bulletin No.: 10-08-52-003 Date: July 21, 2010 Subject: Remote Keyless Entry Transmitter (RKE) Button Inoperative or Will Not Reprogram to Vehicle Models: 2006-2008 Buick Allure/LaCrosse 2006-2010 Buick Lucerne 2008-2010 Buick Enclave 2006-2007 Cadillac SRX 2006-2009 Cadillac DTS 2008-2009 Cadillac CTS (Non-EZ Key), Escalade, Escalade ESV, Escalade EXT 2006-2010 Chevrolet Impala 2007-2009 Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Silverado, Tahoe, Suburban 2008-2010 Chevrolet Express 2009-2010 Chevrolet Captiva 2007-2010 GMC Acadia, Sierra, Yukon, Yukon XL (Including Denali Models) 2008-2010 GMC Savana 2007-2009 Pontiac Torrent 2007-2010 Saturn OUTLOOK 2008-2010 Saturn VUE 2008-2010 HUMMER H2, H2 SUT with Remote Keyless Entry Attention: This bulletin should be distributed and reviewed by the Service Manager and Service Advisors. A copy of this bulletin may be given to your customer to assist in explaining the remote keyless entry (RKE) transmitter operation. This bulletin provides information regarding any remote keyless entry/transmitter (key fob) that may be inoperative intermittently or in which a particular button(s) does not work. To prevent transmitter battery drain, the RKE transmitter will disable any button or buttons that are depressed longer than 30 seconds. The disabled button or buttons will remain disabled until another button that has not been disabled is pressed. If a button or buttons on a transmitter are not functioning, or if a transmitter cannot be programmed to a vehicle, press and release each and every button on the fob one at a time until you find one that works then retest the other buttons. If all buttons are now working, the button(s) were disabled and the transmitter is working as designed. If the transmitter still fails to function properly, use the J-43241 tester and follow normal diagnostics as shown in SI. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Customer Interest: > 08-08-52-001G > Aug > 10 > Keyless Entry Intermittent/Inoperative Remote Keyless Entry Transmitter: Customer Interest Keyless Entry - Intermittent/Inoperative Remote TECHNICAL Bulletin No.: 08-08-52-001G Date: August 24, 2010 Subject: EI08028 - Intermittent, Inoperative Remote Keyless Entry (RKE) (Reprogram Key Fobs) Models: 2008-2011 Buick Enclave 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2009-2011 Chevrolet Traverse 2007-2011 GMC Acadia, Sierra, Sierra Denali, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2007-2010 Saturn OUTLOOK Supercede: This bulletin is being revised to change the labor operation number. Please discard Corporate Bulletin Number 08-08-52-001F (Section 08 - Body and Accessories). Condition Some customers may comment that one or more key fobs are inoperative. A number of warranty claims have been submitted that show relearning the key fobs has corrected this concern. Cause Based on technician feedback, engineering has determined two possible causes for key fob concerns: - The fobs may not be programmed when the vehicles leave the plant. - There may be Issues with the fobs internal components. Correction To correct the customer's concern, reprogram the transmitter (key fob). Refer to the procedure for Transmitter Programming found in Service Information. If reprogramming the transmitter is not successful, it will be necessary to replace the transmitter. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Transmitter: > 10-08-52-003 > Jul > 10 > Keyless Entry - Transmitter Button Inop/Won't Program Keyless Entry Transmitter: All Technical Service Bulletins Keyless Entry - Transmitter Button Inop/Won't Program INFORMATION Bulletin No.: 10-08-52-003 Date: July 21, 2010 Subject: Remote Keyless Entry Transmitter (RKE) Button Inoperative or Will Not Reprogram to Vehicle Models: 2006-2008 Buick Allure/LaCrosse 2006-2010 Buick Lucerne 2008-2010 Buick Enclave 2006-2007 Cadillac SRX 2006-2009 Cadillac DTS 2008-2009 Cadillac CTS (Non-EZ Key), Escalade, Escalade ESV, Escalade EXT 2006-2010 Chevrolet Impala 2007-2009 Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Silverado, Tahoe, Suburban 2008-2010 Chevrolet Express 2009-2010 Chevrolet Captiva 2007-2010 GMC Acadia, Sierra, Yukon, Yukon XL (Including Denali Models) 2008-2010 GMC Savana 2007-2009 Pontiac Torrent 2007-2010 Saturn OUTLOOK 2008-2010 Saturn VUE 2008-2010 HUMMER H2, H2 SUT with Remote Keyless Entry Attention: This bulletin should be distributed and reviewed by the Service Manager and Service Advisors. A copy of this bulletin may be given to your customer to assist in explaining the remote keyless entry (RKE) transmitter operation. This bulletin provides information regarding any remote keyless entry/transmitter (key fob) that may be inoperative intermittently or in which a particular button(s) does not work. To prevent transmitter battery drain, the RKE transmitter will disable any button or buttons that are depressed longer than 30 seconds. The disabled button or buttons will remain disabled until another button that has not been disabled is pressed. If a button or buttons on a transmitter are not functioning, or if a transmitter cannot be programmed to a vehicle, press and release each and every button on the fob one at a time until you find one that works then retest the other buttons. If all buttons are now working, the button(s) were disabled and the transmitter is working as designed. If the transmitter still fails to function properly, use the J-43241 tester and follow normal diagnostics as shown in SI. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions Keyless Entry Transmitter: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Schematic Symbols Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15736 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15737 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15738 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15739 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15740 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15741 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15742 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15743 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15744 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15745 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15746 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15747 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15748 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15749 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15750 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15751 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15752 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15753 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15754 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15755 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15756 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15757 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15758 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15759 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15760 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15761 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15762 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15763 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15764 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15765 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15766 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15767 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15768 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15769 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15770 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15771 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15772 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15773 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15774 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15775 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15776 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15777 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15778 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15779 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15780 Keyless Entry Transmitter: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed with Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15781 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15782 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Connector Test Adapters) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15783 Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Test Lamp) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Fused Jumper Wires) * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage Drop) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Frequency) * Testing Ground and Low Reference Circuits (See: Testing and Inspection/Component Tests and General Diagnostics/Testing Ground and Low Reference Circuits) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fuses) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Circuit Breakers) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fusible Links) Troubleshooting with a Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Testing for a Short to Voltage Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15784 Testing for a Short to Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure tests for a short to voltage in a circuit. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the Digital Multimeter (DMM) to the V (DC) position. 4. Connect the positive lead of the DMM to one end of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. Turn ON the ignition and operate all accessories. 7. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Special Tools J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure). Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents). Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15785 The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the frequency of a signal. Note: Connecting the Digital Multimeter (DMM) to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Set to Hz on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15786 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the Digital Multimeter (DMM). 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the difference in voltage potential between 2 points. 1. Set the Digital Multimeter (DMM) to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15787 Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Backprobe Note: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15788 (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for Continuity Testing for Continuity Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures verify good continuity in a circuit. With a Digital Multimeter (DMM) 1. Set the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Select the MIN MAX function on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15789 Testing for Electrical Intermittents Testing for Electrical Intermittents Special Tools J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. Note: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions). 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15790 visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing for Terminal Fretting Some intermittent conditions can be caused by wire terminal fretting corrosion. Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can pile up enough at the electrical contact spots that the electrical resistance across the connection increases. Movement between the contacting surfaces as small as 10 to 100 microns can cause fretting. To put this in perspective, a sheet of paper is about 100 microns thick, so fretting motion is small and hard to see. Vibration and thermal expansion/contraction are the main sources that create fretting motion. Since vehicles vibrate and can experience large temperature swings, they are a good source for fretting motion. Tin, copper, nickel, and iron surfaces are all susceptible to fretting corrosion. Fretting corrosion can be difficult to see but it looks like small, dark smudges on the terminals contact surface. To correct a fretting condition disconnect the suspect connector and add Nyogel lubricant 760G (dielectric grease) to both sides of the connector terminals. Then reconnect the connector and wipe away any excess lubricant. This will correct the additional terminal contact resistance due to the terminal fretting corrosion. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15791 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics). * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Ground Distribution Schematics). Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Checking Aftermarket Accessories). * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15792 Note: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures test for a short to ground in a circuit. With a Digital Multimeter (DMM) 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohms position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Danger: High voltage circuits should only be tested using a digital multimeter (DMM) and test leads with at least a CAT III rating, such as the J 39200-A Digital Multimeter. Failure to follow the procedures exactly as written may result in serious injury or death. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Digital Multimeter (DMM) Basic Requirements Service information is validated using digital multimeters that meet or exceed the following requirements. Using a multimeter that does not meet these basic requirements may give inaccurate readings which could lead to an incorrect diagnosis. Display and Settings 1. Four digits displayed 2. Voltage, amperage, resistance, frequency, diode test settings, and min-max function 3. Display positive and negative values Voltage 1. Have at least 10 M ohm input impedance Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15793 2. Test a DC voltage range of 0.1-1000 V. 3. Test an AC voltage range of 0.1-1000 V. Amperage 1. Test a DC amperage range of 0.1µA-10 A. 2. Test an AC amperage range of 0.1µA-10 A. Resistance Test a resistance range of 0.1 ohm-40 Mohm and displays infinite for a value greater than 40 M ohm (O.L. (Over-load)) Frequency Test for a frequency range of 0.5 HZ-199 K HZ Diode Test 1. Apply at least 1 mA when performing the diode bias test 2. Display the break over voltage drop (0-3 V) of a forward biased diode 3. Display infinite (O.L. (Over-load)) when a diode is reverse biased Min-Max Readings 1. Can update at a 1 ms sample rate 2. Saves and displays minimum and maximum values Note: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Probe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors). * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the EL-38125-580 GM Approved Terminal Release Tool Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the EL-38125-580 GM Approved Terminal Release Tool Kit , ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the EL-38125-580 GM Approved Terminal Release Tool Kit label on the inside of the EL-38125-580 GM Approved Terminal Release Tool Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15794 Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/EPC Connectors AFL/EPC Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15795 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 3. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15796 View showing depressing of the lever lock release tab. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15797 6. Release the rear lower half of the wiredress cover. 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15798 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15799 Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Bosch Connectors (ECM) Bosch Connectors (ECM) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15800 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. 2. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15801 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-bladed tool to release the locking tabs and remove the dress cover. 4. The terminal positive assurance (TPA) is located in the front of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15802 5. Use a small flat-blade tool to remove TPA from the connector. 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15803 Note: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15804 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15805 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Terminal Replacement Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15806 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15807 5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Position Assurance Locks) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Terminal Position Assurance Locks) * AFL/EPC Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/AFL/EPC Connectors) * Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (BSK))Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (0.64))Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (2.8 JPT))Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (ECM)) * Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Weather Pack))Delphi Connectors (Push To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Push to Seat))Delphi Connectors Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15808 (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Pull to Seat))Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro-Pack 100W))Delphi Connectors (Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro .64))Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (12-Way)) * FCI Connectors (Lever Lock) (See: General Electrical Diagnostic Procedures/Connector Repairs/FCI Connectors (Lever Lock)) * JST Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/JST Connectors) * Kostal Connectors (Glow Plug Control Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Glow Plug Control Module))Kostal Connectors (Transmission) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Transmission)) * Molex Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Molex Connectors) * Sumitomo Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Sumitomo Connectors) * Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (CM 42-Way))Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Sensor))Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (0.25 Cap))Tyco/AMP Connectors (43-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (43-Way))Tyco/AMP Connectors (Door Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Door Module))Tyco/AMP Connectors (102-Way Inline) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (102-Way Inline))Tyco/AMP Connectors (Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Seat))Tyco/AMP Connectors (SIR) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (SIR)) * Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (2-Way))Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (16-Way)) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15809 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15810 * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15811 * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15812 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15813 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15814 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Push to Seat) Delphi Connectors (Push To Seat) Special Tools J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15815 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs). 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Terminated Lead Repair 1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice sleeves depending on the gauge size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Delphi Connectors (Pull to Seat) Delphi Connectors (Pull To Seat) Special Tools Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15816 J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Note: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15817 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. View of a typical Micro 64 connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15818 Depress the lock and pull the lever over and past the lock. View of the connector when released from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15819 View of another type of Micro 64 connector. Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15820 View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15821 Note: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15822 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15823 Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Note: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15824 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15825 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15826 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15827 1. Cut the wire as close to the terminal as possible. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15828 Terminal Replacement Procedure After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Special Tools J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Note: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals). 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12-Way) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15829 Delphi Connectors (12-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15830 4. Release the lower wire dress cover locking tab. 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15831 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15832 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors (Lever Lock) FCI Connectors (Lever Lock) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15833 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. The release tab is located on the top of the wiredress cover. 3. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15834 6. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15835 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15836 1. While depressing the lock, remove the connector from the component. 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15837 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. 4. View of the TPA when removed from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15838 5. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Glow Plug Control Module) Kostal Connectors (Glow Plug Control Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15839 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15840 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15841 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. Note: The front TPA cannot be removed from the connector. Only move it to the preset position. 6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm). 7. Use a small flat-blade tool to completely remove the rear TPA from the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15842 8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Transmission) Kostal Connectors (Transmission) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15843 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15844 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Terminal Replacement Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15845 After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15846 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15847 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15848 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15849 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15850 3. To assemble the connector, reverse the connector disassembly procedure. Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15851 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15852 7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15853 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15854 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15855 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15856 Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15857 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15858 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15859 6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (102-Way Inline) Tyco/AMP Connectors (102-Way Inline) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15860 View of a typical connector in the assembled position. 1. Pull the locking lever to the 90 degree position from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15861 2. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal. 3. Slide the male connector body out away from the guide plates. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15862 Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 4. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. 5. Using terminal release tool J 38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15863 6. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 7. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15864 8. The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool J-38125-11A or equivalent to release the locking tab and slide the connector off the female body. 9. Move the locking lever 180 degrees from the connected position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15865 10. With the locking lever in the 180 degree position the guide plates can be removed from the connector body. Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 11. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15866 12. Using terminal release tool J 38125-216, lift the terminal plate past the terminals and out of the connector body cavity. 13. Terminal plate will bind slightly on each corner. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15867 14. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 15. Using terminal release tool J 38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15868 16. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 17. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15869 18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever. 19. Slide the male connector body back inward toward the guide plates. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15870 20. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly. 21. Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Seat) Tyco/AMP Connectors (Seat) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15871 Removal Procedure 1. Grasp the locking slide lever and pull outward from the end of the connector. 2. As the slide lever is pulled out the mating connector is lifted from the seated position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15872 Note: TPA is keyed and can only be inserted in one direction. 3. Using terminal release tool J 38125-11A or equivalent, push the TPA tabs into the connector body. 4. Pull the TPA from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15873 5. Using terminal release tool J 38125-11A or equivalent, release the connector wire dress cover locking tab. 6. With the lock tab released, lift the connector wire dress cover from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15874 7. Using terminal release tool J 38125-212, press the prongs into the holes each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 8. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15875 9. Using terminal release tool J 38125-556, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (SIR) Tyco/AMP Connectors (SIR) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15876 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15877 3. Using terminal tool J-38125-11A or equivalent, release the wire dress cover locking tabs. 4. Pivot connector wire dress cover while removing from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15878 5. Using terminal tool J-38125-11A or equivalent, remove the TPA by lifting straight off the connector body. 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals Repairing Connector Terminals Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15879 Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gauge size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15880 2. Disconnect the connector from the component. 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15881 4. Relieve the tension on the nose piece retainers by inserting J 38125-12A into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. 5. Once the nose piece retainers are relaxed, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15882 6. On the opposite side of the nose piece, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15883 8. Insert the J 38125-553 tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15884 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. If the TPA is removed, be sure to reinstall it before reconnecting the connector. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15885 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Special Tools Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15886 J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Note: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15887 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15888 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15889 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15890 1. While depressing the lock, pull the two connector halves apart. Note: The TPA is fragile and may break if not done carefully. 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. 3. View of the male half of the connector with female terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15891 4. View of the female half of the connector with male terminals. 5. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. View of the female half of the connector with male terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15892 7. View of the male half of the connector with female terminals. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15893 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are a one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine if the element in the fuse is broken (2). If not broken (1), also check for continuity using a Digital Multimeter (DMM) or a continuity tester. If the element is broken or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a Digital Multimeter (DMM) at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gauge size. Repairing a Fusible Link Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15894 Flat Wire Repairs The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Special Tools J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool * J 38125-5 Ultra Torch Special Tool The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Note: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation). GMLAN Connector Terminal Repair Note: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) for the appropriate connector repair procedure. GMLAN Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15895 Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15896 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Special Tools J-38125 Terminal Repair Kit Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15897 repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs High Temperature Wiring Repairs Special Tools J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gauge size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15898 splice. Note: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15899 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15900 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the wire insulation has been chafed, or broken, enough to show the conductive portion of the wire, and the wire is not damaged, determine the length of insulation that needs to be repaired. If the repair is less than 280 mm (11 in), cut the wire within the damaged area. Then slide the appropriate heat shrink tubing (listed below) over the wire, and repair the wire by splicing the wires together. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Once the wire is spliced together slide heat shrink tubing over the damaged area and apply heat to seal the repaired wire. If the wire is damaged, or the damaged area is larger than 280 mm (11 in), then replace the damaged wire by splicing in a new section of wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15901 SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Special Tools J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15902 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15903 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15904 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Special Tools J-38125 Terminal Repair Kit Note: Use only DuraSeal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use DuraSeal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use DuraSeal splice sleeves where there are special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15905 * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15906 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15907 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the instructions for Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Staggering the splices by 65 mm (2.5 in) is recommended. Note: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product AL-36FR to replace the damaged mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Flat Wire Repairs) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/GMLAN Wiring Repairs) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Heated Oxygen Sensor Wiring Repairs) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves) * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Twisted or Shielded Cable) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Inline Harness Diodes) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/SIR/SRS Wiring Repairs) US English/Metric Conversion US English/Metric Conversion Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15908 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15909 Testing Ground and Low Reference Circuits Testing Ground and Low Reference Circuits Because a test lamp can light with up to 200 ohm in a ground or low reference circuit they are not recommended to be used for this type of test. A low impedance test lamp can light and indicate the circuit is good when there is as much as 20-30 ohm present, while a high impedance test lamp can light with up to 200 ohm present in the circuit. This is why the Digital Multi-Meter (DMM) is used when validating a ground or low reference circuit continuity. When using the DMM there are many vehicle conditions that can affect the ground and low reference continuity testing. If these conditions are not met, a ground or low reference circuit test can fail on a good circuit. This may cause longer diagnosis time and incorrect component replacement. Any current flow through a ground or low reference circuit, while being tested, will skew the DMM continuity reading, or display a reading higher than when there is no current flowing. Performing a ground or low reference circuit continuity test, in reference to the vehicles battery negative terminal, will have the highest risk of failing a good ground or low reference circuit test than any other ground reference point. The best ground test points would be a control module housing (if the control modules housing is metal and grounded), door jamb striker (if attached to metal), under dash metal frame work, engine block, or body ground studs (other than where the negative battery cable is attached). A typical DMM ground or low reference circuit continuity reading can be as high as 100 ohm with the ignition ON, and drop to 15-25 ohm after the ignition is turned OFF. The reading will drop below 10 ohm after 30-40 seconds, then below 5 ohm after 60 seconds. Once the vehicle completely goes to sleep (generally 3-10 minutes) the reading will drop below 0.3 ohm. The following list of conditions may need to be met to ensure a valid continuity reading on a ground or low reference circuit: * Ignition OFF * Key out of the ignition switch (when not equipped with keyless entry and remote start) * Retained Accessory Power (RAP) OFF (open and close the driver door after ignition OFF) * Battery charger set at a 2 A or less charge rate * Scan tool not communicating with any vehicle control module (in some cases it may need to be disconnected from the DLC) * All entry doors closed * Headlamps OFF (auto headlamps disabled) * Any delay lighting OFF * HVAC after blow OFF * Any accessory that can work when the ignition is OFF * Wait up to 60 seconds (after all other listed conditions are met) Activating the DOOR LOCK function with a key fob can greatly reduce the time to achieve a valid ground or low reference continuity test result. Terminal Removal Terminal Removal Special Tools * EL-38125-580 - Terminal Release Tool Kit * EL-35616 - Connector Test Adapter Kit For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repair procedures. 1. Find the appropriate connector end view within the connector end view section. The connector end view has the following information: Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15910 * Diagnostic probe tool * Terminal release tool * Terminal/terminated lead part numbers Note: Not using the proper test kit probe may cause damage to the terminal(s) that are probed. 2. Determine if a terminal is damaged. * Locate the diagnostic probe tool from the connector end view. The connector end view describes the color and part number to help the technician find and use the correct tool. * Connect the probe tool to the Digital Multimeter. * Insert the probe tool into the cavity and follow the procedures from the Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter). 3. Disconnect the connector body to perform the repair. 4. Use the following procedure to remove the terminal from the connector body. Note: Several procedures for specific connector bodies are called out in the Wiring Repairs section. * The terminal position assurance (TPA) and connector position assurance (CPA) should be removed before releasing the terminal for the connector body. * Look at the connector end view to locate the cavity of the damaged terminal and find the proper terminal release tool from the terminal release tool kit. Note: Using the incorrect terminal release tool can damage the connector body. * Insert the terminal release tool into the cavity. Note: Some terminals have a lever that must be disengaged before the terminal can be released. 5. Gently pull the wire out of the back of the connector. 6. Repair the terminal by following the Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) procedure. 7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminated Lead Repair Terminated Lead Repair Special Tools * J-38125-8 - Splice Sleeve Crimp Tool Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15911 * J-38125-5 - Ultra Torch For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) procedures. Terminated leads are terminals that are crimped onto wires. The terminated lead can be used throughout the vehicle since it is designed for temperatures up to 150°C. The length of the wire is 450 mm. The DuraSeal splice sleeve has the following 2 critical features: * A special heat shrink tubing that environmentally seals the splice. The shrink tubing contains a sealing adhesive inside the shrink tubing. * A cross hatched (knurled) core crimp that provides the necessary contact integrity for sensitive low energy circuits. 1. Use the connector end view to identify the correct terminated lead. 2. The terminated lead package should include a DuraSeal splice sleeve. If not, use the chart to identify the correct part. 3. Open the harness by removing any tape: Use a sewing seam ripper, or a comparable tool, to cut open the harness, to avoid wire insulation damage. 4. Depending on how many terminals need repairs, cut the terminal and wire back at least 40 mm. Try to keep the harness wire length the same. If more than one terminated lead is required, stagger the lengths by 40 mm. This helps reduce the bundle size of the wire harness. 5. Use the EL-38125-10 - tool in order to position the DuraSeal splice sleeve in the proper color nest of the splice sleeve crimp tool. The crimp tool has four nests, one for each color. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15912 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the J-38125-5 - ultra torch , apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 15913 Keyless Entry Transmitter: Electrical Diagrams Remote Function Schematics Keyless Entry Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Diagrams > Page 15914 Keyless Entry Transmitter: Tools and Equipment Special Tools Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Locations > Fuse Block - I/P Power Door Lock Relay: Locations Fuse Block - I/P Electrical Center Identification Views Fuse Block - I/P Label Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Locations > Fuse Block - I/P > Page 15920 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Locations > Fuse Block - I/P > Page 15921 Power Door Lock Relay: Locations Fuse Block - Underhood Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Locations > Fuse Block - I/P > Page 15922 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Locations > Fuse Block - I/P > Page 15923 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Locations > Fuse Block - I/P > Page 15924 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Locations > Fuse Block - I/P > Page 15925 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Locations > Fuse Block - I/P > Page 15926 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Locations > Fuse Block - I/P > Page 15927 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Locations > Fuse Block - I/P > Page 15928 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams Power Door Lock Switch: Diagrams Component Connector End Views Door Lock Switch - Driver (AU3 without AN3 or DL3) Door Lock Switch - Passenger (AU3 without AN3 or DL3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Page 15932 Door Lock/Window Switch - Driver X1 (AN3 or DL3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Page 15933 Door Lock/Window Switch - Driver X2 (AN3 or DL3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Page 15934 Door Lock/Window Switch - Driver X3 (AN3 or DL3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Page 15935 Door Lock/Window Switch - Driver X4 (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Page 15936 Door Lock/Window Switch - Driver X7 (AN3 or DL3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Page 15937 Door Lock/Window Switch - Passenger X1 (AN3 or DL3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Page 15938 Door Lock/Window Switch - Passenger X2 (AN3 or DL3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Page 15939 Door Lock/Window Switch - Passenger X3 (AN3 or DL3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Page 15940 Door Lock/Window Switch - Passenger X4 (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Page 15941 Door Lock/Window Switch - Passenger X7 (AN3 or DL3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Page 15942 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Service and Repair > Door Lock Switch Replacement - Front (with DL8 and without SLT) Power Door Lock Switch: Service and Repair Door Lock Switch Replacement - Front (with DL8 and without SLT) Door Lock Switch Replacement - Front (with DL8 and without SLT) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Service and Repair > Door Lock Switch Replacement - Front (with DL8 and without SLT) > Page 15945 Power Door Lock Switch: Service and Repair Door Lock and Side Window Switch Replacement Driver Side Door Lock and Side Window Switch Replacement - Driver Side Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Service and Repair > Door Lock Switch Replacement - Front (with DL8 and without SLT) > Page 15946 Power Door Lock Switch: Service and Repair Door Lock and Side Window Switch Replacement Passenger Side Door Lock and Side Window Switch Replacement - Passenger Side Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Service and Repair Trunk / Liftgate Lock Cylinder: Service and Repair Lock Cylinder Binding In many cases, applying the proper lubrication can correct the following conditions: * Binding or sticking door lock cylinders * Difficulty in inserting and removing the keys For lubricating the above components, use lubricant GM P/N 12346241 or equivalent. Do not use penetrating lubricants such as GM P/N 1052949 or WD-40(R). Penetrating lubricants wash out the original lubrication. Penetrating lubricants eventually evaporate, leaving little or no lubricating material. However, when using penetrating lubricants in order to thaw or in order to loosen the lock cylinder components, refer to steps 2-4 in the procedure below for the proper methods of lubrication. Repair lock cylinders frozen in cold weather by using the following procedure: 1. While carefully avoiding damage to the painted surfaces, apply heat to the cylinder with a heat gun. 2. Using a paper clip or a similar item, hold the door shutter open. Force air into the cylinders using compressed air through a blow gun attachment. 3. While holding the shutter door open, inject small amounts of a recommended lubricant into the cylinder. 4. Work the key into the cylinder repeatedly. Wipe away any excess lubrication from the key. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Technical Service Bulletins > Mirrors - Heated Mirrors, Defrosting Time Heated Element: Technical Service Bulletins Mirrors - Heated Mirrors, Defrosting Time INFORMATION Bulletin No.: 08-08-64-011A Date: February 25, 2010 Subject: Information on Heated Electrochromatic Outside Rearview Mirror Performance Models: 2010 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-08-64-011 (Section 08 - Body and Accessories). Defrosting Time/Performance Concern The electrochromatic (auto-dimming) outside rearview mirror used on the driver's side of many GM vehicles is slower to defrost than the passenger side outside rearview mirror. This is a normal condition. The glass on the driver's side electrochromatic mirror is twice as thick as the traditional glass on the passenger side mirror. The heating elements for the mirrors on both sides draw the same wattage, therefore the driver's side mirror will take approximately twice as long to defrost as the passenger mirror (approximately four minutes versus two minutes). Should a customer indicate that the driver's side heated mirror is not functioning correctly, verify it's function based upon this information prior to replacing the mirror. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations Memory Positioning Module: Locations Harness Routing Views Driver Seat Harness Routing 1 - Seat Recline Motor - Driver (AN3) 2 - Seat Lumbar Vertical Motor Position Sensor - Driver (AN3) 3 - Seat Lumbar Vertical Motor - Driver (AN3) 4 - X324 (AN3) 5 - Seat Lumbar Horizontal Motor - Driver (AN3) 6 - Seat Lumbar Horizontal Motor Position Sensor - Driver (AN3) 7 - Seat Recline Position Sensor - Driver (AN3) 8 - Seat Lumbar Switch - Driver (AN3) 9 - Seat Adjuster Switch - Driver (AG1) 10 - Memory Seat Module (MSM) (AN3) 11 - Inflatable Restraint Seat Position Sensor (SPS) - Driver (10 Series) 12 - Seat Adjuster Motor Assembly - Driver (AG1) 13 Seat Belt Buckle - Driver Passenger Seat Harness Routing Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 15959 1 - Seat Frame 2 - X325 (AN3) 3 - Seat Lumbar Vertical Motor - Passenger (AN3) 4 - Seat Adjuster Switch - Passenger (AG2) 5 - Seat Lumbar Switch - Passenger (AN3) 6 - Seat Belt Buckle Passenger 7 - Inflatable Restraint Passenger Presence System (PPS) Module (AL0) 8 - Seat Adjuster Motor Assembly - Passenger (AG2) 9 - Inflatable Restraint Passenger Presence System (PPS) Sensor (AL0) 10 - Seat Recline Motor - Passenger (AN3) 11 - Seat Lumbar Horizontal Motor - Passenger (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 15960 Memory Positioning Module: Diagrams Component Connector End Views Memory Seat Module (MSM) X1 (AN3) Memory Seat Module (MSM) X2 (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 15961 Memory Seat Module (MSM) X3 (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 15962 Memory Seat Module (MSM) X4 (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 15963 Memory Seat Module (MSM) X5 (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 15964 Memory Seat Module (MSM) X6 (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 15965 Memory Seat Module (MSM) X7 (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 15966 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 15967 Memory Positioning Module: Service and Repair Memory Seat Control Module Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations Seat Memory Switch: Locations Harness Routing Views Driver Seat Harness Routing 1 - Seat Recline Motor - Driver (AN3) 2 - Seat Lumbar Vertical Motor Position Sensor - Driver (AN3) 3 - Seat Lumbar Vertical Motor - Driver (AN3) 4 - X324 (AN3) 5 - Seat Lumbar Horizontal Motor - Driver (AN3) 6 - Seat Lumbar Horizontal Motor Position Sensor - Driver (AN3) 7 - Seat Recline Position Sensor - Driver (AN3) 8 - Seat Lumbar Switch - Driver (AN3) 9 - Seat Adjuster Switch - Driver (AG1) 10 - Memory Seat Module (MSM) (AN3) 11 - Inflatable Restraint Seat Position Sensor (SPS) - Driver (10 Series) 12 - Seat Adjuster Motor Assembly - Driver (AG1) 13 Seat Belt Buckle - Driver Passenger Seat Harness Routing Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations > Page 15971 1 - Seat Frame 2 - X325 (AN3) 3 - Seat Lumbar Vertical Motor - Passenger (AN3) 4 - Seat Adjuster Switch - Passenger (AG2) 5 - Seat Lumbar Switch - Passenger (AN3) 6 - Seat Belt Buckle Passenger 7 - Inflatable Restraint Passenger Presence System (PPS) Module (AL0) 8 - Seat Adjuster Motor Assembly - Passenger (AG2) 9 - Inflatable Restraint Passenger Presence System (PPS) Sensor (AL0) 10 - Seat Recline Motor - Passenger (AN3) 11 - Seat Lumbar Horizontal Motor - Passenger (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations > Page 15972 Seat Memory Switch: Service and Repair Driver Seat Adjuster Memory Switch Replacement (Crew Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Power Mirror Motor > Component Information > Service and Repair Power Mirror Motor: Service and Repair Outside Rearview Mirror Motor Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Power Mirror Position Switch/Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 06-08-64-027I > Apr > 11 > Body - LH/RH Outside Rearview Mirror Glass Shake/Flutter Power Mirror Position Switch/Sensor: Customer Interest Body - LH/RH Outside Rearview Mirror Glass Shake/Flutter TECHNICAL Bulletin No.: 06-08-64-027I Date: April 12, 2011 Subject: Left or Right Outside Rearview Mirror Glass Shake or Flutter (Relearn Power Mirrors and Replace Mirror, If Necessary) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon XL, Yukon Denali All Equipped with Power Folding Mirrors RPO DL3 Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 06-08-64-027H (Section 08 - Body and Accessories). Condition Some customers may comment that the left or right outside rearview mirror glass shakes or flutters at normal driving speeds. Cause - The mirror may have been accidentally pushed in manually or obstructed while folding. - The mirror actuator screws may be loose, allowing the mirror to move. - The metal spring may not have enough tension to hold the mirror from moving. Correction Follow the procedure below to correct this condition. 1. The power folding mirrors should be cycled three complete times to relearn the mirror positions. Then perform a road test and check the mirror glass for stability. If stability is not corrected, proceed to Step 2. 2. Remove the mirror glass. Refer to Mirror Face Replacement in SI. 3. Verify the torque on the four retaining screws on the actuator. Tighten Tighten the screws to 1.13-1.6 Nm (10-14 lb in). 4. Bend the metal spring up to increase the tension engagement to the mirror housing 13 mm (1/2 in). 5. Install the glass assembly by pressing firmly, taking care not to allow the spring finger to unseat from its intended track in the mirror housing. Road test the vehicle. If stability is not improved, replace the mirror assembly. Refer to Power Mirror Replacement in SI. Parts Information If replacing the mirror assembly, see Mirror in Group 16.068 of the appropriate Parts Catalog for part numbers and usage. Warranty Information Important Only one Labor Operation should be claimed depending on the actual repair. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Power Mirror Position Switch/Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 06-08-64-027I > Apr > 11 > Body - LH/RH Outside Rearview Mirror Glass Shake/Flutter > Page 15984 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Power Mirror Position Switch/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-08-64-027I > Apr > 11 > Body - LH/RH Outside Rearview Mirror Glass Shake/Flutter Power Mirror Position Switch/Sensor: All Technical Service Bulletins Body - LH/RH Outside Rearview Mirror Glass Shake/Flutter TECHNICAL Bulletin No.: 06-08-64-027I Date: April 12, 2011 Subject: Left or Right Outside Rearview Mirror Glass Shake or Flutter (Relearn Power Mirrors and Replace Mirror, If Necessary) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon XL, Yukon Denali All Equipped with Power Folding Mirrors RPO DL3 Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 06-08-64-027H (Section 08 - Body and Accessories). Condition Some customers may comment that the left or right outside rearview mirror glass shakes or flutters at normal driving speeds. Cause - The mirror may have been accidentally pushed in manually or obstructed while folding. - The mirror actuator screws may be loose, allowing the mirror to move. - The metal spring may not have enough tension to hold the mirror from moving. Correction Follow the procedure below to correct this condition. 1. The power folding mirrors should be cycled three complete times to relearn the mirror positions. Then perform a road test and check the mirror glass for stability. If stability is not corrected, proceed to Step 2. 2. Remove the mirror glass. Refer to Mirror Face Replacement in SI. 3. Verify the torque on the four retaining screws on the actuator. Tighten Tighten the screws to 1.13-1.6 Nm (10-14 lb in). 4. Bend the metal spring up to increase the tension engagement to the mirror housing 13 mm (1/2 in). 5. Install the glass assembly by pressing firmly, taking care not to allow the spring finger to unseat from its intended track in the mirror housing. Road test the vehicle. If stability is not improved, replace the mirror assembly. Refer to Power Mirror Replacement in SI. Parts Information If replacing the mirror assembly, see Mirror in Group 16.068 of the appropriate Parts Catalog for part numbers and usage. Warranty Information Important Only one Labor Operation should be claimed depending on the actual repair. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Power Mirror Position Switch/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-08-64-027I > Apr > 11 > Body - LH/RH Outside Rearview Mirror Glass Shake/Flutter > Page 15990 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Power Mirror Position Switch/Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Mirror Position Switch/Sensor: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information Back Window Glass: All Technical Service Bulletins A/C - Window Defroster Contact/Tab Repair Information INFORMATION Bulletin No.: 03-08-48-006H Date: April 11, 2011 Subject: Repair Information for Reconnection of Rear Window Defroster Contact or Tab Models: 2000-2012 GM Passenger Cars and Trucks 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X 2007-2010 Opel GT 2007-2008 Daewoo G2X Equipped With Electric Rear Window Defroster - RPO C49 Supercede: This bulletin is being revised to add the 2012 model year. Please discard Corporate Bulletin Number 03-08-48-006G (Section 08 - Body and Accessories). Repair Suggestions Soldering Defroster Contact Tabs In many cases the terminal tab will still be in the connector when you examine the vehicle. For Chevrolet Tahoe, Suburban, GMC Yukon, and Cadillac Escalade vehicles (with moveable glass), always replace the defroster tab (GM P/N 25916031) and the defroster electrical power connector (P/N 12034110). For all other vehicles, reconnect the original defroster tab. In most applications it is preferable to create a new solder connection to reattach a separated rear defroster tab. If you take note of the steps below, it is possible to create a new solder joint that is equal to, or stronger than, the original. The generic procedure below is not very time intensive, but does include minor preparation work to create a good bonding surface. Be sure to follow each of the steps, as combined they will produce the strongest bond possible. Please consider the following before attempting the repair: - Soldering introduces significant heat to the glass window of the vehicle. When performing the re-connection of the tab, use only the heat required to do the job. Pre-heat the soldering iron and have the solder in your other hand, ready to go, the moment you have enough heat to melt the solder. - If it is winter, bring the vehicle into the service garage and remove any snow from the back window area. Allow time for the glass to warm to the temperature inside the building. Soldering creates a "hot spot" in the glass. DO NOT solder on cold glass. Caution Heating the glass excessively, or repeatedly without time to cool, may result in glass breakage. ALWAYS wear safety glasses when performing this repair! - You MUST use a silver-bearing solder to make the connection. DO NOT attempt this repair with conventional tin/lead alloy solders. Silver bearing solder will adhere to the electrical buss bar, making a strong and lasting repair. - Protect surfaces under the area to be soldered. It is very easy to drip solder when performing this repair. Placing a shop towel under the soldering area is sufficient protection. Soldering Procedure 1. It is imperative to remove and replace the rear defroster electrical power connector by crimping a new connector to the feed wire. The proper connector P/N 12034110 can be found in the Packard Electrical Assortment, Tray 18, Position 5. - Insert Delphi pick 12094430 to depress the locking tab on the terminal. - Insert Delphi pick 12094429 to release the secondary lock tab. Important DO NOT re-use the existing defroster tab on new-style full-size utility vehicles with moveable glass. 2. Connect the electrical connector to the defroster tab. Fully engage the connector. An improperly seated connector may cause excessive resistance and impede the proper operation of the defroster. Add a small bead of solder to mate the electrical connector tab to the defroster tab. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Power Mirror Position Switch/Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Mirror Position Switch/Sensor: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 15996 3. Prepare the surface of the used defroster tab (not required for new tabs on new-style full-size utility models) and the defroster buss bar with fine grain (500 grit) sandpaper or Emery cloth. It is not necessary to remove all of the original solder, but it should be scuffed sufficiently so that no oxidation is present. The photo above shows a close up of a properly prepared surface. Tip You may want to mask the glass around the contact area with tape. This is easy to do and will allow you to safely prepare the contact surface without the risk of scratching the glass or the black painted shading. Important Most rear glass has a black painted masking around the edge of the glass. When cleaning up the connection surface, be very careful not to damage the surface of the black shading or the surface of the glass. 4. Wipe the newly prepared contact area with Kent Automotive* Acrysol(TM) (or equivalent) to remove any residual oil or dirt. Important Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Power Mirror Position Switch/Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Mirror Position Switch/Sensor: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 15997 You MUST use a silver-bearing solder to make the solder joint. DO NOT attempt this repair with conventional tin/lead alloy solders. Most suppliers have this type of solder available and it is available nationally at Radio Shack(R)*. It is sold in several diameters and either are acceptable for this repair. 5. For this step, it is permitted that two technicians be used if required. Heat the new connector on the surface of the buss bar that is to be soldered. Long nose pliers are suggested to hold the electrical connector and the defroster tab in place. Keep the solder ready and begin flowing out the solder as soon as the melting temperature has been reached. Tip If a single technician is attempting this repair, it is beneficial to wrap one turn of the solder around the new contacts base. In this manner, as the melting point of the solder is reached, a layer is deposited on the bottom side of the contact. Important Try to align the new contact so that it is positioned with the same orientation as the original contact. 6. The above illustrates an ideal finished solder joint. Additional stray solder will not harm the performance of the bond; however, while it is unlikely that customers may refer to the appearance of the rear window defroster and its components as a positive styling feature of the vehicle interior, it is easy to elicit the opposite reaction due to a poor cosmetic application. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Acrysol(TM) can be ordered directly from Kent Automotive at 1-800-654-6333 (in Canada, 1-800-563-1717). Radio Shack(R) products can be found nationally at retail locations, www.radioshack.com, or at 1-800-843-7422. All other parts can be ordered through GMSPO or SSPO. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Power Mirror Position Switch/Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Mirror Position Switch/Sensor: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 15998 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Power Mirror Position Switch/Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Mirror Position Switch/Sensor: > 00-08-48-005D > Sep > 10 > Body - Vehicle Glass Distortion Information Back Window Glass: All Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Power Mirror Position Switch/Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Mirror Position Switch/Sensor: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 16008 3. Prepare the surface of the used defroster tab (not required for new tabs on new-style full-size utility models) and the defroster buss bar with fine grain (500 grit) sandpaper or Emery cloth. It is not necessary to remove all of the original solder, but it should be scuffed sufficiently so that no oxidation is present. The photo above shows a close up of a properly prepared surface. Tip You may want to mask the glass around the contact area with tape. This is easy to do and will allow you to safely prepare the contact surface without the risk of scratching the glass or the black painted shading. Important Most rear glass has a black painted masking around the edge of the glass. When cleaning up the connection surface, be very careful not to damage the surface of the black shading or the surface of the glass. 4. Wipe the newly prepared contact area with Kent Automotive* Acrysol(TM) (or equivalent) to remove any residual oil or dirt. Important Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Power Mirror Position Switch/Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Mirror Position Switch/Sensor: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 16009 You MUST use a silver-bearing solder to make the solder joint. DO NOT attempt this repair with conventional tin/lead alloy solders. Most suppliers have this type of solder available and it is available nationally at Radio Shack(R)*. It is sold in several diameters and either are acceptable for this repair. 5. For this step, it is permitted that two technicians be used if required. Heat the new connector on the surface of the buss bar that is to be soldered. Long nose pliers are suggested to hold the electrical connector and the defroster tab in place. Keep the solder ready and begin flowing out the solder as soon as the melting temperature has been reached. Tip If a single technician is attempting this repair, it is beneficial to wrap one turn of the solder around the new contacts base. In this manner, as the melting point of the solder is reached, a layer is deposited on the bottom side of the contact. Important Try to align the new contact so that it is positioned with the same orientation as the original contact. 6. The above illustrates an ideal finished solder joint. Additional stray solder will not harm the performance of the bond; however, while it is unlikely that customers may refer to the appearance of the rear window defroster and its components as a positive styling feature of the vehicle interior, it is easy to elicit the opposite reaction due to a poor cosmetic application. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Acrysol(TM) can be ordered directly from Kent Automotive at 1-800-654-6333 (in Canada, 1-800-563-1717). Radio Shack(R) products can be found nationally at retail locations, www.radioshack.com, or at 1-800-843-7422. All other parts can be ordered through GMSPO or SSPO. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Power Mirror Position Switch/Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Mirror Position Switch/Sensor: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 16010 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Diagrams Power Mirror Switch: Diagrams Component Connector End Views Outside Rearview Mirror Switch (DL8 or DPN) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Diagrams > Page 16018 Power Mirror Switch: Service and Repair Power Mirror Switch Replacement (with DL8 and without SLT) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest: > 05-08-51-008C > Jun > 09 > Body - Bumps or Rust Colored Spots in Paint Paint: Customer Interest Body - Bumps or Rust Colored Spots in Paint TECHNICAL Bulletin No.: 05-08-51-008C Date: June 22, 2009 Subject: Bumps or Rust Colored Spots in Paint Due to Rail or Iron Dust (Remove Rail Dust) Models: 1994-2010 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 05-08-51-008B (Section 08 - Body and Accessories). Condition Visible rust colored spots or bumps on a vehicle's paint surface from rail or iron dust. Cause Rail dust comes from tiny iron particles produced from the friction between train wheels and the tracks and gets deposited on the vehicle surfaces. Iron dust can get deposited on the surface if the vehicle is stored near any operation producing iron dust such as an iron ore yard. Either material can lay on top of, or become embedded in, the paint surface. Correction Because the severity of the condition varies, proper diagnosis of the damage is critical to the success of repairs. Diagnosis should be performed on horizontal surfaces (hood, roof, deck lid, pick up box, etc.) after the vehicle has been properly cleaned. There are two types of repair materials recommended to repair rail dust or iron dust: 1. GEL TYPE OXALIC ACID: - Has the characteristics of the liquid type oxalic acid but stays where you put it because of its gel consistency. 2. CLAY TYPE NON-ACID BASED: - Requires surface lubricant during use. - Has different grades available. Caution Rail dust remover (Oxalic Acid) is an acidic substance containing chemicals that will break down the iron particles embedded in the finish. When working with rail dust remover, use the necessary safety equipment, including gloves and goggles. Follow the chemical manufacturer's directions closely because it may require special handling and disposal. If, upon inspection, some particles are still present, the various chemical manufacturer's processes can be repeated. After the removal process, small pits may remain in the clearcoat and can be corrected, in most cases, with a finesse/polish operation. Procedure 1. Move the vehicle to a cool shaded area and make sure that the vehicle surfaces are cool during the removal process. DO NOT PERFORM THE REMOVAL PROCESS IN DIRECT SUNLIGHT OR ON A VEHICLE WITH HOT OR WARM BODY PANELS. 2. Wash the vehicle with soap and water. Dry it immediately and clean the affected areas with a wax and grease remover. 3. Perform the removal process according to the chemical manufacturer's directions. Once the damage has been repaired, the final step involves a polishing process. Rail Dust Remover Manufacturers Use the chemical manufacturers listed below, or equivalent: Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest: > 05-08-51-008C > Jun > 09 > Body - Bumps or Rust Colored Spots in Paint > Page 16028 Auto Magic(R) or Clay Magic(R) products available from: Auto Wax Company, Inc. 1275 Round Table Dr. Dallas, TX 75247 (800) 826-0828 (Toll-Free) or (214) 631-4000 (Local) Fax (214) 634-1342 www.automagic.com [email protected] E038 Fallout Gel or E038E Liquid Fallout Remover II available from: Valvoline Car Brite Company 1910 South State Avenue Indianapolis, In 46203 (800) 347-2439 (Toll Free) or (317) 788-9925 (Local) Fax (317) 788-9930 www.carbrite.com [email protected] *We believe these sources and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from these firms or for any such items which may be available from other sources. If rail dust remover is not available in your area, call one of the numbers listed above for a distributor near your location. Warranty Information (excluding Saab U.S. Models) Important Refer to the Policy & Procedures Manual, section 1.2.1.7 for detailed information regarding warranty coverage for this condition. Important In certain cases where the vehicle finish is severely damaged and the actual repair time exceeds the published time, the additional time should be submitted in the "Other Labor Hours" field. Warranty Information (Saab U.S. Models) Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 10-08-51-001 > Jan > 10 > Body/Paint - 2010 Exterior Paint Codes Paint: All Technical Service Bulletins Body/Paint - 2010 Exterior Paint Codes INFORMATION Bulletin No.: 10-08-51-001 Date: January 05, 2010 Subject: Exterior Paint Codes Models: 2010 Passenger Cars and Light Duty Trucks (Including Saturn and Saab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 10-08-51-001 > Jan > 10 > Body/Paint - 2010 Exterior Paint Codes > Page 16034 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 10-08-51-001 > Jan > 10 > Body/Paint - 2010 Exterior Paint Codes > Page 16035 The primary exterior body paint codes on the SPID label may be missing on some 2010 vehicles. Above is a chart with the primary exterior body colors for your reference. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 05-08-51-008C > Jun > 09 > Body - Bumps or Rust Colored Spots in Paint Paint: All Technical Service Bulletins Body - Bumps or Rust Colored Spots in Paint TECHNICAL Bulletin No.: 05-08-51-008C Date: June 22, 2009 Subject: Bumps or Rust Colored Spots in Paint Due to Rail or Iron Dust (Remove Rail Dust) Models: 1994-2010 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 05-08-51-008B (Section 08 - Body and Accessories). Condition Visible rust colored spots or bumps on a vehicle's paint surface from rail or iron dust. Cause Rail dust comes from tiny iron particles produced from the friction between train wheels and the tracks and gets deposited on the vehicle surfaces. Iron dust can get deposited on the surface if the vehicle is stored near any operation producing iron dust such as an iron ore yard. Either material can lay on top of, or become embedded in, the paint surface. Correction Because the severity of the condition varies, proper diagnosis of the damage is critical to the success of repairs. Diagnosis should be performed on horizontal surfaces (hood, roof, deck lid, pick up box, etc.) after the vehicle has been properly cleaned. There are two types of repair materials recommended to repair rail dust or iron dust: 1. GEL TYPE OXALIC ACID: - Has the characteristics of the liquid type oxalic acid but stays where you put it because of its gel consistency. 2. CLAY TYPE NON-ACID BASED: - Requires surface lubricant during use. - Has different grades available. Caution Rail dust remover (Oxalic Acid) is an acidic substance containing chemicals that will break down the iron particles embedded in the finish. When working with rail dust remover, use the necessary safety equipment, including gloves and goggles. Follow the chemical manufacturer's directions closely because it may require special handling and disposal. If, upon inspection, some particles are still present, the various chemical manufacturer's processes can be repeated. After the removal process, small pits may remain in the clearcoat and can be corrected, in most cases, with a finesse/polish operation. Procedure 1. Move the vehicle to a cool shaded area and make sure that the vehicle surfaces are cool during the removal process. DO NOT PERFORM THE REMOVAL PROCESS IN DIRECT SUNLIGHT OR ON A VEHICLE WITH HOT OR WARM BODY PANELS. 2. Wash the vehicle with soap and water. Dry it immediately and clean the affected areas with a wax and grease remover. 3. Perform the removal process according to the chemical manufacturer's directions. Once the damage has been repaired, the final step involves a polishing process. Rail Dust Remover Manufacturers Use the chemical manufacturers listed below, or equivalent: Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 05-08-51-008C > Jun > 09 > Body - Bumps or Rust Colored Spots in Paint > Page 16040 Auto Magic(R) or Clay Magic(R) products available from: Auto Wax Company, Inc. 1275 Round Table Dr. Dallas, TX 75247 (800) 826-0828 (Toll-Free) or (214) 631-4000 (Local) Fax (214) 634-1342 www.automagic.com [email protected] E038 Fallout Gel or E038E Liquid Fallout Remover II available from: Valvoline Car Brite Company 1910 South State Avenue Indianapolis, In 46203 (800) 347-2439 (Toll Free) or (317) 788-9925 (Local) Fax (317) 788-9930 www.carbrite.com [email protected] *We believe these sources and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from these firms or for any such items which may be available from other sources. If rail dust remover is not available in your area, call one of the numbers listed above for a distributor near your location. Warranty Information (excluding Saab U.S. Models) Important Refer to the Policy & Procedures Manual, section 1.2.1.7 for detailed information regarding warranty coverage for this condition. Important In certain cases where the vehicle finish is severely damaged and the actual repair time exceeds the published time, the additional time should be submitted in the "Other Labor Hours" field. Warranty Information (Saab U.S. Models) Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > Page 16041 Paint: By Symptom Technical Service Bulletin # 05-08-51-008C Date: 090622 Body - Bumps or Rust Colored Spots in Paint TECHNICAL Bulletin No.: 05-08-51-008C Date: June 22, 2009 Subject: Bumps or Rust Colored Spots in Paint Due to Rail or Iron Dust (Remove Rail Dust) Models: 1994-2010 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 05-08-51-008B (Section 08 - Body and Accessories). Condition Visible rust colored spots or bumps on a vehicle's paint surface from rail or iron dust. Cause Rail dust comes from tiny iron particles produced from the friction between train wheels and the tracks and gets deposited on the vehicle surfaces. Iron dust can get deposited on the surface if the vehicle is stored near any operation producing iron dust such as an iron ore yard. Either material can lay on top of, or become embedded in, the paint surface. Correction Because the severity of the condition varies, proper diagnosis of the damage is critical to the success of repairs. Diagnosis should be performed on horizontal surfaces (hood, roof, deck lid, pick up box, etc.) after the vehicle has been properly cleaned. There are two types of repair materials recommended to repair rail dust or iron dust: 1. GEL TYPE OXALIC ACID: - Has the characteristics of the liquid type oxalic acid but stays where you put it because of its gel consistency. 2. CLAY TYPE NON-ACID BASED: - Requires surface lubricant during use. - Has different grades available. Caution Rail dust remover (Oxalic Acid) is an acidic substance containing chemicals that will break down the iron particles embedded in the finish. When working with rail dust remover, use the necessary safety equipment, including gloves and goggles. Follow the chemical manufacturer's directions closely because it may require special handling and disposal. If, upon inspection, some particles are still present, the various chemical manufacturer's processes can be repeated. After the removal process, small pits may remain in the clearcoat and can be corrected, in most cases, with a finesse/polish operation. Procedure 1. Move the vehicle to a cool shaded area and make sure that the vehicle surfaces are cool during the removal process. DO NOT PERFORM THE REMOVAL PROCESS IN DIRECT SUNLIGHT OR ON A VEHICLE WITH HOT OR WARM BODY PANELS. 2. Wash the vehicle with soap and water. Dry it immediately and clean the affected areas with a wax and grease remover. 3. Perform the removal process according to the chemical manufacturer's directions. Once the damage has been repaired, the final step involves a polishing process. Rail Dust Remover Manufacturers Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > Page 16042 Use the chemical manufacturers listed below, or equivalent: Auto Magic(R) or Clay Magic(R) products available from: Auto Wax Company, Inc. 1275 Round Table Dr. Dallas, TX 75247 (800) 826-0828 (Toll-Free) or (214) 631-4000 (Local) Fax (214) 634-1342 www.automagic.com [email protected] E038 Fallout Gel or E038E Liquid Fallout Remover II available from: Valvoline Car Brite Company 1910 South State Avenue Indianapolis, In 46203 (800) 347-2439 (Toll Free) or (317) 788-9925 (Local) Fax (317) 788-9930 www.carbrite.com [email protected] *We believe these sources and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from these firms or for any such items which may be available from other sources. If rail dust remover is not available in your area, call one of the numbers listed above for a distributor near your location. Warranty Information (excluding Saab U.S. Models) Important Refer to the Policy & Procedures Manual, section 1.2.1.7 for detailed information regarding warranty coverage for this condition. Important In certain cases where the vehicle finish is severely damaged and the actual repair time exceeds the published time, the additional time should be submitted in the "Other Labor Hours" field. Warranty Information (Saab U.S. Models) Disclaimer Technical Service Bulletin # 05-08-51-008C Date: 090622 Body - Bumps or Rust Colored Spots in Paint Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > Page 16043 TECHNICAL Bulletin No.: 05-08-51-008C Date: June 22, 2009 Subject: Bumps or Rust Colored Spots in Paint Due to Rail or Iron Dust (Remove Rail Dust) Models: 1994-2010 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 05-08-51-008B (Section 08 - Body and Accessories). Condition Visible rust colored spots or bumps on a vehicle's paint surface from rail or iron dust. Cause Rail dust comes from tiny iron particles produced from the friction between train wheels and the tracks and gets deposited on the vehicle surfaces. Iron dust can get deposited on the surface if the vehicle is stored near any operation producing iron dust such as an iron ore yard. Either material can lay on top of, or become embedded in, the paint surface. Correction Because the severity of the condition varies, proper diagnosis of the damage is critical to the success of repairs. Diagnosis should be performed on horizontal surfaces (hood, roof, deck lid, pick up box, etc.) after the vehicle has been properly cleaned. There are two types of repair materials recommended to repair rail dust or iron dust: 1. GEL TYPE OXALIC ACID: - Has the characteristics of the liquid type oxalic acid but stays where you put it because of its gel consistency. 2. CLAY TYPE NON-ACID BASED: - Requires surface lubricant during use. - Has different grades available. Caution Rail dust remover (Oxalic Acid) is an acidic substance containing chemicals that will break down the iron particles embedded in the finish. When working with rail dust remover, use the necessary safety equipment, including gloves and goggles. Follow the chemical manufacturer's directions closely because it may require special handling and disposal. If, upon inspection, some particles are still present, the various chemical manufacturer's processes can be repeated. After the removal process, small pits may remain in the clearcoat and can be corrected, in most cases, with a finesse/polish operation. Procedure 1. Move the vehicle to a cool shaded area and make sure that the vehicle surfaces are cool during the removal process. DO NOT PERFORM THE REMOVAL PROCESS IN DIRECT SUNLIGHT OR ON A VEHICLE WITH HOT OR WARM BODY PANELS. 2. Wash the vehicle with soap and water. Dry it immediately and clean the affected areas with a wax and grease remover. 3. Perform the removal process according to the chemical manufacturer's directions. Once the damage has been repaired, the final step involves a polishing process. Rail Dust Remover Manufacturers Use the chemical manufacturers listed below, or equivalent: Auto Magic(R) or Clay Magic(R) products available from: Auto Wax Company, Inc. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > Page 16044 1275 Round Table Dr. Dallas, TX 75247 (800) 826-0828 (Toll-Free) or (214) 631-4000 (Local) Fax (214) 634-1342 www.automagic.com [email protected] E038 Fallout Gel or E038E Liquid Fallout Remover II available from: Valvoline Car Brite Company 1910 South State Avenue Indianapolis, In 46203 (800) 347-2439 (Toll Free) or (317) 788-9925 (Local) Fax (317) 788-9930 www.carbrite.com [email protected] *We believe these sources and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from these firms or for any such items which may be available from other sources. If rail dust remover is not available in your area, call one of the numbers listed above for a distributor near your location. Warranty Information (excluding Saab U.S. Models) Important Refer to the Policy & Procedures Manual, section 1.2.1.7 for detailed information regarding warranty coverage for this condition. Important In certain cases where the vehicle finish is severely damaged and the actual repair time exceeds the published time, the additional time should be submitted in the "Other Labor Hours" field. Warranty Information (Saab U.S. Models) Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 16050 Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Service Precautions > Brake Fluid Effects on Paint and Electrical Components Caution Paint: Service Precautions Brake Fluid Effects on Paint and Electrical Components Caution Brake Fluid Effects on Paint and Electrical Components Caution Caution: Avoid spilling brake fluid onto painted surfaces, electrical connections, wiring, or cables. Brake fluid will damage painted surfaces and cause corrosion to electrical components. If any brake fluid comes in contact with painted surfaces, immediately flush the area with water. If any brake fluid comes in contact with electrical connections, wiring, or cables, use a clean shop cloth to wipe away the fluid. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Service Precautions > Brake Fluid Effects on Paint and Electrical Components Caution > Page 16053 Paint: Service Precautions Clearcoat/Ultraviolet Screeners Caution Clearcoat/Ultraviolet Screeners Caution Caution: Removing more than 0.5 mils of the clearcoat can result in early paint failure. The clearcoat contains ultraviolet screeners. Do not finesse sand more than what is required to remove the defect. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Basecoat/Clearcoat Paint Systems Paint: Application and ID Basecoat/Clearcoat Paint Systems Basecoat/Clearcoat Paint Systems Warning Exposure to isocyanates during paint preparation and application processes can cause severe breathing problems. Read and follow all of the instructions from the manufacturers of painting materials, equipment, and protective gear. All paint finish repairs of rigid exterior surfaces must meet GM standards. Refer to the latest revision of the GM Approved Refinish Materials book to identify the paint systems you may use that have been engineered to meet GM standards. The GM Approved Refinish Materials book supplies all approved products, including volatile organic compound (VOC) compliant regulations recommended by the individual manufacturer, and detailed procedures for materials used in their paint system. The latest revision of the GM Approved Refinish Materials booklet is located on the Goodwrench website at www.gmgoodwrench.com. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Basecoat/Clearcoat Paint Systems > Page 16056 Paint: Application and ID Paint Identification Paint Identification Warning Exposure to isocyanates during paint preparation and application processes can cause severe breathing problems. Read and follow all of the instructions from the manufacturers of painting materials, equipment, and protective gear. Note: Always refer to the GM Approved Refinish Materials book. This book identifies the paint systems you may use. The latest revision of the GM Approved Refinish Materials booklet is located on the Goodwrench website at www.gmgoodwrench.com. Use the service parts identification label to identify the type of paint technology, paint codes, trim level, and any special order paint colors on the vehicle. Refer to Vehicle Certification, Tire Placard, Anti-Theft, and Service Parts ID Label (See: Application and ID/Vehicle Certification, Tire Placard, Anti-Theft and Service Parts ID Label). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Radiator Support > Component Information > Service and Repair > Front End Upper Tie Bar Replacement Radiator Support: Service and Repair Front End Upper Tie Bar Replacement Front End Upper Tie Bar Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Radiator Support > Component Information > Service and Repair > Front End Upper Tie Bar Replacement > Page 16061 Radiator Support: Service and Repair Radiator Support Replacement Radiator Support Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Radiator Support > Component Information > Service and Repair > Front End Upper Tie Bar Replacement > Page 16062 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Service and Repair Keyless Entry Module: Service and Repair Remote Control Door Lock Receiver Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations Memory Positioning Module: Locations Harness Routing Views Driver Seat Harness Routing 1 - Seat Recline Motor - Driver (AN3) 2 - Seat Lumbar Vertical Motor Position Sensor - Driver (AN3) 3 - Seat Lumbar Vertical Motor - Driver (AN3) 4 - X324 (AN3) 5 - Seat Lumbar Horizontal Motor - Driver (AN3) 6 - Seat Lumbar Horizontal Motor Position Sensor - Driver (AN3) 7 - Seat Recline Position Sensor - Driver (AN3) 8 - Seat Lumbar Switch - Driver (AN3) 9 - Seat Adjuster Switch - Driver (AG1) 10 - Memory Seat Module (MSM) (AN3) 11 - Inflatable Restraint Seat Position Sensor (SPS) - Driver (10 Series) 12 - Seat Adjuster Motor Assembly - Driver (AG1) 13 Seat Belt Buckle - Driver Passenger Seat Harness Routing Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations > Page 16070 1 - Seat Frame 2 - X325 (AN3) 3 - Seat Lumbar Vertical Motor - Passenger (AN3) 4 - Seat Adjuster Switch - Passenger (AG2) 5 - Seat Lumbar Switch - Passenger (AN3) 6 - Seat Belt Buckle Passenger 7 - Inflatable Restraint Passenger Presence System (PPS) Module (AL0) 8 - Seat Adjuster Motor Assembly - Passenger (AG2) 9 - Inflatable Restraint Passenger Presence System (PPS) Sensor (AL0) 10 - Seat Recline Motor - Passenger (AN3) 11 - Seat Lumbar Horizontal Motor - Passenger (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations > Page 16071 Memory Positioning Module: Diagrams Component Connector End Views Memory Seat Module (MSM) X1 (AN3) Memory Seat Module (MSM) X2 (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations > Page 16072 Memory Seat Module (MSM) X3 (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations > Page 16073 Memory Seat Module (MSM) X4 (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations > Page 16074 Memory Seat Module (MSM) X5 (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations > Page 16075 Memory Seat Module (MSM) X6 (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations > Page 16076 Memory Seat Module (MSM) X7 (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations > Page 16077 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations > Page 16078 Memory Positioning Module: Service and Repair Memory Seat Control Module Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Fuse Block - I/P Power Door Lock Relay: Locations Fuse Block - I/P Electrical Center Identification Views Fuse Block - I/P Label Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Fuse Block - I/P > Page 16083 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Fuse Block - I/P > Page 16084 Power Door Lock Relay: Locations Fuse Block - Underhood Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Fuse Block - I/P > Page 16085 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Fuse Block - I/P > Page 16086 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Fuse Block - I/P > Page 16087 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Fuse Block - I/P > Page 16088 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Fuse Block - I/P > Page 16089 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Fuse Block - I/P > Page 16090 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Fuse Block - I/P > Page 16091 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm Seat Heater Control Module: Customer Interest Seats - Driver/Passenger Heated Seats Inop./Slow to Warm TECHNICAL Bulletin No.: 10-08-50-008B Date: January 13, 2011 Subject: Driver or Passenger Heated Seat Inoperative, Slow to Warm, DTC(s) Set (Repair Connector, Re-Route Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Silverado, Suburban, Tahoe 2011 Chevrolet Silverado Heavy Duty 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2011 GMC Sierra Heavy Duty All Equipped with Heated Front Seat (RPO AN3, KA1) or Heated and Cooled Seat (RPO KB6) and/or Luxury Package (RPO PCK) Supercede: This bulletin is being revised to update the RPOs. Please discard Corporate Bulletin Number 10-08-50-008A (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger heated seat system exhibits the following symptoms: - Heated seat turns on and then turns off within 1 to 10 minutes (at any 60 second interval). - The system doesn't get warm enough, or gets warm very slowly. - The heated seat system is completely inoperative. Upon further review, DTCs B2430 0D and/or B2180 0D may be set as a current or history code if the vehicle is equipped with heated seats only (RPO KA1). Also, the LED indicator for the heated seats may come On and then flash after approximately 1 minute, then go out. If the vehicle is equipped with heated and cooled seats (KB6), the switch LED indicator may stay On, but the heated and cooled seat is inoperative. The fan will continue to blow air. Cause Heated Seats (RPO AN3, KA1) The heated seat control circuit terminal and/or ground terminal in harness connector X1 to the memory seat module (MSM) may have lost tension and is loose. The reduced terminal tension increases resistance in the connector, which may result in the symptoms described above. Heated and Cooled Seats (RPO KB6) The thermo-electric device (TED) in the seat cushion/seat back ventilation heating and cooling module may have become inoperative. Correction Heated Seats (RPO AN3, KA1) Follow the steps below to correct the concern with the heated seats. Note This repair requires a unique anti-abrasion electrical tape and harness clip from Kent Automotive. Refer to the Parts Information below. 1. Access and remove the seat bolts/nuts. 2. Adjust the seat rearward about halfway. Adjust the seat recline full forward. 3. Tilt the seat backward to access the bottom of the seat. Prop the seat up with a suitable tool if required. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 16100 4. Disconnect seat harness connectors (1) X1, X2, X3 and X4 from the MSM. 5. Identify connector X1. Refer to Component Connector End Views in SI. 6. Perform a terminal drag test on connector X1, paying special attention to terminals 1, 4, 6, 11 and 14. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Refer to Testing for Intermittent Conditions and Poor Connections in SI. 7. Replace any terminal in question including connector X1 terminals 1, 4, 6, 11 and 14 if necessary. Refer to Repairing Connector Terminals in SI. 8. Identify connector X4. Refer to Component Connector End Views in SI. 9. Perform the terminal drag test described in step 6, paying special attention to terminal 14. 10. Replace any terminal in question including connector X4 terminal 14 if necessary. Refer to Repairing Connector Terminals in SI. 11. Remove the harness clip (1) from the plastic carrier. 12. Cut the electrical tape holding the harness in the plastic carrier using a sharp utility knife in the area shown (1). 13. Free the harness from the carrier back to the area shown (1). 14. Obtain "*Woven Polyester (PET) Electrical Tape" (Special Order P/N RZ97156A00) from Kent Automotive. Refer to Parts Information below. Important Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 16101 DO NOT substitute with vinyl electrical tape or friction tape. Use only the tape specified above. 15. Tape the harness starting at the MSM connectors (1) extending back to the new break-out location (2) in the plastic carrier. 16. Install a plastic tie strap around the harness and the plastic carrier at the break-out point (1). 17. Install the new harness edge clip (1) 10 mm (0.4 in) further from the connectors and the existing harness clip. Ensure the clip is installed in the orientation shown. 18. Install the harness with the new harness clip in the location shown (1). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 16102 19. Reinstall the harness connectors (1) to the MSM. 20. Reinstall the seat to the vehicle. Heated and Cooled Seats (RPO KB6) Follow the steps below to correct the concern with the heated and cooled seats. 1. Inspect the ventilation heating and cooling module for a concern with the TED. Refer to Seat Heating and Cooling, Diagnostic Information and Procedures in SI. Note If the heated and cooled seat function is inoperative, but the heat switch indicators are On, the MSM is functioning properly and the concern is with the TED. 2. If the TED is found to be the concern, replace the seat cushion or seat back ventilation heating and cooling module. Refer to Driver or Passenger Seat Back Ventilation Heating and Cooling Blower Replacement or Driver or Passenger Seat Cushion Ventilation Heating and Cooling Blower Replacement in SI. If the TED is not the concern, follow normal diagnostics and repair in SI. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Use the appropriate Labor Operation based on the repair completed. Heated Seats (RPO AN3, KA1) For vehicles repaired under warranty, use: Heated and Cooled Seats (RPO KB6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 16103 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Control Module: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm Seat Heater Control Module: All Technical Service Bulletins Seats - Driver/Passenger Heated Seats Inop./Slow to Warm TECHNICAL Bulletin No.: 10-08-50-008B Date: January 13, 2011 Subject: Driver or Passenger Heated Seat Inoperative, Slow to Warm, DTC(s) Set (Repair Connector, Re-Route Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Silverado, Suburban, Tahoe 2011 Chevrolet Silverado Heavy Duty 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2011 GMC Sierra Heavy Duty All Equipped with Heated Front Seat (RPO AN3, KA1) or Heated and Cooled Seat (RPO KB6) and/or Luxury Package (RPO PCK) Supercede: This bulletin is being revised to update the RPOs. Please discard Corporate Bulletin Number 10-08-50-008A (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger heated seat system exhibits the following symptoms: - Heated seat turns on and then turns off within 1 to 10 minutes (at any 60 second interval). - The system doesn't get warm enough, or gets warm very slowly. - The heated seat system is completely inoperative. Upon further review, DTCs B2430 0D and/or B2180 0D may be set as a current or history code if the vehicle is equipped with heated seats only (RPO KA1). Also, the LED indicator for the heated seats may come On and then flash after approximately 1 minute, then go out. If the vehicle is equipped with heated and cooled seats (KB6), the switch LED indicator may stay On, but the heated and cooled seat is inoperative. The fan will continue to blow air. Cause Heated Seats (RPO AN3, KA1) The heated seat control circuit terminal and/or ground terminal in harness connector X1 to the memory seat module (MSM) may have lost tension and is loose. The reduced terminal tension increases resistance in the connector, which may result in the symptoms described above. Heated and Cooled Seats (RPO KB6) The thermo-electric device (TED) in the seat cushion/seat back ventilation heating and cooling module may have become inoperative. Correction Heated Seats (RPO AN3, KA1) Follow the steps below to correct the concern with the heated seats. Note This repair requires a unique anti-abrasion electrical tape and harness clip from Kent Automotive. Refer to the Parts Information below. 1. Access and remove the seat bolts/nuts. 2. Adjust the seat rearward about halfway. Adjust the seat recline full forward. 3. Tilt the seat backward to access the bottom of the seat. Prop the seat up with a suitable tool if required. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Control Module: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 16109 4. Disconnect seat harness connectors (1) X1, X2, X3 and X4 from the MSM. 5. Identify connector X1. Refer to Component Connector End Views in SI. 6. Perform a terminal drag test on connector X1, paying special attention to terminals 1, 4, 6, 11 and 14. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Refer to Testing for Intermittent Conditions and Poor Connections in SI. 7. Replace any terminal in question including connector X1 terminals 1, 4, 6, 11 and 14 if necessary. Refer to Repairing Connector Terminals in SI. 8. Identify connector X4. Refer to Component Connector End Views in SI. 9. Perform the terminal drag test described in step 6, paying special attention to terminal 14. 10. Replace any terminal in question including connector X4 terminal 14 if necessary. Refer to Repairing Connector Terminals in SI. 11. Remove the harness clip (1) from the plastic carrier. 12. Cut the electrical tape holding the harness in the plastic carrier using a sharp utility knife in the area shown (1). 13. Free the harness from the carrier back to the area shown (1). 14. Obtain "*Woven Polyester (PET) Electrical Tape" (Special Order P/N RZ97156A00) from Kent Automotive. Refer to Parts Information below. Important Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Control Module: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 16110 DO NOT substitute with vinyl electrical tape or friction tape. Use only the tape specified above. 15. Tape the harness starting at the MSM connectors (1) extending back to the new break-out location (2) in the plastic carrier. 16. Install a plastic tie strap around the harness and the plastic carrier at the break-out point (1). 17. Install the new harness edge clip (1) 10 mm (0.4 in) further from the connectors and the existing harness clip. Ensure the clip is installed in the orientation shown. 18. Install the harness with the new harness clip in the location shown (1). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Control Module: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 16111 19. Reinstall the harness connectors (1) to the MSM. 20. Reinstall the seat to the vehicle. Heated and Cooled Seats (RPO KB6) Follow the steps below to correct the concern with the heated and cooled seats. 1. Inspect the ventilation heating and cooling module for a concern with the TED. Refer to Seat Heating and Cooling, Diagnostic Information and Procedures in SI. Note If the heated and cooled seat function is inoperative, but the heat switch indicators are On, the MSM is functioning properly and the concern is with the TED. 2. If the TED is found to be the concern, replace the seat cushion or seat back ventilation heating and cooling module. Refer to Driver or Passenger Seat Back Ventilation Heating and Cooling Blower Replacement or Driver or Passenger Seat Cushion Ventilation Heating and Cooling Blower Replacement in SI. If the TED is not the concern, follow normal diagnostics and repair in SI. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Use the appropriate Labor Operation based on the repair completed. Heated Seats (RPO AN3, KA1) For vehicles repaired under warranty, use: Heated and Cooled Seats (RPO KB6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Control Module: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 16112 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 16113 Seat Heater Control Module: Diagrams Component Connector End Views Seat Back Ventilation Heating and Cooling Module - Driver (KB6) Seat Back Ventilation Heating and Cooling Module - Passenger (KB6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 16114 Seat Climate Control Module X1 (KB6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 16115 Seat Climate Control Module X2 (KB6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 16116 Seat Climate Control Module X3 (KB6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 16117 Seat Cushion Ventilation Heating and Cooling Module - Driver (KB6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 16118 Seat Cushion Ventilation Heating and Cooling Module - Passenger (KB6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 16119 Heated Seat Control Module X1 (SPO Heated Seats) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 16120 Heated Seat Control Module X2 (SPO Heated Seats) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 16121 Heated Seat Control Module X3 (SPO Heated Seats) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 16122 Heated Seat Control Module X4 (SPO Heated Seats) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 16123 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Service and Repair > Front Seat Heater Control Module Seat Heater Control Module: Service and Repair Front Seat Heater Control Module Front Seat Heater Control Module Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Service and Repair > Front Seat Heater Control Module > Page 16126 Seat Heater Control Module: Service and Repair Module Replacement - Seat Climate Control Front Seat (Denali with KB6) Module Replacement - Seat Climate Control - Front Seat (Denali with KB6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Diagrams Sunroof / Moonroof Module: Diagrams Component Connector End Views Sunroof Control Module (CF5) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Diagrams Trailer Towing Relay: Diagrams Component Connector End Views Trailer Brake Control Relay (JL1) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Diagrams > Page 16133 Trailer Towing Relay: Service and Repair Trailer Brake Control Relay Replacement (2500, 3500) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Luggage Rack > Component Information > Specifications Luggage Rack: Specifications Fastener Tightening Specifications Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Luggage Rack > Component Information > Service and Repair > Luggage Carrier Replacement Luggage Rack: Service and Repair Luggage Carrier Replacement Luggage Carrier Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Luggage Rack > Component Information > Service and Repair > Luggage Carrier Replacement > Page 16140 Luggage Rack: Service and Repair Luggage Carrier Nut Replacement Luggage Carrier Nut Replacement Removal Procedure 1. Remove the luggage carrier. Refer to Luggage Carrier Replacement (See: Luggage Carrier Replacement). Warning: Refer to Safety Glasses Warning (See: Service Precautions/Technician Safety Information/Safety Glasses Warning). 2. Drill through the luggage carrier rivnut head using a 7.5 mm (0.295 in) drill bit. 3. Remove the rivnut from the roof. Installation Procedure 1. Using a 10 mm (0.3937 in) drill bit, drill the rivnut hex shape hole in the roof out to a round 10 mm hole. 2. Install a replacement rivnut to the hole in roof using a rivnut tool, or equivalent. 3. Install the luggage carrier. Refer to Luggage Carrier Replacement (See: Luggage Carrier Replacement). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sun Shade > Component Information > Diagrams Sun Shade: Diagrams Component Connector End Views Sunshade - Left (DH6) Sunshade - Right (DH6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sun Shade > Component Information > Diagrams > Page 16145 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sun Shade > Component Information > Service and Repair > Sunroof Sunshade Guide Replacement Sun Shade: Service and Repair Sunroof Sunshade Guide Replacement Sunroof Sunshade Guide Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sun Shade > Component Information > Service and Repair > Sunroof Sunshade Guide Replacement > Page 16148 Sun Shade: Service and Repair Sunroof Sunshade Replacement (Extended Cab) Sunroof Sunshade Replacement (Extended Cab) Removal Procedure Important: If the sunshade spring releases, it will be necessary to rewind it. Turn the sunshade roller end slot 20 times in the counterclockwise direction. Important: A new sunshade service part comes pre-loaded with a pin tool holding spring tension on the sunshade. If the sunshade spring releases, it will be necessary to rewind it and reinstall the pin tool. Following installation, retain the pin tool for future applications. 1. Remove the sunroof window. Refer to Sunroof Window Replacement (Extended Cab) (See: Sunroof / Moonroof Panel/Service and Repair/Sunroof Window Replacement (Extended Cab))Sunroof Window Replacement (Crew Cab) (See: Sunroof / Moonroof Panel/Service and Repair/Sunroof Window Replacement (Crew Cab)). 2. Power the sunroof window guides to the fully open position. Important: The cam locking hole will come in to view when the sunshade is in the fully open position on the passengers side. 3. Close the sunshade (1) until the cam locking hole (2) come in to view. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sun Shade > Component Information > Service and Repair > Sunroof Sunshade Guide Replacement > Page 16149 4. Insert a suitable tool (1) into the sunshade cam locking hole (2). 5. Turn the sunshade (1) counterclockwise until the shade cam (2) is align with the bracket (3) notch. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sun Shade > Component Information > Service and Repair > Sunroof Sunshade Guide Replacement > Page 16150 6. Lift upward on the sunshade (1) removing it from the bracket (2). Important: The sunshade must be removed from the top of the vehicle. 7. Push the sunshade (1) inward to the driver side releasing it from the bracket (2) notch. 8. Remove the sunshade from outside of the vehicle. Installation Procedure 1. Install the sunshade to the vehicle from the passengers side. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sun Shade > Component Information > Service and Repair > Sunroof Sunshade Guide Replacement > Page 16151 2. Insert the end of the sunshade (1) to the driver side bracket (2) notch. 3. Insert the sunshade (1) to the passengers side bracket (2) notch. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sun Shade > Component Information > Service and Repair > Sunroof Sunshade Guide Replacement > Page 16152 4. Turn the sunshade cam (2) until it is aligned with the bracket (3) notch. 5. Install the sunshade. 6. Remove the suitable tool (1) from the sunshade cam locking hole (2). 7. Ensure that the sunshade cam (2) is fully seated in the bracket (3) and the sunshade slides smoothly. 8. Install the sunroof window. Refer to Sunroof Window Replacement (Extended Cab) (See: Sunroof / Moonroof Panel/Service and Repair/Sunroof Window Replacement (Extended Cab))Sunroof Window Replacement (Crew Cab) (See: Sunroof / Moonroof Panel/Service and Repair/Sunroof Window Replacement (Crew Cab)). 9. Verify the operation of the sunshade. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sun Shade > Component Information > Service and Repair > Sunroof Sunshade Guide Replacement > Page 16153 Sun Shade: Service and Repair Sunroof Sunshade Replacement (Crew Cab) Sunroof Sunshade Replacement (Crew Cab) Removal Procedure 1. Remove the sunroof window. Refer to Sunroof Window Replacement (Extended Cab) (See: Sunroof / Moonroof Panel/Service and Repair/Sunroof Window Replacement (Extended Cab))Sunroof Window Replacement (Crew Cab) (See: Sunroof / Moonroof Panel/Service and Repair/Sunroof Window Replacement (Crew Cab)). 2. Remove the screws (1) that retain the water trough to the sunroof frame 3. Remove the water trough through the roof opening of the vehicle. 4. It is only necessary to lower the headliner. Only do those steps in the headliner replacement procedure that will lower the headline enough to gain access to the part to be remove. Refer to Headlining Trim Panel Replacement (Crew Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair/Headlining Trim Panel Replacement (Crew Cab))Headlining Trim Panel Replacement (Extended Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair/Headlining Trim Panel Replacement (Extended Cab))Headlining Trim Panel Replacement (Regular Cab) ( See: Interior Moulding / Trim/Headliner/Service and Repair/Headlining Trim Panel Replacement (Regular Cab)). 5. Remove the left and right sunroof housing drain gutters (1) from the rear of the sunroof frame (2). Refer to Sunroof Housing Drain Gutter Replacement (Extended Cab) (See: Sunroof / Moonroof Drain/Service and Repair/Removal and Replacement/Sunroof Housing Drain Gutter Replacement (Extended Cab))Sunroof Housing Drain Gutter Replacement (Crew Cab) (See: Sunroof / Moonroof Drain/Service and Repair/Removal and Replacement/Sunroof Housing Drain Gutter Replacement (Crew Cab)) 6. Slide the sunshade (3) rearward to release it from the tracks. 7. Remove the sunshade from the of the vehicle. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sun Shade > Component Information > Service and Repair > Sunroof Sunshade Guide Replacement > Page 16154 1. Position the front of the sunshade (3) to the rear of the sunroof frame (2). 2. Install the retaining tabs of the sunshade into the left and right sides of the track slots in the sunroof frame. 3. Slide the sunshade forward while simultaneously inserting the rear retaining tabs into the track slot 4. Ensure that the sunshade tabs are fully seated in the track slots, and the sunshade slides smoothly. 5. Install the left and right sunroof housing drain gutters (1) to the rear of the sunroof frame (2). Refer to Sunroof Housing Drain Gutter Replacement (Extended Cab) (See: Sunroof / Moonroof Drain/Service and Repair/Removal and Replacement/Sunroof Housing Drain Gutter Replacement (Extended Cab))Sunroof Housing Drain Gutter Replacement (Crew Cab) (See: Sunroof / Moonroof Drain/Service and Repair/Removal and Replacement/Sunroof Housing Drain Gutter Replacement (Crew Cab)) 6. Install the headliner. Refer to Headlining Trim Panel Replacement (Crew Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair/Headlining Trim Panel Replacement (Crew Cab))Headlining Trim Panel Replacement (Extended Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair/Headlining Trim Panel Replacement (Extended Cab))Headlining Trim Panel Replacement (Regular Cab) ( See: Interior Moulding / Trim/Headliner/Service and Repair/Headlining Trim Panel Replacement (Regular Cab)). 7. Install the water trough to the sunroof from the top of the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 8. Install the screws (1) that retain the water trough to the sunroof frame. Tighten the screws to 1 Nm (9 lb in). 9. Install the sunroof window. Refer to Sunroof Window Replacement (Extended Cab) (See: Sunroof / Moonroof Panel/Service and Repair/Sunroof Window Replacement (Extended Cab))Sunroof Window Replacement (Crew Cab) (See: Sunroof / Moonroof Panel/Service and Repair/Sunroof Window Replacement (Crew Cab)). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sun Shade > Component Information > Service and Repair > Sunroof Sunshade Guide Replacement > Page 16155 Sun Shade: Service and Repair Sunroof Sunshade Stop Replacement Sunroof Sunshade Stop Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Testing and Inspection > Sunroof Motor/Actuator Initialization/Teach Process (Extended Cab Existing Motor) Sunroof / Moonroof Motor: Testing and Inspection Sunroof Motor/Actuator Initialization/Teach Process (Extended Cab Existing Motor) Sunroof Motor/Actuator Initialization/Teach Process (Extended Cab Existing Motor) Perform the Initialization/Teach Procedure any time a new sunroof motor/actuator is installed in the vehicle. 1. Press and hold the open switch until the full open position. 2. Release the switch. 3. Press and hold the open switch for 10 seconds or more. The glass panel will move further rearward of the open position, stall at the hard stop, and move back slightly to the soft stop or full open position. 4. Release the switch 5. Press and hold the open switch within 6 seconds. 6. Hold the open switch until the glass panel moves to the closed position and stops. 7. Release the switch. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Testing and Inspection > Sunroof Motor/Actuator Initialization/Teach Process (Extended Cab Existing Motor) > Page 16160 Sunroof / Moonroof Motor: Testing and Inspection Sunroof Motor/Actuator Initialization/Teach Process (Extended Cab New Motor) Sunroof Motor/Actuator Initialization/Teach Process (Extended Cab New Motor) Perform the Initialization/Teach Procedure any time a new sunroof motor/actuator is installed in the vehicle. 1. Press and hold the open switch until the glass panel stalls at the hard stop, then moves slightly forward. This position is called the soft stop or full open position. 2. Release the switch. 3. Press and hold the open switch within 6 seconds. 4. Hold the open switch until the glass panel moves to the closed position and stops. 5. Release the switch. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Testing and Inspection > Sunroof Motor/Actuator Initialization/Teach Process (Extended Cab Existing Motor) > Page 16161 Sunroof / Moonroof Motor: Testing and Inspection Sunroof Motor/Actuator Initialization/Teach Process (Crew Cab New Motor) Sunroof Motor/Actuator Initialization/Teach Process (Crew Cab New Motor) Initialization/Teach Procedure (Manual Method), New/First Time Installation Perform the initialization/teach procedure at the first operation test of the sunroof. Ensure the electrical harness on the headliner is connected to the large roof, battery power is applied and the ignition switch is on. 1. Press the sunroof switch to the VENT OPEN position until the window stall at the front hard stop in the VENT OPEN position, and then moves slightly to the soft stop position. Release the button. (This is the initialization portion). 2. Within 3 seconds, press and hold the sunroof switch-vent open again. The sunroof window will move toward and past the flush position. (This is the teach portion). 3. Continue holding the switch until the sunroof window moves to full open and then back to close and stops at the closed position. Release the button. The initialization/teach procedure is complete. 4. Verify the operation of the roof. The initialization/teach procedure is not completed if one of the following events occurs before the initialization/teach cycle is finished: * The sunroof switch is not held in the VENT OPEN position. * Ignition and/or battery power has not been removed. * Glass panel has not reached the CLOSE position. If the initialization/teach procedure is not carried out completely, it must be started again. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Testing and Inspection > Sunroof Motor/Actuator Initialization/Teach Process (Extended Cab Existing Motor) > Page 16162 Sunroof / Moonroof Motor: Testing and Inspection Sunroof Motor/Actuator Initialization/Teach Process (Crew Cab Existing Motor) Sunroof Motor/Actuator Initialization/Teach Process (Crew Cab Existing Motor) Re-Initialization/Teach Procedure (Manual Method), possible Re-Installation Perform the initialization/teach procedure at the first operation test of the sunroof. Ensure the electrical harness on the headliner is connected to the large roof, battery power is applied and the ignition switch is on. 1. Press the sunroof switch to the VENT OPEN position until the window reaches the vent open soft stop position and release. Press the sunroof switch - vent open and hold for approximately 10 seconds, until the window stalls at the front hard stop in the vent open position, and then moves slightly to the soft stop position. Release the button. (This is the re-initialization portion.) Continue with steps 2-4. 2. Within 3 seconds, press and hold the sunroof switch-vent open again. The sunroof window will move toward and past the flush position. (This is the teach portion.) 3. Continue holding the switch until the sunroof window moves to full open and then back to close and stops at the closed position. Release the button. The initialization/teach procedure is complete. 4. Verify the operation of the roof. The initialization/teach procedure is not completed if one of the following events occurs before the initialization/teach cycle is finished: * The sunroof switch is not held in the VENT OPEN position. * Ignition and/or battery power has not been removed. * Glass panel has not reached the CLOSE position. If the initialization/teach procedure is not carried out completely, it must be started again. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Service and Repair > Sunroof Motor/Actuator Replacement (Extended Cab) Sunroof / Moonroof Motor: Service and Repair Sunroof Motor/Actuator Replacement (Extended Cab) Sunroof Motor/Actuator Replacement (Extended Cab) Removal Procedure Note: The sunroof motor/actuator drive shaft turns in both directions and contains no limit switches. You may replace the sunroof motor/actuator with the window panel in any position. 1. It is only necessary to lower the headliner. Only do those step in headliner replacement that will lower the headliner enough to gain access to the part. Refer to Headlining Trim Panel Replacement (Crew Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair/Headlining Trim Panel Replacement (Crew Cab))Headlining Trim Panel Replacement (Extended Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair/Headlining Trim Panel Replacement (Extended Cab))Headlining Trim Panel Replacement (Regular Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair/Headlining Trim Panel Replacement (Regular Cab)). 2. Disconnect the electrical connector (1) from the motor/actuator. 3. Remove the screws (2) from the sunroof motor/actuator. 4. Pull straight down to disengage the drive gear from the cables housed within the sunroof cable drive tubes. 5. Remove the sunroof motor/actuator (3) from the sunroof module. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Service and Repair > Sunroof Motor/Actuator Replacement (Extended Cab) > Page 16165 1. Position the sunroof motor/actuator (3) to the sunroof module. 2. Push the sunroof motor/actuator straight upward to engage the drive gear between the cables housed within the sunroof cable drive tubes. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the sunroof motor/actuator screws (2) to the sunroof actuator. Tighten the screws to 4 Nm (35 lb in). 4. Connect the electrical connector (1) to the sunroof motor/actuator. 5. Install the headliner. Refer to Headlining Trim Panel Replacement (Crew Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair/Headlining Trim Panel Replacement (Crew Cab))Headlining Trim Panel Replacement (Extended Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair/Headlining Trim Panel Replacement (Extended Cab))Headlining Trim Panel Replacement (Regular Cab) ( See: Interior Moulding / Trim/Headliner/Service and Repair/Headlining Trim Panel Replacement (Regular Cab)). 6. Initialize/teach the sunroof motor/actuator. Refer to Sunroof Motor/Actuator Initialization/Teach Process (Crew Cab Existing Motor) (See: Testing and Inspection/Sunroof Motor/Actuator Initialization/Teach Process (Crew Cab Existing Motor))Sunroof Motor/Actuator Initialization/Teach Process (Extended Cab New Motor) (See: Testing and Inspection/Sunroof Motor/Actuator Initialization/Teach Process (Extended Cab New Motor))Sunroof Motor/Actuator Initialization/Teach Process (Extended Cab Existing Motor) (See: Testing and Inspection/Sunroof Motor/Actuator Initialization/Teach Process (Extended Cab Existing Motor))Sunroof Motor/Actuator Initialization/Teach Process (Crew Cab New Motor) (See: Testing and Inspection/Sunroof Motor/Actuator Initialization/Teach Process (Crew Cab New Motor)). 7. Inspect the sunroof for proper operation. 8. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for programming and setup information. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Service and Repair > Sunroof Motor/Actuator Replacement (Extended Cab) > Page 16166 Sunroof / Moonroof Motor: Service and Repair Sunroof Motor/Actuator Replacement (Crew Cab) Sunroof Motor/Actuator Replacement (Crew Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Diagrams Sunroof / Moonroof Switch: Diagrams Component Connector End Views Sunroof Switch (CF5) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Diagrams > Page 16170 Sunroof / Moonroof Switch: Service and Repair Sunroof Switch Replacement (Crew Cab) Removal Procedure 1. Remove the overhead console in order to access the sunroof switch. Refer to Roof Console Replacement (See: Interior Moulding / Trim/Console/Service and Repair/Roof Console Replacement). 2. Disconnect the electrical connector from the sunroof switch. 3. With a flat-bladed tool, carefully release the tabs that retain the sunroof switch to the overhead console. 4. Remove the sunroof switch from the overhead console. Installation Procedure 1. Position the sunroof switch alignment tabs to the slots in the console. 2. Install the sunroof switch into the console, ensuring that the retaining tabs are fully seated. 3. Connect the electrical connector to the sunroof switch. 4. Install the overhead console to the roof. Refer to Roof Console Replacement (See: Interior Moulding / Trim/Console/Service and Repair/Roof Console Replacement). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Track > Component Information > Service and Repair > Sunroof Track Timing/Synchronization (Extended Cab) Sunroof / Moonroof Track: Service and Repair Sunroof Track Timing/Synchronization (Extended Cab) Sunroof Track Timing/Synchronization (Extended Cab) Removal Procedure 1. Place the module in the full open position. 2. It is only necessary to lower the headliner. Only do those step in headliner replacement that will lower the headliner enough to gain access to the part. Refer to Headlining Trim Panel Replacement (Crew Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair/Headlining Trim Panel Replacement (Crew Cab))Headlining Trim Panel Replacement (Extended Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair/Headlining Trim Panel Replacement (Extended Cab))Headlining Trim Panel Replacement (Regular Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair/Headlining Trim Panel Replacement (Regular Cab)). 3. Disconnect the electrical connector from the motor/actuator. 4. Remove the motor/actuator. Refer to Sunroof Motor/Actuator Replacement (Extended Cab) (See: Sunroof / Moonroof Motor/Service and Repair/Sunroof Motor/Actuator Replacement (Extended Cab))Sunroof Motor/Actuator Replacement (Crew Cab) (See: Sunroof / Moonroof Motor/Service and Repair/Sunroof Motor/Actuator Replacement (Crew Cab)). 5. Push the window guides rearward on the track until the guides are positioned against the rear hard stop. Installation Procedure 1. Install the motor/actuator. Refer to Sunroof Motor/Actuator Replacement (Extended Cab) (See: Sunroof / Moonroof Motor/Service and Repair/Sunroof Motor/Actuator Replacement (Extended Cab))Sunroof Motor/Actuator Replacement (Crew Cab) (See: Sunroof / Moonroof Motor/Service and Repair/Sunroof Motor/Actuator Replacement (Crew Cab)). 2. Connect the electrical connector to the motor/actuator. 3. Install the headliner. Refer to Headlining Trim Panel Replacement (Crew Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair/Headlining Trim Panel Replacement (Crew Cab))Headlining Trim Panel Replacement (Extended Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair/Headlining Trim Panel Replacement (Extended Cab))Headlining Trim Panel Replacement (Regular Cab) ( See: Interior Moulding / Trim/Headliner/Service and Repair/Headlining Trim Panel Replacement (Regular Cab)). 4. Perform the Initialization/Teach Procedure. Refer to Sunroof Motor/Actuator Initialization/Teach Process (Crew Cab Existing Motor) (See: Sunroof / Moonroof Motor/Testing and Inspection/Sunroof Motor/Actuator Initialization/Teach Process (Crew Cab Existing Motor))Sunroof Motor/Actuator Initialization/Teach Process (Extended Cab New Motor) (See: Sunroof / Moonroof Motor/Testing and Inspection/Sunroof Motor/Actuator Initialization/Teach Process (Extended Cab New Motor))Sunroof Motor/Actuator Initialization/Teach Process (Extended Cab Existing Motor) (See: Sunroof / Moonroof Motor/Testing and Inspection/Sunroof Motor/Actuator Initialization/Teach Process (Extended Cab Existing Motor))Sunroof Motor/Actuator Initialization/Teach Process (Crew Cab New Motor) (See: Sunroof / Moonroof Motor/Testing and Inspection/Sunroof Motor/Actuator Initialization/Teach Process (Crew Cab New Motor)). 5. Verify the operation of the sunroof. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Track > Component Information > Service and Repair > Sunroof Track Timing/Synchronization (Extended Cab) > Page 16175 Sunroof / Moonroof Track: Service and Repair Sunroof Track Timing/Synchronization (Crew Cab) Sunroof Track Timing/Synchronization (Crew Cab) Removal Procedure 1. Place the module in the closed/flush position. 2. Remove the sunroof window. Sunroof Window Replacement (Extended Cab) (See: Sunroof / Moonroof Panel/Service and Repair/Sunroof Window Replacement (Extended Cab))Sunroof Window Replacement (Crew Cab) (See: Sunroof / Moonroof Panel/Service and Repair/Sunroof Window Replacement (Crew Cab)). 3. It is only necessary to lower the headliner. Only do those step in headliner replacement that will lower the headliner enough to gain access to the part. Refer to Headlining Trim Panel Replacement (Crew Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair/Headlining Trim Panel Replacement (Crew Cab))Headlining Trim Panel Replacement (Extended Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair/Headlining Trim Panel Replacement (Extended Cab))Headlining Trim Panel Replacement (Regular Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair/Headlining Trim Panel Replacement (Regular Cab)). 4. Disconnect the electrical connector from the motor/actuator. 5. Remove the motor/actuator. Refer to Sunroof Motor/Actuator Replacement (Extended Cab) (See: Sunroof / Moonroof Motor/Service and Repair/Sunroof Motor/Actuator Replacement (Extended Cab))Sunroof Motor/Actuator Replacement (Crew Cab) (See: Sunroof / Moonroof Motor/Service and Repair/Sunroof Motor/Actuator Replacement (Crew Cab)). 6. Push the cam assembly (2) forward until the timing hole (3) in the cam is aligned with the timing hole (4) in the lifter arm (1). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Track > Component Information > Service and Repair > Sunroof Track Timing/Synchronization (Extended Cab) > Page 16176 7. Insert a pin (1) in the holes to hold the position while installing the drive motor. Note: Both mechanisms should now be in the closed position. 8. Repeat this procedure for the opposite side. Installation Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the sunroof window. Refer to Sunroof Window Replacement (Extended Cab) (See: Sunroof / Moonroof Panel/Service and Repair/Sunroof Window Replacement (Extended Cab))Sunroof Window Replacement (Crew Cab) (See: Sunroof / Moonroof Panel/Service and Repair/Sunroof Window Replacement (Crew Cab)). Tighten the screws to 4 Nm (35 lb in). 2. Install the motor/actuator. Refer to Sunroof Motor/Actuator Replacement (Extended Cab) (See: Sunroof / Moonroof Motor/Service and Repair/Sunroof Motor/Actuator Replacement (Extended Cab))Sunroof Motor/Actuator Replacement (Crew Cab) (See: Sunroof / Moonroof Motor/Service and Repair/Sunroof Motor/Actuator Replacement (Crew Cab)). Tighten the motor attachment screws to 3.5 Nm (31 lb in). 3. Connect the electrical connector to the motor/actuator. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Track > Component Information > Service and Repair > Sunroof Track Timing/Synchronization (Extended Cab) > Page 16177 4. Remove the pin (1) from the holes that held the position while installing the drive motor. 5. Install the headliner. Refer to Headlining Trim Panel Replacement (Crew Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair/Headlining Trim Panel Replacement (Crew Cab))Headlining Trim Panel Replacement (Extended Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair/Headlining Trim Panel Replacement (Extended Cab))Headlining Trim Panel Replacement (Regular Cab) ( See: Interior Moulding / Trim/Headliner/Service and Repair/Headlining Trim Panel Replacement (Regular Cab)). 6. Perform the Initialization/Teach Procedure. Refer to Sunroof Motor/Actuator Initialization/Teach Process (Crew Cab Existing Motor) (See: Sunroof / Moonroof Motor/Testing and Inspection/Sunroof Motor/Actuator Initialization/Teach Process (Crew Cab Existing Motor))Sunroof Motor/Actuator Initialization/Teach Process (Extended Cab New Motor) (See: Sunroof / Moonroof Motor/Testing and Inspection/Sunroof Motor/Actuator Initialization/Teach Process (Extended Cab New Motor))Sunroof Motor/Actuator Initialization/Teach Process (Extended Cab Existing Motor) (See: Sunroof / Moonroof Motor/Testing and Inspection/Sunroof Motor/Actuator Initialization/Teach Process (Extended Cab Existing Motor))Sunroof Motor/Actuator Initialization/Teach Process (Crew Cab New Motor) (See: Sunroof / Moonroof Motor/Testing and Inspection/Sunroof Motor/Actuator Initialization/Teach Process (Crew Cab New Motor)). 7. Verify the operation of the sunroof. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Windguard > Component Information > Service and Repair > Sunroof Air Deflector Replacement (Extended Cab) Sunroof / Moonroof Windguard: Service and Repair Sunroof Air Deflector Replacement (Extended Cab) Sunroof Air Deflector Replacement (Extended Cab) Removal Procedure 1. Open the power sunroof window to the fully rear position. 2. Remove the actuators screws (1) and actuators (2) from each side of the sunroof module. 3. Remove the screws (1) attaching the sunroof air deflector (2) to the sunroof module (3). 4. Slide the air deflector rearward until it releases from the sunroof module. 5. Remove the sunroof air deflector (2) from the sunroof module (3). Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Windguard > Component Information > Service and Repair > Sunroof Air Deflector Replacement (Extended Cab) > Page 16182 Note: Transfer the air deflector parts to the new air deflector. 1. Position the sunroof air deflector (2) to the sunroof module (3). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the screws (1) attaching the sunroof air deflector (2) to the sunroof module (3). Tighten the screws to 2 Nm (18 lb in). 3. Install the actuators screws (1) and actuators (2) to each side sunroof module. Tighten the screws to 2 Nm (18 lb in). 4. Verify that the spring action of the sunroof air deflector is operating. 5. Close the sunroof window. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Windguard > Component Information > Service and Repair > Sunroof Air Deflector Replacement (Extended Cab) > Page 16183 Sunroof / Moonroof Windguard: Service and Repair Sunroof Air Deflector Replacement (Crew Cab) Sunroof Air Deflector Replacement (Crew Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Service and Repair > Procedures Sunroof / Moonroof Drain: Procedures Sunroof Drain Inspection and Cleaning Drain Hose Routing Note: If the headliner is wet DO NOT remove any interior trim. Do the Plugged Drain Hose test first. A drain trough encircles the sunroof window panel and water is drained off by the drain hoses located at each corner of the housing. A drain channel spans across the sunroof module at the rear of the window panel and directs water into the trough. 1. The front drain hoses are routed down the windshield pillars and out the center of the pillar between the door hinges. The front hoses are installed in a rubber grommet and retained by clips. 2. The rear drain hoses are routed through the rear pillars and out of the rocker panel. In some vehicle the drain hoses are routed out through the metal roof slots and routed to the lower wheelhouse to drain out of the vehicle. The rear hoses are installed in a rubber grommet and retained by clips. Plugged Drain Hose If a waterleak has occurred check for a plugged drain hose at each corner of drainage system. 1. Open the sunroof window. 2. To test for blockage, pour a small container of water into the module housing drain trough. Check each corner to confirm the drain hose is draining water. Warning Wear safety glasses in order to avoid eye damage. 3. Use compressed air, 241 kPa (35 psi) or less to blow out any drain hose that is plugged. 4. Test the system again. 5. If the hose remains plugged, check to see it is properly routed and does not have a kink. Refer to Sunroof Housing Front Drain Hose Replacement (See: Removal and Replacement/Sunroof Housing Front Drain Hose Replacement) or Sunroof Housing Rear Drain Hose Replacement (See: Removal and Replacement/Sunroof Housing Rear Drain Hose Replacement). 6. Remove the blockage using the following steps. 1. Push mechanics wire through the hose to remove the obstruction. 2. Use compressed air in order to blow out any remaining material. Disconnected Drain Hose Inspect the drainage system for disconnected drain hoses. Complete the following steps in order to obtain partial access to drain hoses and check for a disconnected hose. 1. Open the sunroof window panel. 2. Lower the headliner as needed. Refer to Headlining Trim Panel Replacement (Crew Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair/Headlining Trim Panel Replacement (Crew Cab))Headlining Trim Panel Replacement (Extended Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair/Headlining Trim Panel Replacement (Extended Cab))Headlining Trim Panel Replacement (Regular Cab) ( See: Interior Moulding / Trim/Headliner/Service and Repair/Headlining Trim Panel Replacement (Regular Cab)). 3. Connect any disconnected hoses. 4. Ensure that the rear drain hoses are properly routed in the metal roof slot and taped in place. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Service and Repair > Procedures > Page 16188 Sunroof / Moonroof Drain: Removal and Replacement Sunroof Housing Drain Gutter Replacement (Extended Cab) Sunroof Housing Drain Gutter Replacement (Extended Cab) Removal Procedure Note: Tape off the perimeter of the sunroof window opening before removing the sunroof module to prevent scratching. 1. Remove the air deflector. Refer to Sunroof Air Deflector Replacement (Extended Cab) (See: Sunroof / Moonroof Windguard/Service and Repair/Sunroof Air Deflector Replacement (Extended Cab))Sunroof Air Deflector Replacement (Crew Cab) (See: Sunroof / Moonroof Windguard/Service and Repair/Sunroof Air Deflector Replacement (Crew Cab)). 2. Set the sunroof window to be in the open position of a minimum of 25 mm (1 in). Note: It is only necessary to lower the headliner. Only do those steps in headliner replacement that will lower the headliner enough to grain access. 3. Remove the sunroof module assembly. 4. Remove the screws (1) from the water gutter (2). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Service and Repair > Procedures > Page 16189 5. Slide the water gutter rearward to release the retaining tabs (1) from the slots (2) in the track. 6. Remove the water gutter (3) from the track. Installation Procedure 1. Position the sunroof water gutter to the sunroof window track. 2. Seat the retaining tabs (1) on the water gutter (3) into the slots (2) in the track, and push the water gutter forward until the retaining tabs lock into place. 3. Ensure that all 6 tabs are secured. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Service and Repair > Procedures > Page 16190 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the water gutter screws (1). Tighten the screws to 2 Nm (18 lb in). 5. Install the sunroof module. 6. Open the sunroof window to the fully open position. 7. Install the air deflector. Refer to Sunroof Air Deflector Replacement (Extended Cab) (See: Sunroof / Moonroof Windguard/Service and Repair/Sunroof Air Deflector Replacement (Extended Cab))Sunroof Air Deflector Replacement (Crew Cab) (See: Sunroof / Moonroof Windguard/Service and Repair/Sunroof Air Deflector Replacement (Crew Cab)). 8. Remove the tape from around the perimeter of the sunroof window. 9. Verify that the sunroof is operating properly. Sunroof Housing Drain Gutter Replacement (Crew Cab) Sunroof Housing Drain Gutter Replacement (Crew Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Service and Repair > Procedures > Page 16191 Sunroof Housing Front Drain Hose Replacement Sunroof Housing Front Drain Hose Replacement Removal Procedure 1. Remove the instrument panel trim. Refer to Instrument Panel Upper Trim Panel with Windshield Defroster Nozzle Grille Replacement (with RPO SLT) (See: Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Upper Trim Panel with Windshield Defroster Nozzle Grille Replacement (with RPO SLT))Instrument Panel Upper Trim Panel with Windshield Defroster Nozzle Grille Replacement (without RPO SLT) (See: Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Upper Trim Panel with Windshield Defroster Nozzle Grille Replacement (without RPO SLT)). Important: It is only necessary to lower the headliner. Only do those steps in headliner replacement that will lower the headliner enough to gain access. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Service and Repair > Procedures > Page 16192 2. It is only necessary to lower the headliner. Only do those steps in headliner replacement that will lower the headliner enough to gain access to the part. Refer to Headlining Trim Panel Replacement (Crew Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair/Headlining Trim Panel Replacement (Crew Cab))Headlining Trim Panel Replacement (Extended Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair/Headlining Trim Panel Replacement (Extended Cab))Headlining Trim Panel Replacement (Regular Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair/Headlining Trim Panel Replacement (Regular Cab)). 3. Disconnect the front sunroof drain hose from the sunroof module front spigot, right or left side, as needed. 4. Remove the 1 hose clips securing the drain hose to the windshield pillar, right or left side, as needed. 5. Remove the drain hose from the vehicle, right or left side, as needed. Installation Procedure 1. Install the drain hose by passing it threw the front of the dash panel. 2. Route the end of the drain hose through side cowl panel until the paint mark is visible, right or left side, as needed. 3. Install the 1 hose clips securing the drain hose to the side door frame, right or left side, as needed. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Service and Repair > Procedures > Page 16193 4. Connect the front sunroof drain hose to the sunroof module front spigot, right or left side, as needed. 5. Install the instrument panel trim. Refer to Instrument Panel Upper Trim Panel with Windshield Defroster Nozzle Grille Replacement (with RPO SLT) (See: Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Upper Trim Panel with Windshield Defroster Nozzle Grille Replacement (with RPO SLT))Instrument Panel Upper Trim Panel with Windshield Defroster Nozzle Grille Replacement (without RPO SLT) (See: Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Upper Trim Panel with Windshield Defroster Nozzle Grille Replacement (without RPO SLT)). 6. Install the headliner. Refer to Headlining Trim Panel Replacement (Crew Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair/Headlining Trim Panel Replacement (Crew Cab))Headlining Trim Panel Replacement (Extended Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair/Headlining Trim Panel Replacement (Extended Cab))Headlining Trim Panel Replacement (Regular Cab) ( See: Interior Moulding / Trim/Headliner/Service and Repair/Headlining Trim Panel Replacement (Regular Cab)). Sunroof Housing Rear Drain Hose Replacement Sunroof Housing Rear Drain Hose Replacement Removal Procedure Important: It is only necessary to lower the headliner. Only do those steps in headliner replacement that will lower the headliner enough to grain access. 1. Lower the headliner. Refer to Headlining Trim Panel Replacement (Crew Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair/Headlining Trim Panel Replacement (Crew Cab))Headlining Trim Panel Replacement (Extended Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair/Headlining Trim Panel Replacement (Extended Cab))Headlining Trim Panel Replacement (Regular Cab) ( See: Interior Moulding / Trim/Headliner/Service and Repair/Headlining Trim Panel Replacement (Regular Cab)). 2. Disconnect the rear sunroof drain hose from the sunroof module rear spigot, right or left side, as needed. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Service and Repair > Procedures > Page 16194 3. Remove the hose clip securing the drain hose to the vehicle, right or left side, as needed. 4. Remove the drain hose from the vehicle, right or left side, as needed. Installation Procedure 1. Route the end of the drain hose through the access hole and down the inner side panel, right or left side, as needed. 2. Install the hose clip to the door frame securing the drain hose to the vehicle, right or left side, as needed. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Service and Repair > Procedures > Page 16195 3. Connect the rear drain sunroof hose to the sunroof module rear spigot, right or left side, as needed. 4. Install the headliner. Refer to Headlining Trim Panel Replacement (Crew Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair/Headlining Trim Panel Replacement (Crew Cab))Headlining Trim Panel Replacement (Extended Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair/Headlining Trim Panel Replacement (Extended Cab))Headlining Trim Panel Replacement (Regular Cab) ( See: Interior Moulding / Trim/Headliner/Service and Repair/Headlining Trim Panel Replacement (Regular Cab)). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Frame > Component Information > Service and Repair Sunroof / Moonroof Frame: Service and Repair Sunroof Frame Replacement Removal Procedure Note: Transfer all necessary parts to the new sunroof module assembly. 1. Remove the sunroof window. Refer to Sunroof Window Replacement (Extended Cab) (See: Sunroof / Moonroof Panel/Service and Repair/Sunroof Window Replacement (Extended Cab))Sunroof Window Replacement (Crew Cab) (See: Sunroof / Moonroof Panel/Service and Repair/Sunroof Window Replacement (Crew Cab)). 2. Remove the sunshade. Refer to Sunroof Sunshade Replacement (Crew Cab) (See: Sun Shade/Service and Repair/Sunroof Sunshade Replacement (Crew Cab))Sunroof Sunshade Replacement (Extended Cab) (See: Sun Shade/Service and Repair/Sunroof Sunshade Replacement (Extended Cab)). 3. Remove the sunroof finish lace. Refer to Sunroof Opening Trim Finish Lace Replacement (Extended Cab) (See: Sunroof / Moonroof Interior Trim Panel/Service and Repair/Sunroof Opening Trim Finish Lace Replacement (Extended Cab)). 4. Remove the air deflector. Refer to Sunroof Air Deflector Replacement (Extended Cab) (See: Sunroof / Moonroof Windguard/Service and Repair/Sunroof Air Deflector Replacement (Extended Cab))Sunroof Air Deflector Replacement (Crew Cab) (See: Sunroof / Moonroof Windguard/Service and Repair/Sunroof Air Deflector Replacement (Crew Cab)). 5. It is only necessary to lower the headliner. Only do those step in headliner replacement that will lower the headliner enough to gain access to the part. Refer to Headlining Trim Panel Replacement (Crew Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair/Headlining Trim Panel Replacement (Crew Cab))Headlining Trim Panel Replacement (Extended Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair/Headlining Trim Panel Replacement (Extended Cab))Headlining Trim Panel Replacement (Regular Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair/Headlining Trim Panel Replacement (Regular Cab)). 6. Disconnect the front sunroof drain hoses from the drain spigot. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Frame > Component Information > Service and Repair > Page 16199 7. Disconnect the rear sunroof drain hoses from the drain spigot. 8. Remove the front to bolts located at the motor base first. 9. With the aid of an assistant, remove the remaining bolts (1) that secure the module (2) to the roof ring. Lower and remove the sunroof module assembly out through the passenger side door. 10. If you are replacing the sunroof module assembly, remove the sunroof motor/actuator. Refer to Sunroof Motor/Actuator Replacement (Extended Cab) (See: Sunroof / Moonroof Motor/Service and Repair/Sunroof Motor/Actuator Replacement (Extended Cab))Sunroof Motor/Actuator Replacement (Crew Cab) (See: Sunroof / Moonroof Motor/Service and Repair/Sunroof Motor/Actuator Replacement (Crew Cab)). Installation Procedure 1. If you are replacing the sunroof module assembly, install the sunroof motor/actuator. Refer to Sunroof Motor/Actuator Replacement (Extended Cab) (See: Sunroof / Moonroof Motor/Service and Repair/Sunroof Motor/Actuator Replacement (Extended Cab))Sunroof Motor/Actuator Replacement (Crew Cab) (See: Sunroof / Moonroof Motor/Service and Repair/Sunroof Motor/Actuator Replacement (Crew Cab)). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Frame > Component Information > Service and Repair > Page 16200 2. With the aid of an assistant, position the sunroof module assembly to the roof ring. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) 3. Install the 4 bolts (1) that secure the module (2) to the roof ring. Tighten the bolts to 10 Nm (89 lb in). 4. Install the remaining bolts at the motor base. Tighten the bolts to 10 Nm (89 lb in). 5. Connect the front and rear drain hoses to the drain spigots. 6. Install the sunshade. Refer to Sunroof Sunshade Replacement (Crew Cab) (See: Sun Shade/Service and Repair/Sunroof Sunshade Replacement (Crew Cab))Sunroof Sunshade Replacement (Extended Cab) (See: Sun Shade/Service and Repair/Sunroof Sunshade Replacement (Extended Cab)). 7. Install the headliner. Refer to Headlining Trim Panel Replacement (Crew Cab) (See: Interior Moulding / Trim/Headliner/Service and Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Frame > Component Information > Service and Repair > Page 16201 Repair/Headlining Trim Panel Replacement (Crew Cab))Headlining Trim Panel Replacement (Extended Cab) (See: Interior Moulding / Trim/Headliner/Service and Repair/Headlining Trim Panel Replacement (Extended Cab))Headlining Trim Panel Replacement (Regular Cab) ( See: Interior Moulding / Trim/Headliner/Service and Repair/Headlining Trim Panel Replacement (Regular Cab)). Verify that the electrical connector is connected to the sunroof motor/actuator. 8. Install the sunroof window. Adjust as necessary. Refer to Sunroof Window Height and Opening Fit Adjustment (Extended Cab) (See: Sunroof / Moonroof Panel/Adjustments/Sunroof Window Height and Opening Fit Adjustment (Extended Cab))Sunroof Window Height and Opening Fit Adjustment (Crew Cab) (See: Sunroof / Moonroof Panel/Adjustments/Sunroof Window Height and Opening Fit Adjustment (Crew Cab)). 9. Initialize the sunroof motor/actuator. Refer to Sunroof Motor/Actuator Initialization/Teach Process (Crew Cab Existing Motor) (See: Sunroof / Moonroof Motor/Testing and Inspection/Sunroof Motor/Actuator Initialization/Teach Process (Crew Cab Existing Motor))Sunroof Motor/Actuator Initialization/Teach Process (Extended Cab New Motor) (See: Sunroof / Moonroof Motor/Testing and Inspection/Sunroof Motor/Actuator Initialization/Teach Process (Extended Cab New Motor))Sunroof Motor/Actuator Initialization/Teach Process (Extended Cab Existing Motor) (See: Sunroof / Moonroof Motor/Testing and Inspection/Sunroof Motor/Actuator Initialization/Teach Process (Extended Cab Existing Motor))Sunroof Motor/Actuator Initialization/Teach Process (Crew Cab New Motor) (See: Sunroof / Moonroof Motor/Testing and Inspection/Sunroof Motor/Actuator Initialization/Teach Process (Crew Cab New Motor)). 10. Install the air deflector. Refer to Sunroof Air Deflector Replacement (Extended Cab) (See: Sunroof / Moonroof Windguard/Service and Repair/Sunroof Air Deflector Replacement (Extended Cab))Sunroof Air Deflector Replacement (Crew Cab) (See: Sunroof / Moonroof Windguard/Service and Repair/Sunroof Air Deflector Replacement (Crew Cab)). 11. Install the sunroof finish lace. Refer to Sunroof Opening Trim Finish Lace Replacement (Extended Cab) (See: Sunroof / Moonroof Interior Trim Panel/Service and Repair/Sunroof Opening Trim Finish Lace Replacement (Extended Cab)). 12. Inspect the sunroof for proper operation. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Interior Trim Panel > Component Information > Service and Repair > Sunroof Opening Trim Finish Lace Replacement (Extended Cab) Sunroof / Moonroof Interior Trim Panel: Service and Repair Sunroof Opening Trim Finish Lace Replacement (Extended Cab) Sunroof Opening Trim Finish Lace Replacement (Extended Cab) Removal Procedure 1. Beginning at the joint located in the center rear of the lace of the sunroof opening, pull the sunroof finishing lace from the sunroof window track assembly. 2. Remove the sunroof finishing lace from the track. Installation Procedure 1. Position the end of the sunroof finishing lace at the center rear of the sunroof opening. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Interior Trim Panel > Component Information > Service and Repair > Sunroof Opening Trim Finish Lace Replacement (Extended Cab) > Page 16206 2. Push the finishing lace (2) onto the track assembly flange (1) until fully seated around the sunroof opening. 3. Pull the finishing lace draw cord toward the sunroof opening. Remove the cord from the periphery of the opening. 4. Ensure that the finishing lace (2) is properly seated over the outer surface of the headliner (3). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Interior Trim Panel > Component Information > Service and Repair > Sunroof Opening Trim Finish Lace Replacement (Extended Cab) > Page 16207 Sunroof / Moonroof Interior Trim Panel: Service and Repair Sunroof Panel/Window Garnish Molding Replacement (Crew Cab) Sunroof Panel/Window Garnish Molding Replacement (Crew Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Diagrams Sunroof / Moonroof Module: Diagrams Component Connector End Views Sunroof Control Module (CF5) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Adjustments > Sunroof Window Height and Opening Fit Adjustment (Extended Cab) Sunroof / Moonroof Panel: Adjustments Sunroof Window Height and Opening Fit Adjustment (Extended Cab) Sunroof Window Height and Opening Fit Adjustment (Extended Cab) 1. Open the sunshade. 2. Close the sunroof window. 3. Loosen the adjusting screws on each side of the sunroof window. 4. Adjust the corners of the window panel using the following guidelines: * Adjust the front of the sunroof window flush to 2 mm (0.08 in) below the top surface of the roof panel. * Adjust the rear of the sunroof window flush to 2 mm (0.08 in) above the top surface of the roof panel. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Install the sunroof window adjustment screws. Tighten the screws to 5 Nm (44 lb in). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Adjustments > Sunroof Window Height and Opening Fit Adjustment (Extended Cab) > Page 16215 Sunroof / Moonroof Panel: Adjustments Sunroof Window Height and Opening Fit Adjustment (Crew Cab) Sunroof Window Height and Opening Fit Adjustment (Crew Cab) Note: Correct adjustment cannot be achieved if the sunroof window is closed from vent position. 1. Cycle the sunroof window from full open to closed position. Note: Do Not remove or lower headliner to access sunroof window screws. 2. Loosen the adjusting screws on the window. 3. Adjust the corners of the front window panel using the following guidelines: * Adjust the front of the sunroof window to 0.0 mm - 1.0 mm (0.0 in - 0.04 in ) below the top surface of the roof panel. * Adjust the rear center line of the sunroof window to 1 mm to 2 mm (0.04 in to 0.08 in ) below the top surface of the roof panel. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) 4. Tighten the sunroof window adjustment screws. Tighten the sunroof window adjusting screws to 5 Nm (44 lb in). 5. Cycle sunroof window through all positions. 6. Inspect the sunroof window adjustment. Adjust if necessary. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Service and Repair > Sunroof Window Replacement (Crew Cab) Sunroof / Moonroof Panel: Service and Repair Sunroof Window Replacement (Crew Cab) Sunroof Window Replacement (Crew Cab) Removal Procedure Note: The sunroof must be in the fully closed position prior to removing the sunroof window. 1. Open the sunshade panel. 2. Remove the 4 screws (2) that retain the sunroof window (1) to the sunroof module assembly. 3. Remove the sunroof window from the top of the vehicle. Installation Procedure 1. Position the sunroof window (1) to the vehicle. 2. Loosely insert the screws (2) that retain the sunroof window (1) to the sunroof module assembly. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Adjust the sunroof window panel as necessary. Refer to Sunroof Window Height and Opening Fit Adjustment (Extended Cab) (See: Adjustments/Sunroof Window Height and Opening Fit Adjustment (Extended Cab))Sunroof Window Height and Opening Fit Adjustment (Crew Cab) (See: Adjustments/Sunroof Window Height and Opening Fit Adjustment (Crew Cab)). Tighten the screws to 3 Nm (27 lb in). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Service and Repair > Sunroof Window Replacement (Crew Cab) > Page 16218 Sunroof / Moonroof Panel: Service and Repair Sunroof Window Replacement (Extended Cab) Sunroof Window Replacement (Extended Cab) Removal Procedure 1. Position the sunshade panel fully rearward. 2. Position the sunroof window panel to the vent position. 3. Remove the sunroof window panel screws from the sunroof window panel. 4. Remove the sunroof window panel from the sunroof module. Installation Procedure 1. Position the sunroof window panel to the sunroof module. Ensure that the information logo stencil is towards the rear of the sunroof opening. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the sunroof window panel screws to the sunroof window panel. Tighten the sunroof window panel screws to 4 Nm (35 lb in). 3. Adjust the sunroof window panel as necessary. Refer to Sunroof Window Height and Opening Fit Adjustment (Extended Cab) (See: Adjustments/Sunroof Window Height and Opening Fit Adjustment (Extended Cab))Sunroof Window Height and Opening Fit Adjustment (Crew Cab) (See: Adjustments/Sunroof Window Height and Opening Fit Adjustment (Crew Cab)). 4. Inspect the sunroof window panel for proper operation. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest: > 08-08-67-006B > Apr > 11 > Body - Headliner Wet/Water Leak Into Cab Past Sunroof Sunroof / Moonroof Weatherstrip: Customer Interest Body - Headliner Wet/Water Leak Into Cab Past Sunroof TECHNICAL Bulletin No.: 08-08-67-006B Date: April 11, 2011 Subject: Headliner Wet, Water Leak into Cab, Water Leak Past Sunroof Glass Weatherstrip/Seal (Inspect Sunroof Weatherstrip/Seal and Replace if Necessary) Models: 2007-2012 Chevrolet Silverado Crew Cab Models 2007-2012 GMC Sierra Crew Cab Models with Sunroof (RPO CF5) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 08-08-67-006A (Section 08 - Body and Accessories). Condition Some customers may comment on the headliner being wet or water leaking into the cab. Cause The sunroof glass weatherstrip/seal may not be completely water tight. The weatherstrip/seal may not be properly secured to the glass panel. Correction Important DO NOT replace the sunroof glass panel. Technicians are to inspect the glass panel seal appearance at the corners and around the glass panel. If the weatherstrip/seal looks depressed or concave in the middle, as shown above, replace the seal. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest: > 08-08-67-006B > Apr > 11 > Body - Headliner Wet/Water Leak Into Cab Past Sunroof > Page 16227 Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-08-67-006B > Apr > 11 > Body - Headliner Wet/Water Leak Into Cab Past Sunroof Sunroof / Moonroof Weatherstrip: All Technical Service Bulletins Body - Headliner Wet/Water Leak Into Cab Past Sunroof TECHNICAL Bulletin No.: 08-08-67-006B Date: April 11, 2011 Subject: Headliner Wet, Water Leak into Cab, Water Leak Past Sunroof Glass Weatherstrip/Seal (Inspect Sunroof Weatherstrip/Seal and Replace if Necessary) Models: 2007-2012 Chevrolet Silverado Crew Cab Models 2007-2012 GMC Sierra Crew Cab Models with Sunroof (RPO CF5) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 08-08-67-006A (Section 08 - Body and Accessories). Condition Some customers may comment on the headliner being wet or water leaking into the cab. Cause The sunroof glass weatherstrip/seal may not be completely water tight. The weatherstrip/seal may not be properly secured to the glass panel. Correction Important DO NOT replace the sunroof glass panel. Technicians are to inspect the glass panel seal appearance at the corners and around the glass panel. If the weatherstrip/seal looks depressed or concave in the middle, as shown above, replace the seal. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-08-67-006B > Apr > 11 > Body - Headliner Wet/Water Leak Into Cab Past Sunroof > Page 16233 Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > All Other Service Bulletins for Sunroof / Moonroof Weatherstrip: > 07-08-42-006E > Nov > 10 > Instruments - Bulb Outage Detection Restoration Lamp Out Indicator: All Technical Service Bulletins Instruments - Bulb Outage Detection Restoration INFORMATION Bulletin No.: 07-08-42-006E Date: November 11, 2010 Subject: Information on BCM Calibrations Available to Restore Bulb Outage Detection on Vehicles Produced by a Second Stage Manufacturer, Turn Signals Flash Fast after Factory Box Removed (Upfitter) Models: 2007-2011 Chevrolet Silverado 2007-2011 GMC Sierra Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 07-08-42-006D (Section 08 - Body and Accessories). The information contained in this bulletin applies to vehicles that are to be completed by a second stage manufacturer (upfitter) and may need to have the Body Control Module (BCM) rear turn signal bulb outage detection capability changed. All production vehicles will be manufactured with one of the following BCM rear turn signal bulb outage detection software options: 1. A standard production vehicle will have BCM software that checks for two bulbs functioning in each rear turn signal bulb circuit. If one or more bulbs are inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 2. Certain 2500 and 3500 models can be ordered with a new option (RPO 9U5) where the BCM checks for one bulb functioning in each rear turn signal bulb circuit. If the bulb goes inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 3. A vehicle built with a pickup box delete or chassis cab option (RPO ZW9) will be produced with a BCM program that has no turn signal bulb outage detection capability (LED compatible). The IPC turn signal indicator will flash at the same rate no matter how many turn signal bulbs are inoperative. In some cases, the upfitter may wish to change the turn signal bulb outage detection capability so that the turn signals work correctly with their upfit or to meet certain requirements. This will require contacting the Techline Customer Support Center (TCSC) to open a case and obtain a Vehicle Configuration Index (VCI) number. Advise the TCSC consultant which turn signal bulb outage detection capability is needed: 1. Factory standard production TWO bulb outage detection. 2. Optional (RPO 9U5) ONE bulb outage detection. NOTE: ONLY AVAILABLE ON CERTAIN 2007-2011 MODEL 2500 AND 3500 VEHICLES. 3. NO bulb outage detection (LED compatible). The BCM can then be reprogrammed with the correct software. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Weatherstrip > Component Information > Service and Repair > Sunroof Window Weatherstrip Replacement (Crew Cab) Sunroof / Moonroof Weatherstrip: Service and Repair Sunroof Window Weatherstrip Replacement (Crew Cab) Sunroof Window Weatherstrip Replacement (Crew Cab) Removal Procedure 1. Remove the sunroof window. Refer to Sunroof Window Replacement (Extended Cab) (See: Sunroof / Moonroof Panel/Service and Repair/Sunroof Window Replacement (Extended Cab))Sunroof Window Replacement (Crew Cab) (See: Sunroof / Moonroof Panel/Service and Repair/Sunroof Window Replacement (Crew Cab)). 2. Carefully remove the sunroof window weatherstrip from the perimeter of the sunroof window. Installation Procedure 1. Carefully install the sunroof window weatherstrip (2) to the perimeter of the sunroof window (1), ensuring that the weatherstrip is fully seated. 2. Install the sunroof window to the sunroof module assembly. Refer to Sunroof Window Replacement (Extended Cab) (See: Sunroof / Moonroof Panel/Service and Repair/Sunroof Window Replacement (Extended Cab))Sunroof Window Replacement (Crew Cab) (See: Sunroof / Moonroof Panel/Service and Repair/Sunroof Window Replacement (Crew Cab)). 3. Ensure that the sunroof does not have any air or waterleaks. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Weatherstrip > Component Information > Service and Repair > Sunroof Window Weatherstrip Replacement (Crew Cab) > Page 16246 Sunroof / Moonroof Weatherstrip: Service and Repair Sunroof Window Weatherstrip Replacement (Extended Cab) Sunroof Window Weatherstrip Replacement (Extended Cab) Removal Procedure 1. Remove the sunroof window. Refer to Sunroof Window Replacement (Extended Cab) (See: Sunroof / Moonroof Panel/Service and Repair/Sunroof Window Replacement (Extended Cab))Sunroof Window Replacement (Crew Cab) (See: Sunroof / Moonroof Panel/Service and Repair/Sunroof Window Replacement (Crew Cab)). 2. Carefully remove the sunroof window weatherstrip (2) from the perimeter of the sunroof window (1). Installation Procedure 1. Carefully install the sunroof window weatherstrip (2) to the perimeter of the sunroof window (1), ensuring that the weatherstrip is fully seated. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Weatherstrip > Component Information > Service and Repair > Sunroof Window Weatherstrip Replacement (Crew Cab) > Page 16247 2. Install the sunroof window. Refer to Sunroof Window Replacement (Extended Cab) (See: Sunroof / Moonroof Panel/Service and Repair/Sunroof Window Replacement (Extended Cab))Sunroof Window Replacement (Crew Cab) (See: Sunroof / Moonroof Panel/Service and Repair/Sunroof Window Replacement (Crew Cab)). 3. Ensure that the sunroof does not have any air or waterleaks. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Service and Repair > Head Restraint Replacement Head Rest: Service and Repair Head Restraint Replacement Head Restraint Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Service and Repair > Head Restraint Replacement > Page 16253 Head Rest: Service and Repair Head Restraint Guide Replacement Head Restraint Guide Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Service and Repair > Head Restraint Replacement > Page 16254 Head Rest: Service and Repair Rear Seat Head Restraint Replacement Rear Seat Head Restraint Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Service and Repair > Head Restraint Replacement > Page 16255 Head Rest: Service and Repair Rear Seat Head Restraint Guide Replacement Rear Seat Head Restraint Guide Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Head Restraint System > System Information > Technical Service Bulletins > Restraints - Driver/Passenger Seat Head Rest Information Head Restraint System: Technical Service Bulletins Restraints - Driver/Passenger Seat Head Rest Information INFORMATION Bulletin No.: 10-08-50-003A Date: March 24, 2011 Subject: Information on Driver or Passenger Seat Head Restraint Concerns with Comfort, Custom Upholstery or Other Comfort Enhancing Devices Models: 2012 and Prior GM Passenger Cars and Trucks Equipped with Adjustable Head Restraints Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 10-08-50-003 (Section 08 - Body and Accessories). Important ON A GM VEHICLE EQUIPPED WITH ADJUSTABLE HEAD RESTRAINTS, USE THE HEAD RESTRAINT COVERS, FOAM AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER OR REPOSITION THE HEAD RESTRAINT SYSTEM. ANY ALTERATIONS TO HEAD RESTRAINTS DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER DESIGN ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. You may have a customer with a concern that the head restraint is uncomfortable or sits too far forward. The front driver and passenger seats are equipped with head restraints that have been designed to help minimize injuries while still providing comfort to the occupants. Each GM vehicle has its own specifically designed head restraint. The head restraints should only be used in the vehicle for which they were designed. The head restraint will not operate to its design intent if the original foam is replaced (1) by non-GM foam or head restraint, (2) by GM foam or head restraint designed for a different vehicle, (3) by GM foam or head restraint that has been altered by a trim shop or (4) if any object, such as an aftermarket comfort enhancing pad or device, is installed. Never modify the design of the head restraint or remove the head restraint from the vehicle as this may interfere with the operation of the seating and restraint systems and may prevent proper positioning of the passenger within the vehicle. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations Memory Positioning Module: Locations Harness Routing Views Driver Seat Harness Routing 1 - Seat Recline Motor - Driver (AN3) 2 - Seat Lumbar Vertical Motor Position Sensor - Driver (AN3) 3 - Seat Lumbar Vertical Motor - Driver (AN3) 4 - X324 (AN3) 5 - Seat Lumbar Horizontal Motor - Driver (AN3) 6 - Seat Lumbar Horizontal Motor Position Sensor - Driver (AN3) 7 - Seat Recline Position Sensor - Driver (AN3) 8 - Seat Lumbar Switch - Driver (AN3) 9 - Seat Adjuster Switch - Driver (AG1) 10 - Memory Seat Module (MSM) (AN3) 11 - Inflatable Restraint Seat Position Sensor (SPS) - Driver (10 Series) 12 - Seat Adjuster Motor Assembly - Driver (AG1) 13 Seat Belt Buckle - Driver Passenger Seat Harness Routing Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 16264 1 - Seat Frame 2 - X325 (AN3) 3 - Seat Lumbar Vertical Motor - Passenger (AN3) 4 - Seat Adjuster Switch - Passenger (AG2) 5 - Seat Lumbar Switch - Passenger (AN3) 6 - Seat Belt Buckle Passenger 7 - Inflatable Restraint Passenger Presence System (PPS) Module (AL0) 8 - Seat Adjuster Motor Assembly - Passenger (AG2) 9 - Inflatable Restraint Passenger Presence System (PPS) Sensor (AL0) 10 - Seat Recline Motor - Passenger (AN3) 11 - Seat Lumbar Horizontal Motor - Passenger (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 16265 Memory Positioning Module: Diagrams Component Connector End Views Memory Seat Module (MSM) X1 (AN3) Memory Seat Module (MSM) X2 (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 16266 Memory Seat Module (MSM) X3 (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 16267 Memory Seat Module (MSM) X4 (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 16268 Memory Seat Module (MSM) X5 (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 16269 Memory Seat Module (MSM) X6 (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 16270 Memory Seat Module (MSM) X7 (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 16271 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 16272 Memory Positioning Module: Service and Repair Memory Seat Control Module Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations Seat Memory Switch: Locations Harness Routing Views Driver Seat Harness Routing 1 - Seat Recline Motor - Driver (AN3) 2 - Seat Lumbar Vertical Motor Position Sensor - Driver (AN3) 3 - Seat Lumbar Vertical Motor - Driver (AN3) 4 - X324 (AN3) 5 - Seat Lumbar Horizontal Motor - Driver (AN3) 6 - Seat Lumbar Horizontal Motor Position Sensor - Driver (AN3) 7 - Seat Recline Position Sensor - Driver (AN3) 8 - Seat Lumbar Switch - Driver (AN3) 9 - Seat Adjuster Switch - Driver (AG1) 10 - Memory Seat Module (MSM) (AN3) 11 - Inflatable Restraint Seat Position Sensor (SPS) - Driver (10 Series) 12 - Seat Adjuster Motor Assembly - Driver (AG1) 13 Seat Belt Buckle - Driver Passenger Seat Harness Routing Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations > Page 16276 1 - Seat Frame 2 - X325 (AN3) 3 - Seat Lumbar Vertical Motor - Passenger (AN3) 4 - Seat Adjuster Switch - Passenger (AG2) 5 - Seat Lumbar Switch - Passenger (AN3) 6 - Seat Belt Buckle Passenger 7 - Inflatable Restraint Passenger Presence System (PPS) Module (AL0) 8 - Seat Adjuster Motor Assembly - Passenger (AG2) 9 - Inflatable Restraint Passenger Presence System (PPS) Sensor (AL0) 10 - Seat Recline Motor - Passenger (AN3) 11 - Seat Lumbar Horizontal Motor - Passenger (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations > Page 16277 Seat Memory Switch: Service and Repair Driver Seat Adjuster Memory Switch Replacement (Crew Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations Power Seat Motor: Locations Harness Routing Views Driver Seat Harness Routing 1 - Seat Recline Motor - Driver (AN3) 2 - Seat Lumbar Vertical Motor Position Sensor - Driver (AN3) 3 - Seat Lumbar Vertical Motor - Driver (AN3) 4 - X324 (AN3) 5 - Seat Lumbar Horizontal Motor - Driver (AN3) 6 - Seat Lumbar Horizontal Motor Position Sensor - Driver (AN3) 7 - Seat Recline Position Sensor - Driver (AN3) 8 - Seat Lumbar Switch - Driver (AN3) 9 - Seat Adjuster Switch - Driver (AG1) 10 - Memory Seat Module (MSM) (AN3) 11 - Inflatable Restraint Seat Position Sensor (SPS) - Driver (10 Series) 12 - Seat Adjuster Motor Assembly - Driver (AG1) 13 Seat Belt Buckle - Driver Passenger Seat Harness Routing Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Page 16281 1 - Seat Frame 2 - X325 (AN3) 3 - Seat Lumbar Vertical Motor - Passenger (AN3) 4 - Seat Adjuster Switch - Passenger (AG2) 5 - Seat Lumbar Switch - Passenger (AN3) 6 - Seat Belt Buckle Passenger 7 - Inflatable Restraint Passenger Presence System (PPS) Module (AL0) 8 - Seat Adjuster Motor Assembly - Passenger (AG2) 9 - Inflatable Restraint Passenger Presence System (PPS) Sensor (AL0) 10 - Seat Recline Motor - Passenger (AN3) 11 - Seat Lumbar Horizontal Motor - Passenger (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Page 16282 Power Seat Motor: Diagrams Component Connector End Views Seat Adjuster Motor Assembly - Driver (AG1 without AN3) Seat Adjuster Motor Assembly - Driver X1 (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Page 16283 Seat Adjuster Motor Assembly - Driver X2 (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Page 16284 Seat Adjuster Motor Assembly - Passenger (AG2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Page 16285 Seat Front Vertical Motor - Driver (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Page 16286 Seat Front Vertical Motor - Passenger (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Page 16287 Seat Horizontal Motor - Driver (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Page 16288 Seat Horizontal Motor - Passenger (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Page 16289 Seat Lumbar Horizontal Motor - Driver (AN3) Seat Lumbar Horizontal Motor - Passenger (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Page 16290 Seat Lumbar Vertical Motor - Driver (AN3) Seat Lumbar Vertical Motor - Passenger (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Page 16291 Seat Rear Vertical Motor - Driver (HP2) Seat Rear Vertical Motor - Passenger (HP2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Page 16292 Seat Recline Motor - Driver (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Page 16293 Seat Recline Motor - Passenger (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Page 16294 Power Seat Motor: Service and Repair Front Seat Adjuster Replacement (Power) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor Position Sensor > Component Information > Locations Power Seat Motor Position Sensor: Locations Harness Routing Views Driver Seat Harness Routing 1 - Seat Recline Motor - Driver (AN3) 2 - Seat Lumbar Vertical Motor Position Sensor - Driver (AN3) 3 - Seat Lumbar Vertical Motor - Driver (AN3) 4 - X324 (AN3) 5 - Seat Lumbar Horizontal Motor - Driver (AN3) 6 - Seat Lumbar Horizontal Motor Position Sensor - Driver (AN3) 7 - Seat Recline Position Sensor - Driver (AN3) 8 - Seat Lumbar Switch - Driver (AN3) 9 - Seat Adjuster Switch - Driver (AG1) 10 - Memory Seat Module (MSM) (AN3) 11 - Inflatable Restraint Seat Position Sensor (SPS) - Driver (10 Series) 12 - Seat Adjuster Motor Assembly - Driver (AG1) 13 Seat Belt Buckle - Driver Passenger Seat Harness Routing Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor Position Sensor > Component Information > Locations > Page 16298 1 - Seat Frame 2 - X325 (AN3) 3 - Seat Lumbar Vertical Motor - Passenger (AN3) 4 - Seat Adjuster Switch - Passenger (AG2) 5 - Seat Lumbar Switch - Passenger (AN3) 6 - Seat Belt Buckle Passenger 7 - Inflatable Restraint Passenger Presence System (PPS) Module (AL0) 8 - Seat Adjuster Motor Assembly - Passenger (AG2) 9 - Inflatable Restraint Passenger Presence System (PPS) Sensor (AL0) 10 - Seat Recline Motor - Passenger (AN3) 11 - Seat Lumbar Horizontal Motor - Passenger (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor Position Sensor > Component Information > Locations > Page 16299 Power Seat Motor Position Sensor: Diagrams Component Connector End Views Seat Lumbar Horizontal Motor Position Sensor - Driver (AN3) Seat Lumbar Vertical Motor Position Sensor - Driver (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor Position Sensor > Component Information > Locations > Page 16300 Seat Recline Position Sensor - Driver (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor Position Sensor > Component Information > Locations > Page 16301 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Seat Switch: > 09-08-50-011A > Apr > 11 > Body Sticking/Binding Door Mounted Seat Switches Power Seat Switch: All Technical Service Bulletins Body - Sticking/Binding Door Mounted Seat Switches TECHNICAL Bulletin No.: 09-08-50-011A Date: April 13, 2011 Subject: Sticking/Binding Door Mounted Seat Switches (Align Switch) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon XL Denali All Equipped with RPOs AN3, KA1, KB6 Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 09-08-50-011 (Section 08 - Body and Accessories). Condition Some customers may comment that the door mounted memory/ heated/ cool seat switch buttons are sticking or binding. Cause This condition may be caused by the switch being out of alignment in the bezel, creating a hard contact between the switch button and the inside release handle bezel. Correction 1. Remove the door trim. Refer to Front Side Door Trim Panel Replacement in SI. 2. Loosen both screws (1) holding the switch to the inside release handle bezel. 3. Using a flat-bladed tool (1), carefully shift the position of the switch to create a nominal gap all around its perimeter within the bezel. Tighten the two screws holding the switch. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Seat Switch: > 09-08-50-011A > Apr > 11 > Body Sticking/Binding Door Mounted Seat Switches > Page 16310 4. Confirm that the switch buttons are free moving, and there is a nominal gap (1) all around its perimeter within the bezel. 5. Reinstall the door trim. Refer to Front Side Door Trim Panel Replacement in SI. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Technical Service Bulletins > Customer Interest for Power Seat Switch: > 09-08-50-011A > Apr > 11 > Body - Sticking/Binding Door Mounted Seat Switches Power Seat Switch: Customer Interest Body - Sticking/Binding Door Mounted Seat Switches TECHNICAL Bulletin No.: 09-08-50-011A Date: April 13, 2011 Subject: Sticking/Binding Door Mounted Seat Switches (Align Switch) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon XL Denali All Equipped with RPOs AN3, KA1, KB6 Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 09-08-50-011 (Section 08 - Body and Accessories). Condition Some customers may comment that the door mounted memory/ heated/ cool seat switch buttons are sticking or binding. Cause This condition may be caused by the switch being out of alignment in the bezel, creating a hard contact between the switch button and the inside release handle bezel. Correction 1. Remove the door trim. Refer to Front Side Door Trim Panel Replacement in SI. 2. Loosen both screws (1) holding the switch to the inside release handle bezel. 3. Using a flat-bladed tool (1), carefully shift the position of the switch to create a nominal gap all around its perimeter within the bezel. Tighten the two screws holding the switch. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Technical Service Bulletins > Customer Interest for Power Seat Switch: > 09-08-50-011A > Apr > 11 > Body - Sticking/Binding Door Mounted Seat Switches > Page 16316 4. Confirm that the switch buttons are free moving, and there is a nominal gap (1) all around its perimeter within the bezel. 5. Reinstall the door trim. Refer to Front Side Door Trim Panel Replacement in SI. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Technical Service Bulletins > Page 16317 Power Seat Switch: Locations Harness Routing Views Driver Seat Harness Routing 1 - Seat Recline Motor - Driver (AN3) 2 - Seat Lumbar Vertical Motor Position Sensor - Driver (AN3) 3 - Seat Lumbar Vertical Motor - Driver (AN3) 4 - X324 (AN3) 5 - Seat Lumbar Horizontal Motor - Driver (AN3) 6 - Seat Lumbar Horizontal Motor Position Sensor - Driver (AN3) 7 - Seat Recline Position Sensor - Driver (AN3) 8 - Seat Lumbar Switch - Driver (AN3) 9 - Seat Adjuster Switch - Driver (AG1) 10 - Memory Seat Module (MSM) (AN3) 11 - Inflatable Restraint Seat Position Sensor (SPS) - Driver (10 Series) 12 - Seat Adjuster Motor Assembly - Driver (AG1) 13 Seat Belt Buckle - Driver Passenger Seat Harness Routing Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Technical Service Bulletins > Page 16318 1 - Seat Frame 2 - X325 (AN3) 3 - Seat Lumbar Vertical Motor - Passenger (AN3) 4 - Seat Adjuster Switch - Passenger (AG2) 5 - Seat Lumbar Switch - Passenger (AN3) 6 - Seat Belt Buckle Passenger 7 - Inflatable Restraint Passenger Presence System (PPS) Module (AL0) 8 - Seat Adjuster Motor Assembly - Passenger (AG2) 9 - Inflatable Restraint Passenger Presence System (PPS) Sensor (AL0) 10 - Seat Recline Motor - Passenger (AN3) 11 - Seat Lumbar Horizontal Motor - Passenger (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Technical Service Bulletins > Page 16319 Power Seat Switch: Diagrams Component Connector End Views Seat Adjuster Switch - Driver (AG1 without AN3) Seat Adjuster Switch - Driver (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Technical Service Bulletins > Page 16320 Seat Adjuster Switch - Passenger (AG2 without AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Technical Service Bulletins > Page 16321 Seat Adjuster Switch - Passenger (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Technical Service Bulletins > Page 16322 Seat Lumbar Switch - Driver (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Technical Service Bulletins > Page 16323 Seat Lumbar Switch - Passenger (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > Driver or Passenger Seat Adjuster Switch Knob Replacement Power Seat Switch: Service and Repair Driver or Passenger Seat Adjuster Switch Knob Replacement Driver or Passenger Seat Adjuster Switch Knob Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > Driver or Passenger Seat Adjuster Switch Knob Replacement > Page 16326 Power Seat Switch: Service and Repair Power Seat Switch Replacement Power Seat Switch Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > Driver or Passenger Seat Adjuster Switch Knob Replacement > Page 16327 Power Seat Switch: Service and Repair Lumbar Switch Replacement Lumbar Switch Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Driver or Passenger Seat Back Cushion Cover and Pad Replacement Seat Back: Service and Repair Driver or Passenger Seat Back Cushion Cover and Pad Replacement Driver or Passenger Seat Back Cushion Cover and Pad Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Driver or Passenger Seat Back Cushion Cover and Pad Replacement > Page 16332 Seat Back: Service and Repair Driver or Passenger Seat Back Cushion Frame Replacement Driver or Passenger Seat Back Cushion Frame Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Driver or Passenger Seat Back Cushion Cover and Pad Replacement > Page 16333 Seat Back: Service and Repair Front Center Seat Back Cushion Latch Upper Cover Replacement (AZ3) Front Center Seat Back Cushion Latch Upper Cover Replacement (AZ3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Driver or Passenger Seat Back Cushion Cover and Pad Replacement > Page 16334 Seat Back: Service and Repair Front Center Seat Back Cushion Latch Upper Cover Replacement (AE7) Front Center Seat Back Cushion Latch Upper Cover Replacement (AE7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Driver or Passenger Seat Back Cushion Cover and Pad Replacement > Page 16335 Seat Back: Service and Repair Driver or Passenger Seat Back Cushion Cover and Pad Replacement Driver or Passenger Seat Back Cushion Cover and Pad Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Driver or Passenger Seat Back Cushion Cover and Pad Replacement > Page 16336 Driver or Passenger Seat Back Cushion Frame Replacement Driver or Passenger Seat Back Cushion Frame Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Driver or Passenger Seat Back Cushion Cover and Pad Replacement > Page 16337 Front Center Seat Back Cushion Latch Upper Cover Replacement (AZ3) Front Center Seat Back Cushion Latch Upper Cover Replacement (AZ3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Driver or Passenger Seat Back Cushion Cover and Pad Replacement > Page 16338 Front Center Seat Back Cushion Latch Upper Cover Replacement (AE7) Front Center Seat Back Cushion Latch Upper Cover Replacement (AE7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Driver or Passenger Seat Back Cushion Cover and Pad Replacement > Page 16339 Front Center Seat Back Cushion Latch Replacement (AZ3) Front Center Seat Back Cushion Latch Replacement (AZ3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Driver or Passenger Seat Back Cushion Cover and Pad Replacement > Page 16340 Front Center Seat Back Cushion Latch Replacement (AE7) Front Center Seat Back Cushion Latch Replacement (AE7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Driver or Passenger Seat Back Cushion Cover and Pad Replacement > Page 16341 Rear Seat Back Cushion Cover and Pad Replacement (Extended Cab with AM7) Rear Seat Back Cushion Cover and Pad Replacement (Extended Cab with AM7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Driver or Passenger Seat Back Cushion Cover and Pad Replacement > Page 16342 Rear Seat Back Cushion Cover and Pad Replacement (Extended Cab with A68) Rear Seat Back Cushion Cover and Pad Replacement (Extended Cab with A68) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Driver or Passenger Seat Back Cushion Cover and Pad Replacement > Page 16343 Rear Seat Back Cushion Cover and Pad Replacement (Crew Cab with A68) Rear Seat Back Cushion Cover and Pad Replacement (Crew Cab with A68) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Driver or Passenger Seat Back Cushion Cover and Pad Replacement > Page 16344 Rear Seat Back Cushion Frame Replacement (Extended Cab with AM7) Rear Seat Back Cushion Frame Replacement (Extended Cab with AM7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Driver or Passenger Seat Back Cushion Cover and Pad Replacement > Page 16345 Rear Seat Back Cushion Frame Replacement (Extended Cab with A68) Rear Seat Back Cushion Frame Replacement (Extended Cab with A68) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Driver or Passenger Seat Back Cushion Cover and Pad Replacement > Page 16346 Rear Seat Back Cushion Frame Replacement (Crew Cab with A68) Rear Seat Back Cushion Frame Replacement (Crew Cab with A68) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Driver or Passenger Seat Back Cushion Cover and Pad Replacement > Page 16347 Rear Seat Back Recliner Cover Replacement (Extended Cab with A68) Rear Seat Back Recliner Cover Replacement (Extended Cab with A68) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Driver or Passenger Seat Back Cushion Cover and Pad Replacement > Page 16348 Rear Seat Back Recliner Cover Replacement (Crew Cab with A68) Rear Seat Back Recliner Cover Replacement (Crew Cab with A68) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Driver or Passenger Seat Back Cushion Cover and Pad Replacement > Page 16349 Driver or Passenger Seat Back Cushion Finish Panel Replacement Driver or Passenger Seat Back Cushion Finish Panel Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Driver or Passenger Seat Back Cushion Cover and Pad Replacement > Page 16350 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Customer Interest: > 08-08-50-001D > Apr > 11 > Interior - Front Seat Cushion Cover Becomes Detached Seat Cover: Customer Interest Interior - Front Seat Cushion Cover Becomes Detached TECHNICAL Bulletin No.: 08-08-50-001D Date: April 06, 2011 Subject: Front Seat Cushion Cover Becomes Detached (Add Push Pin Fasteners to J-Retainer) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL with Front Seat RPO Codes AN3, A95, AE7 or AZ3 Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-08-50-001C (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger front seat cushion cover is coming detached from the seat frame along the front edge, or that the seat cushion foam has become exposed at the front corner(s) of the seat. Correction To improve the retention of the front seat cushion cover to the seat frame, modify the cover J-retainer and add two push pin retainers, GM P/N 10121502, to securely attach the J-retainer. Follow the procedure below: Important A number of the following graphics show the seat assembly removed from the vehicle. This is for illustration purposes only. Do not remove the seat from the vehicle for this repair. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Customer Interest: > 08-08-50-001D > Apr > 11 > Interior - Front Seat Cushion Cover Becomes Detached > Page 16359 1. Release the seat cushion cover J-retainer from the seat frame and roll the J-retainer/trim completely down. 2. Locate the slot on each side of the cushion pan frame by lifting the cushion/cover up and away from the lower edge of the frame to expose the slots (1). 3. Using a ruler and marker, measure and mark the cushion trim to match up with the slots on the cushion pan J-retainer attachment tab location. Repeat this process on the opposite end of cushion trim cover. Important Ensure that the J-retainer is fully unrolled, and that the holes are drilled through the lower edge of the J-retainer (1) and not through the U-channel (2) of the retainer. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Customer Interest: > 08-08-50-001D > Apr > 11 > Interior - Front Seat Cushion Cover Becomes Detached > Page 16360 4. Using a drill with a 5/16 drill bit, or equivalent, pierce holes through the trim and plastic J-retainer at the marked locations on each end of the seat cushion trim. 5. Pushing only approximately 1/4 of the way through, insert a push pin retainer (1) into the drilled holes on each side of the J-retainer. 6. Reposition the seat cushion and cover, and roll the J-retainer and trim to install position. 7. Attach the J-retainer to the seat cushion pan on one side by positioning the push pin retainer (1) to the rear side of the slot on cushion pan, and pushing forward to fully seat the push pin in the slot. 8. Repeat step 7 on the opposite end of J-retainer. 9. The seat cushion cover will now have better retention to the seat frame, and exhibit an improved fit across the forward edge of the seat. Parts Information Purchase the tape locally. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Customer Interest: > 08-08-50-001D > Apr > 11 > Interior - Front Seat Cushion Cover Becomes Detached > Page 16361 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Cover: > 08-08-50-001D > Apr > 11 > Interior - Front Seat Cushion Cover Becomes Detached Seat Cover: All Technical Service Bulletins Interior - Front Seat Cushion Cover Becomes Detached TECHNICAL Bulletin No.: 08-08-50-001D Date: April 06, 2011 Subject: Front Seat Cushion Cover Becomes Detached (Add Push Pin Fasteners to J-Retainer) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL with Front Seat RPO Codes AN3, A95, AE7 or AZ3 Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-08-50-001C (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger front seat cushion cover is coming detached from the seat frame along the front edge, or that the seat cushion foam has become exposed at the front corner(s) of the seat. Correction To improve the retention of the front seat cushion cover to the seat frame, modify the cover J-retainer and add two push pin retainers, GM P/N 10121502, to securely attach the J-retainer. Follow the procedure below: Important A number of the following graphics show the seat assembly removed from the vehicle. This is for illustration purposes only. Do not remove the seat from the vehicle for this repair. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Cover: > 08-08-50-001D > Apr > 11 > Interior - Front Seat Cushion Cover Becomes Detached > Page 16367 1. Release the seat cushion cover J-retainer from the seat frame and roll the J-retainer/trim completely down. 2. Locate the slot on each side of the cushion pan frame by lifting the cushion/cover up and away from the lower edge of the frame to expose the slots (1). 3. Using a ruler and marker, measure and mark the cushion trim to match up with the slots on the cushion pan J-retainer attachment tab location. Repeat this process on the opposite end of cushion trim cover. Important Ensure that the J-retainer is fully unrolled, and that the holes are drilled through the lower edge of the J-retainer (1) and not through the U-channel (2) of the retainer. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Cover: > 08-08-50-001D > Apr > 11 > Interior - Front Seat Cushion Cover Becomes Detached > Page 16368 4. Using a drill with a 5/16 drill bit, or equivalent, pierce holes through the trim and plastic J-retainer at the marked locations on each end of the seat cushion trim. 5. Pushing only approximately 1/4 of the way through, insert a push pin retainer (1) into the drilled holes on each side of the J-retainer. 6. Reposition the seat cushion and cover, and roll the J-retainer and trim to install position. 7. Attach the J-retainer to the seat cushion pan on one side by positioning the push pin retainer (1) to the rear side of the slot on cushion pan, and pushing forward to fully seat the push pin in the slot. 8. Repeat step 7 on the opposite end of J-retainer. 9. The seat cushion cover will now have better retention to the seat frame, and exhibit an improved fit across the forward edge of the seat. Parts Information Purchase the tape locally. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Cover: > 08-08-50-001D > Apr > 11 > Interior - Front Seat Cushion Cover Becomes Detached > Page 16369 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Cover: > 04-08-50-006D > Sep > 10 > Interior - Seat Cover Wrinkle/Crease/Burn Info Seat Cover: All Technical Service Bulletins Interior - Seat Cover Wrinkle/Crease/Burn Info INFORMATION Bulletin No.: 04-08-50-006D Date: September 09, 2010 Subject: Minor Wrinkles/Creases, Discoloration, Cigarette Burns and Customer Induced Cuts and Stains on Front and Rear Driver and Passenger Seats with Leather, Vinyl or Cloth Seat Covers Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2009 and Prior Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add a model year. Please discard Corporate Bulletin Number 04-08-50-006C (Section 08 - Body and Accessories). If a customer comes in to your dealership due to certain conditions of the seat covers (splits, wrinkles, loose stitching, etc.), you must examine the seat cover in order to determine the validity of the customer claim. Some components from the above listed vehicles have been returned to the Warranty Parts Center (WPC) and analysis of these parts showed "customer induced damage" or No Trouble Found (NTF). The dealer should pay particular attention to the following conditions: - Cigarette burns Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Cover: > 04-08-50-006D > Sep > 10 > Interior - Seat Cover Wrinkle/Crease/Burn Info > Page 16374 - Customer induced cuts (knife cuts, cut by customer tools, etc.) - Paint stains (customer should have cleaned paint stains while paint was still wet) - Coffee stains and other removable dirt These should be cleaned as described in the Owner's Manual under Appearance Care. Also, refer to Corporate Bulletin Number 06-00-89-029A or later. - Evidence of chemicals used for cleaning, other than those specified in the Owner's Manual - Other chemical spills - Minor and normal leather wrinkles as a result of use - Other defects to the seat cover not detected during the pre-delivery inspection (PDI). Inform the customer that the above issues were not present when the vehicle was purchased and cannot be replaced under warranty. The covers, however, may be repaired or replaced at the customer's expense. The following conditions are not caused by the customer and should be covered by warranty: - Split seams Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Cover: > 04-08-50-006D > Sep > 10 > Interior - Seat Cover Wrinkle/Crease/Burn Info > Page 16375 - Wear/cracking/peeling - Discoloration/dye transfer from customer clothing (if discoloration/dye transfer is not removed after using GM Leather and Vinyl Plastic Cleaner, P/N 88861401 (in Canada, P/N 88861409), replace the covers.) Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Cover: > 06-00-89-029F > Apr > 10 > Interior - Cleaning Interior Surfaces of Vehicle Seat Cover: All Technical Service Bulletins Interior - Cleaning Interior Surfaces of Vehicle INFORMATION Bulletin No.: 06-00-89-029F Date: April 27, 2010 Subject: Interior Cleaning - Instrument Panel (IP), Hard or Plastic Surfaces, Seats, Carpet, Leather, Vinyl, Fabric Cleaner, Stain Remover, Restorer - Product Availability Models: 2006-2011 GM Passenger Cars and Trucks including Saturn (EXCLUDES Cadillac DTS Platinum and Escalade Platinum with RPO R9N - Tehama Leather) 2006-2010 HUMMER H2, H3 2006-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-00-89-029E (Section 00 - General Information). To keep the vehicle interior looking the best, it should be cleaned often. It is important to keep the upholstery from becoming heavily soiled. The vehicle's interior can experience extreme heat, which can cause stains to set quickly. Lighter color interiors may require more frequent cleaning. Care should be taken because newspapers and garments may transfer color to the vehicle's interior. Many of today's interiors are made with new low gloss materials. Permanent damage may result from using cleaners on ANY surfaces (interior trim, instrument panel, carpet, leather, vinyl and fabric) for which they are not intended. Using non-approved products can actually set the stain to the point that nothing can remove it. Important Do not use silicone or wax-based products or those containing organic solvents (such as naptha, alcohol, etc.) to clean your vehicle's interior because they can alter the appearance by increasing the gloss in a non-uniform manner. The increase in gloss may cause annoying reflections in the windshield and even make it difficult to see through the windshield under certain conditions. - Never use a STIFF brush or a brush that has been previously used with a harsh chemical. This can cause damage to the vehicle's interior surfaces. - Use only mild, Neutral-pH cleaners. Avoid laundry detergents or dishwashing soaps with degreasers. Using too much soap will leave residue that leaves streaks and attracts dirt. Because it is critical to use only mild, neutral-pH cleaners, General Motors has approved the use of the cleaners and conditioners listed in this bulletin for the cleaning of interiors. These products are in the neutral-pH range and will maintain the best vehicle interior appearance. These products are water-based, biodegradable, and do not contain bleach, solvents or harsh chemicals. Interior trim pieces on new vehicles, as well as service components, arrive with a protective film. When removing the protective film, adhesive residue may be left on the trim panels/components. The cleaner (for leather, vinyl, plastic and interior paint) is an effective cleaner in removing adhesive residue without causing damage to the component. Important - If soapy, alkaline cleaning solutions are used on fabrics, and not thoroughly rinsed out, the residual left in the fabric will attract dirt. Because the recommended cleaners/conditioners are in the pH neutral range, they won't leave behind soapy residue. - On heavily stained or difficult to clean fabric/carpet, it is recommended that the entire surface be treated and cleaned vs. spot cleaning. Refer to Extractor Machine and Concentrate section of this bulletin for more information. Effective cleaning steps for hard and/or plastic surfaces: 1. Using a clean towel, apply/spray cleaner - leather, vinyl, plastic, interior paint, directly onto the towel. 2. Wipe the surface with the towel/cleaner. 3. If necessary, use a soft bristle brush to work cleaner into the crevasses of the area being cleaned. 4. Wipe off any excess cleaner from the surface. 5. Using a clean towel, apply/spray the conditioner (leather, vinyl restorer) directly onto the towel. 6. Wipe the conditioner onto the previously cleaned area to restore the material to it's original luster. Important Today's interiors are developed and intended to have a low-gloss appearance. It is important to use only products which provide a low-gloss finish in order to maintain the interior's integrity, customer appeal and satisfaction. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Cover: > 06-00-89-029F > Apr > 10 > Interior - Cleaning Interior Surfaces of Vehicle > Page 16380 Effective cleaning steps for fabric: 1. Remove any residue by lightly rubbing the surface with a clean towel. 2. Choose the appropriate stain remover based on the stain type. 3. Spray and lightly brush the area with a clean, soft bristle brush. 4. Gently blot up the stain. 5. On upholstery/carpet, the use of a fabric protector can help to reduce or eliminate future staining. Upholstery and Carpet Stains When cleaning upholstery and carpet stains ONLY, the following cleaning chart will help you determine which cleaner/formula works best on a particular stain. The chart lists many of the common stains. Some complex stains may require the application of both stain removers, one after the other, to remove both food-based oils and synthetic oils. A soft bristle brush (P/N 88861425) should be used to safely work the cleaner into the leather grain or material. This enables the dirt/stain to be completely removed from the material. Leather Conditioner/Restorer A Leather Conditioner/Restorer is also available. The restorer is safe for all vinyl and leather. It is a water-based product and contains essential emollients to restore suppleness, conditions and adds luster without adding gloss. The restorer will also provide protection against re-staining. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Cover: > 06-00-89-029F > Apr > 10 > Interior - Cleaning Interior Surfaces of Vehicle > Page 16381 Dye Transfer: Dye transfer will happen any time a natural fiber like cotton, silk, wool, or suede comes into contact with leather. The lighter the leather color, the more quickly the dye transfer will appear. Leather should be cleaned on a regular basis so that the dirt and grime do not adversely affect the top coat of the leather. After cleaning the leather, it is important to treat the surface with the restorer. Extractor Machine and Concentrate For difficult to clean materials or when cleaning a large area, the best results will be achieved when using an extractor machine and concentrate. General Motors offers the Ruby Extractor (P/N 627-CC-3000AU) through GM Tools and Equipment 1-800-GM-TOOLS, and has recently released a concentrate for use with the extractor machine. Whichever extractor machine is used, it should meet the minimum specifications of the Ruby Extractor: Ruby Extractor Specifications: - Pump PSI: 55 - Water Lift: 85" - Hose Length: 10 ft Important The Ruby Extractor also comes with a 6 year Outer Body and 3 year Parts warranty. Extractor: The Ruby Extractor machine was designed for automotive use and works effectively in the vehicle's interior. The narrow design of the vacuum head allows detail work in tight areas. The water pressure pump is reduced so the fabric surface is not wet more than is necessary. The dry time is greatly reduced due to less water on the fabric surface, the vacuum head making better contact with the surface and the significant water lift capability of the machine. Concentrate: The concentrated extraction cleaner is engineered with lower pH levels to help remove alkaline buildup on fabrics. The concentrate should be mixed according to the instructions listed on the container. The available concentrate helps to break the stain down and then the stain is easily removed with less water. The concentrate used in the Ruby Extractor is slightly acidic to remove soap and alkalinity from the fabric surfaces left behind by using improper, soapy solutions. Dirt, grease and grime are more easily removed when the proper solution is used during the extraction process. Parts Information Products are available in two sizes; 8 oz / 235 ML and 24 oz / 710 ML bottles. Available Equipment Equipment is available by contacting 1-800-GMTOOLS. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Cover: > 06-00-89-029F > Apr > 10 > Interior - Cleaning Interior Surfaces of Vehicle > Page 16382 Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Cover: > 04-08-50-006D > Sep > 10 > Interior - Seat Cover Wrinkle/Crease/Burn Info Seat Cover: All Technical Service Bulletins Interior - Seat Cover Wrinkle/Crease/Burn Info INFORMATION Bulletin No.: 04-08-50-006D Date: September 09, 2010 Subject: Minor Wrinkles/Creases, Discoloration, Cigarette Burns and Customer Induced Cuts and Stains on Front and Rear Driver and Passenger Seats with Leather, Vinyl or Cloth Seat Covers Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2009 and Prior Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add a model year. Please discard Corporate Bulletin Number 04-08-50-006C (Section 08 - Body and Accessories). If a customer comes in to your dealership due to certain conditions of the seat covers (splits, wrinkles, loose stitching, etc.), you must examine the seat cover in order to determine the validity of the customer claim. Some components from the above listed vehicles have been returned to the Warranty Parts Center (WPC) and analysis of these parts showed "customer induced damage" or No Trouble Found (NTF). The dealer should pay particular attention to the following conditions: - Cigarette burns Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Cover: > 04-08-50-006D > Sep > 10 > Interior - Seat Cover Wrinkle/Crease/Burn Info > Page 16388 - Customer induced cuts (knife cuts, cut by customer tools, etc.) - Paint stains (customer should have cleaned paint stains while paint was still wet) - Coffee stains and other removable dirt These should be cleaned as described in the Owner's Manual under Appearance Care. Also, refer to Corporate Bulletin Number 06-00-89-029A or later. - Evidence of chemicals used for cleaning, other than those specified in the Owner's Manual - Other chemical spills - Minor and normal leather wrinkles as a result of use - Other defects to the seat cover not detected during the pre-delivery inspection (PDI). Inform the customer that the above issues were not present when the vehicle was purchased and cannot be replaced under warranty. The covers, however, may be repaired or replaced at the customer's expense. The following conditions are not caused by the customer and should be covered by warranty: - Split seams Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Cover: > 04-08-50-006D > Sep > 10 > Interior - Seat Cover Wrinkle/Crease/Burn Info > Page 16389 - Wear/cracking/peeling - Discoloration/dye transfer from customer clothing (if discoloration/dye transfer is not removed after using GM Leather and Vinyl Plastic Cleaner, P/N 88861401 (in Canada, P/N 88861409), replace the covers.) Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Cover: > 06-00-89-029F > Apr > 10 > Interior - Cleaning Interior Surfaces of Vehicle Seat Cover: All Technical Service Bulletins Interior - Cleaning Interior Surfaces of Vehicle INFORMATION Bulletin No.: 06-00-89-029F Date: April 27, 2010 Subject: Interior Cleaning - Instrument Panel (IP), Hard or Plastic Surfaces, Seats, Carpet, Leather, Vinyl, Fabric Cleaner, Stain Remover, Restorer - Product Availability Models: 2006-2011 GM Passenger Cars and Trucks including Saturn (EXCLUDES Cadillac DTS Platinum and Escalade Platinum with RPO R9N - Tehama Leather) 2006-2010 HUMMER H2, H3 2006-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-00-89-029E (Section 00 - General Information). To keep the vehicle interior looking the best, it should be cleaned often. It is important to keep the upholstery from becoming heavily soiled. The vehicle's interior can experience extreme heat, which can cause stains to set quickly. Lighter color interiors may require more frequent cleaning. Care should be taken because newspapers and garments may transfer color to the vehicle's interior. Many of today's interiors are made with new low gloss materials. Permanent damage may result from using cleaners on ANY surfaces (interior trim, instrument panel, carpet, leather, vinyl and fabric) for which they are not intended. Using non-approved products can actually set the stain to the point that nothing can remove it. Important Do not use silicone or wax-based products or those containing organic solvents (such as naptha, alcohol, etc.) to clean your vehicle's interior because they can alter the appearance by increasing the gloss in a non-uniform manner. The increase in gloss may cause annoying reflections in the windshield and even make it difficult to see through the windshield under certain conditions. - Never use a STIFF brush or a brush that has been previously used with a harsh chemical. This can cause damage to the vehicle's interior surfaces. - Use only mild, Neutral-pH cleaners. Avoid laundry detergents or dishwashing soaps with degreasers. Using too much soap will leave residue that leaves streaks and attracts dirt. Because it is critical to use only mild, neutral-pH cleaners, General Motors has approved the use of the cleaners and conditioners listed in this bulletin for the cleaning of interiors. These products are in the neutral-pH range and will maintain the best vehicle interior appearance. These products are water-based, biodegradable, and do not contain bleach, solvents or harsh chemicals. Interior trim pieces on new vehicles, as well as service components, arrive with a protective film. When removing the protective film, adhesive residue may be left on the trim panels/components. The cleaner (for leather, vinyl, plastic and interior paint) is an effective cleaner in removing adhesive residue without causing damage to the component. Important - If soapy, alkaline cleaning solutions are used on fabrics, and not thoroughly rinsed out, the residual left in the fabric will attract dirt. Because the recommended cleaners/conditioners are in the pH neutral range, they won't leave behind soapy residue. - On heavily stained or difficult to clean fabric/carpet, it is recommended that the entire surface be treated and cleaned vs. spot cleaning. Refer to Extractor Machine and Concentrate section of this bulletin for more information. Effective cleaning steps for hard and/or plastic surfaces: 1. Using a clean towel, apply/spray cleaner - leather, vinyl, plastic, interior paint, directly onto the towel. 2. Wipe the surface with the towel/cleaner. 3. If necessary, use a soft bristle brush to work cleaner into the crevasses of the area being cleaned. 4. Wipe off any excess cleaner from the surface. 5. Using a clean towel, apply/spray the conditioner (leather, vinyl restorer) directly onto the towel. 6. Wipe the conditioner onto the previously cleaned area to restore the material to it's original luster. Important Today's interiors are developed and intended to have a low-gloss appearance. It is important to use only products which provide a low-gloss finish in order to maintain the interior's integrity, customer appeal and satisfaction. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Cover: > 06-00-89-029F > Apr > 10 > Interior - Cleaning Interior Surfaces of Vehicle > Page 16394 Effective cleaning steps for fabric: 1. Remove any residue by lightly rubbing the surface with a clean towel. 2. Choose the appropriate stain remover based on the stain type. 3. Spray and lightly brush the area with a clean, soft bristle brush. 4. Gently blot up the stain. 5. On upholstery/carpet, the use of a fabric protector can help to reduce or eliminate future staining. Upholstery and Carpet Stains When cleaning upholstery and carpet stains ONLY, the following cleaning chart will help you determine which cleaner/formula works best on a particular stain. The chart lists many of the common stains. Some complex stains may require the application of both stain removers, one after the other, to remove both food-based oils and synthetic oils. A soft bristle brush (P/N 88861425) should be used to safely work the cleaner into the leather grain or material. This enables the dirt/stain to be completely removed from the material. Leather Conditioner/Restorer A Leather Conditioner/Restorer is also available. The restorer is safe for all vinyl and leather. It is a water-based product and contains essential emollients to restore suppleness, conditions and adds luster without adding gloss. The restorer will also provide protection against re-staining. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Cover: > 06-00-89-029F > Apr > 10 > Interior - Cleaning Interior Surfaces of Vehicle > Page 16395 Dye Transfer: Dye transfer will happen any time a natural fiber like cotton, silk, wool, or suede comes into contact with leather. The lighter the leather color, the more quickly the dye transfer will appear. Leather should be cleaned on a regular basis so that the dirt and grime do not adversely affect the top coat of the leather. After cleaning the leather, it is important to treat the surface with the restorer. Extractor Machine and Concentrate For difficult to clean materials or when cleaning a large area, the best results will be achieved when using an extractor machine and concentrate. General Motors offers the Ruby Extractor (P/N 627-CC-3000AU) through GM Tools and Equipment 1-800-GM-TOOLS, and has recently released a concentrate for use with the extractor machine. Whichever extractor machine is used, it should meet the minimum specifications of the Ruby Extractor: Ruby Extractor Specifications: - Pump PSI: 55 - Water Lift: 85" - Hose Length: 10 ft Important The Ruby Extractor also comes with a 6 year Outer Body and 3 year Parts warranty. Extractor: The Ruby Extractor machine was designed for automotive use and works effectively in the vehicle's interior. The narrow design of the vacuum head allows detail work in tight areas. The water pressure pump is reduced so the fabric surface is not wet more than is necessary. The dry time is greatly reduced due to less water on the fabric surface, the vacuum head making better contact with the surface and the significant water lift capability of the machine. Concentrate: The concentrated extraction cleaner is engineered with lower pH levels to help remove alkaline buildup on fabrics. The concentrate should be mixed according to the instructions listed on the container. The available concentrate helps to break the stain down and then the stain is easily removed with less water. The concentrate used in the Ruby Extractor is slightly acidic to remove soap and alkalinity from the fabric surfaces left behind by using improper, soapy solutions. Dirt, grease and grime are more easily removed when the proper solution is used during the extraction process. Parts Information Products are available in two sizes; 8 oz / 235 ML and 24 oz / 710 ML bottles. Available Equipment Equipment is available by contacting 1-800-GMTOOLS. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Cover: > 06-00-89-029F > Apr > 10 > Interior - Cleaning Interior Surfaces of Vehicle > Page 16396 Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Cushion: > 08-08-50-001D > Apr > 11 > Interior - Front Seat Cushion Cover Becomes Detached Seat Cushion: All Technical Service Bulletins Interior - Front Seat Cushion Cover Becomes Detached TECHNICAL Bulletin No.: 08-08-50-001D Date: April 06, 2011 Subject: Front Seat Cushion Cover Becomes Detached (Add Push Pin Fasteners to J-Retainer) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL with Front Seat RPO Codes AN3, A95, AE7 or AZ3 Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-08-50-001C (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger front seat cushion cover is coming detached from the seat frame along the front edge, or that the seat cushion foam has become exposed at the front corner(s) of the seat. Correction To improve the retention of the front seat cushion cover to the seat frame, modify the cover J-retainer and add two push pin retainers, GM P/N 10121502, to securely attach the J-retainer. Follow the procedure below: Important A number of the following graphics show the seat assembly removed from the vehicle. This is for illustration purposes only. Do not remove the seat from the vehicle for this repair. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Cushion: > 08-08-50-001D > Apr > 11 > Interior - Front Seat Cushion Cover Becomes Detached > Page 16405 1. Release the seat cushion cover J-retainer from the seat frame and roll the J-retainer/trim completely down. 2. Locate the slot on each side of the cushion pan frame by lifting the cushion/cover up and away from the lower edge of the frame to expose the slots (1). 3. Using a ruler and marker, measure and mark the cushion trim to match up with the slots on the cushion pan J-retainer attachment tab location. Repeat this process on the opposite end of cushion trim cover. Important Ensure that the J-retainer is fully unrolled, and that the holes are drilled through the lower edge of the J-retainer (1) and not through the U-channel (2) of the retainer. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Cushion: > 08-08-50-001D > Apr > 11 > Interior - Front Seat Cushion Cover Becomes Detached > Page 16406 4. Using a drill with a 5/16 drill bit, or equivalent, pierce holes through the trim and plastic J-retainer at the marked locations on each end of the seat cushion trim. 5. Pushing only approximately 1/4 of the way through, insert a push pin retainer (1) into the drilled holes on each side of the J-retainer. 6. Reposition the seat cushion and cover, and roll the J-retainer and trim to install position. 7. Attach the J-retainer to the seat cushion pan on one side by positioning the push pin retainer (1) to the rear side of the slot on cushion pan, and pushing forward to fully seat the push pin in the slot. 8. Repeat step 7 on the opposite end of J-retainer. 9. The seat cushion cover will now have better retention to the seat frame, and exhibit an improved fit across the forward edge of the seat. Parts Information Purchase the tape locally. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Cushion: > 08-08-50-001D > Apr > 11 > Interior - Front Seat Cushion Cover Becomes Detached > Page 16407 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Technical Service Bulletins > Customer Interest for Seat Cushion: > 08-08-50-001D > Apr > 11 > Interior - Front Seat Cushion Cover Becomes Detached Seat Cushion: Customer Interest Interior - Front Seat Cushion Cover Becomes Detached TECHNICAL Bulletin No.: 08-08-50-001D Date: April 06, 2011 Subject: Front Seat Cushion Cover Becomes Detached (Add Push Pin Fasteners to J-Retainer) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL with Front Seat RPO Codes AN3, A95, AE7 or AZ3 Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-08-50-001C (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger front seat cushion cover is coming detached from the seat frame along the front edge, or that the seat cushion foam has become exposed at the front corner(s) of the seat. Correction To improve the retention of the front seat cushion cover to the seat frame, modify the cover J-retainer and add two push pin retainers, GM P/N 10121502, to securely attach the J-retainer. Follow the procedure below: Important A number of the following graphics show the seat assembly removed from the vehicle. This is for illustration purposes only. Do not remove the seat from the vehicle for this repair. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Technical Service Bulletins > Customer Interest for Seat Cushion: > 08-08-50-001D > Apr > 11 > Interior - Front Seat Cushion Cover Becomes Detached > Page 16413 1. Release the seat cushion cover J-retainer from the seat frame and roll the J-retainer/trim completely down. 2. Locate the slot on each side of the cushion pan frame by lifting the cushion/cover up and away from the lower edge of the frame to expose the slots (1). 3. Using a ruler and marker, measure and mark the cushion trim to match up with the slots on the cushion pan J-retainer attachment tab location. Repeat this process on the opposite end of cushion trim cover. Important Ensure that the J-retainer is fully unrolled, and that the holes are drilled through the lower edge of the J-retainer (1) and not through the U-channel (2) of the retainer. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Technical Service Bulletins > Customer Interest for Seat Cushion: > 08-08-50-001D > Apr > 11 > Interior - Front Seat Cushion Cover Becomes Detached > Page 16414 4. Using a drill with a 5/16 drill bit, or equivalent, pierce holes through the trim and plastic J-retainer at the marked locations on each end of the seat cushion trim. 5. Pushing only approximately 1/4 of the way through, insert a push pin retainer (1) into the drilled holes on each side of the J-retainer. 6. Reposition the seat cushion and cover, and roll the J-retainer and trim to install position. 7. Attach the J-retainer to the seat cushion pan on one side by positioning the push pin retainer (1) to the rear side of the slot on cushion pan, and pushing forward to fully seat the push pin in the slot. 8. Repeat step 7 on the opposite end of J-retainer. 9. The seat cushion cover will now have better retention to the seat frame, and exhibit an improved fit across the forward edge of the seat. Parts Information Purchase the tape locally. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Technical Service Bulletins > Customer Interest for Seat Cushion: > 08-08-50-001D > Apr > 11 > Interior - Front Seat Cushion Cover Becomes Detached > Page 16415 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion Center Cover Replacement Seat Cushion: Service and Repair Front Seat Cushion Center Cover Replacement Front Seat Cushion Center Cover Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion Center Cover Replacement > Page 16418 Seat Cushion: Service and Repair Front Seat Center Cushion Replacement Front Seat Center Cushion Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion Center Cover Replacement > Page 16419 Seat Cushion: Service and Repair Front Seat Cushion Rear Frame Center Cover Replacement Front Seat Cushion Rear Frame Center Cover Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion Center Cover Replacement > Page 16420 Seat Cushion: Service and Repair Front Seat Cushion Outer Trim Panel Replacement (Power) Front Seat Cushion Outer Trim Panel Replacement (Power) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion Center Cover Replacement > Page 16421 Seat Cushion: Service and Repair Front Seat Cushion Center Cover Replacement Front Seat Cushion Center Cover Replacement Front Seat Center Cushion Replacement Front Seat Center Cushion Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion Center Cover Replacement > Page 16422 Front Seat Cushion Rear Frame Center Cover Replacement Front Seat Cushion Rear Frame Center Cover Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion Center Cover Replacement > Page 16423 Front Seat Cushion Outer Trim Panel Replacement (Power) Front Seat Cushion Outer Trim Panel Replacement (Power) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion Center Cover Replacement > Page 16424 Front Seat Cushion Outer Trim Panel Replacement (Manual) Front Seat Cushion Outer Trim Panel Replacement (Manual) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion Center Cover Replacement > Page 16425 Front Seat Cushion Inner Trim Panel Replacement Front Seat Cushion Inner Trim Panel Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion Center Cover Replacement > Page 16426 Seat Cushion Trim Cover and Pad Replacement Seat Cushion Trim Cover and Pad Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion Center Cover Replacement > Page 16427 Rear Seat Cushion Cover and Pad Replacement (Extended Cab with AM7) Rear Seat Cushion Cover and Pad Replacement (Extended Cab with AM7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion Center Cover Replacement > Page 16428 Rear Seat Cushion Cover and Pad Replacement (Extended Cab with A68) Rear Seat Cushion Cover and Pad Replacement (Extended Cab with A68) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion Center Cover Replacement > Page 16429 Rear Seat Cushion Cover and Pad Replacement (Crew Cab with A68) Rear Seat Cushion Cover and Pad Replacement (Crew Cab with A68) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion Center Cover Replacement > Page 16430 Rear Seat Cushion Frame Replacement (Extended Cab with A68) Rear Seat Cushion Frame Replacement (Extended Cab with A68) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion Center Cover Replacement > Page 16431 Rear Seat Cushion Frame Replacement (Extended Cab with AM7) Rear Seat Cushion Frame Replacement (Extended Cab with AM7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion Center Cover Replacement > Page 16432 Rear Seat Cushion Frame Replacement (Crew Cab with A68) Rear Seat Cushion Frame Replacement (Crew Cab with A68) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion Center Cover Replacement > Page 16433 Rear Seat Cushion Outer Trim Panel Replacement (Extended Cab) Rear Seat Cushion Outer Trim Panel Replacement (Extended Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion Center Cover Replacement > Page 16434 Rear Seat Cushion Outer Trim Panel Replacement (Crew Cab) Rear Seat Cushion Outer Trim Panel Replacement (Crew Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Front Seat Cushion Center Cover Replacement > Page 16435 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Technical Service Bulletins > Customer Interest for Seat Fan: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm Seat Fan: Customer Interest Seats - Driver/Passenger Heated Seats Inop./Slow to Warm TECHNICAL Bulletin No.: 10-08-50-008B Date: January 13, 2011 Subject: Driver or Passenger Heated Seat Inoperative, Slow to Warm, DTC(s) Set (Repair Connector, Re-Route Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Silverado, Suburban, Tahoe 2011 Chevrolet Silverado Heavy Duty 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2011 GMC Sierra Heavy Duty All Equipped with Heated Front Seat (RPO AN3, KA1) or Heated and Cooled Seat (RPO KB6) and/or Luxury Package (RPO PCK) Supercede: This bulletin is being revised to update the RPOs. Please discard Corporate Bulletin Number 10-08-50-008A (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger heated seat system exhibits the following symptoms: - Heated seat turns on and then turns off within 1 to 10 minutes (at any 60 second interval). - The system doesn't get warm enough, or gets warm very slowly. - The heated seat system is completely inoperative. Upon further review, DTCs B2430 0D and/or B2180 0D may be set as a current or history code if the vehicle is equipped with heated seats only (RPO KA1). Also, the LED indicator for the heated seats may come On and then flash after approximately 1 minute, then go out. If the vehicle is equipped with heated and cooled seats (KB6), the switch LED indicator may stay On, but the heated and cooled seat is inoperative. The fan will continue to blow air. Cause Heated Seats (RPO AN3, KA1) The heated seat control circuit terminal and/or ground terminal in harness connector X1 to the memory seat module (MSM) may have lost tension and is loose. The reduced terminal tension increases resistance in the connector, which may result in the symptoms described above. Heated and Cooled Seats (RPO KB6) The thermo-electric device (TED) in the seat cushion/seat back ventilation heating and cooling module may have become inoperative. Correction Heated Seats (RPO AN3, KA1) Follow the steps below to correct the concern with the heated seats. Note This repair requires a unique anti-abrasion electrical tape and harness clip from Kent Automotive. Refer to the Parts Information below. 1. Access and remove the seat bolts/nuts. 2. Adjust the seat rearward about halfway. Adjust the seat recline full forward. 3. Tilt the seat backward to access the bottom of the seat. Prop the seat up with a suitable tool if required. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Technical Service Bulletins > Customer Interest for Seat Fan: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 16444 4. Disconnect seat harness connectors (1) X1, X2, X3 and X4 from the MSM. 5. Identify connector X1. Refer to Component Connector End Views in SI. 6. Perform a terminal drag test on connector X1, paying special attention to terminals 1, 4, 6, 11 and 14. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Refer to Testing for Intermittent Conditions and Poor Connections in SI. 7. Replace any terminal in question including connector X1 terminals 1, 4, 6, 11 and 14 if necessary. Refer to Repairing Connector Terminals in SI. 8. Identify connector X4. Refer to Component Connector End Views in SI. 9. Perform the terminal drag test described in step 6, paying special attention to terminal 14. 10. Replace any terminal in question including connector X4 terminal 14 if necessary. Refer to Repairing Connector Terminals in SI. 11. Remove the harness clip (1) from the plastic carrier. 12. Cut the electrical tape holding the harness in the plastic carrier using a sharp utility knife in the area shown (1). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Technical Service Bulletins > Customer Interest for Seat Fan: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 16445 ERROR: stackunderflow OFFENDING COMMAND: ~ STACK: Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Fan: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm Seat Fan: All Technical Service Bulletins Seats - Driver/Passenger Heated Seats Inop./Slow to Warm TECHNICAL Bulletin No.: 10-08-50-008B Date: January 13, 2011 Subject: Driver or Passenger Heated Seat Inoperative, Slow to Warm, DTC(s) Set (Repair Connector, Re-Route Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Silverado, Suburban, Tahoe 2011 Chevrolet Silverado Heavy Duty 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2011 GMC Sierra Heavy Duty All Equipped with Heated Front Seat (RPO AN3, KA1) or Heated and Cooled Seat (RPO KB6) and/or Luxury Package (RPO PCK) Supercede: This bulletin is being revised to update the RPOs. Please discard Corporate Bulletin Number 10-08-50-008A (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger heated seat system exhibits the following symptoms: - Heated seat turns on and then turns off within 1 to 10 minutes (at any 60 second interval). - The system doesn't get warm enough, or gets warm very slowly. - The heated seat system is completely inoperative. Upon further review, DTCs B2430 0D and/or B2180 0D may be set as a current or history code if the vehicle is equipped with heated seats only (RPO KA1). Also, the LED indicator for the heated seats may come On and then flash after approximately 1 minute, then go out. If the vehicle is equipped with heated and cooled seats (KB6), the switch LED indicator may stay On, but the heated and cooled seat is inoperative. The fan will continue to blow air. Cause Heated Seats (RPO AN3, KA1) The heated seat control circuit terminal and/or ground terminal in harness connector X1 to the memory seat module (MSM) may have lost tension and is loose. The reduced terminal tension increases resistance in the connector, which may result in the symptoms described above. Heated and Cooled Seats (RPO KB6) The thermo-electric device (TED) in the seat cushion/seat back ventilation heating and cooling module may have become inoperative. Correction Heated Seats (RPO AN3, KA1) Follow the steps below to correct the concern with the heated seats. Note This repair requires a unique anti-abrasion electrical tape and harness clip from Kent Automotive. Refer to the Parts Information below. 1. Access and remove the seat bolts/nuts. 2. Adjust the seat rearward about halfway. Adjust the seat recline full forward. 3. Tilt the seat backward to access the bottom of the seat. Prop the seat up with a suitable tool if required. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Fan: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 16451 4. Disconnect seat harness connectors (1) X1, X2, X3 and X4 from the MSM. 5. Identify connector X1. Refer to Component Connector End Views in SI. 6. Perform a terminal drag test on connector X1, paying special attention to terminals 1, 4, 6, 11 and 14. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Refer to Testing for Intermittent Conditions and Poor Connections in SI. 7. Replace any terminal in question including connector X1 terminals 1, 4, 6, 11 and 14 if necessary. Refer to Repairing Connector Terminals in SI. 8. Identify connector X4. Refer to Component Connector End Views in SI. 9. Perform the terminal drag test described in step 6, paying special attention to terminal 14. 10. Replace any terminal in question including connector X4 terminal 14 if necessary. Refer to Repairing Connector Terminals in SI. 11. Remove the harness clip (1) from the plastic carrier. 12. Cut the electrical tape holding the harness in the plastic carrier using a sharp utility knife in the area shown (1). 13. Free the harness from the carrier back to the area shown (1). 14. Obtain "*Woven Polyester (PET) Electrical Tape" (Special Order P/N RZ97156A00) from Kent Automotive. Refer to Parts Information below. Important Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Fan: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 16452 DO NOT substitute with vinyl electrical tape or friction tape. Use only the tape specified above. 15. Tape the harness starting at the MSM connectors (1) extending back to the new break-out location (2) in the plastic carrier. 16. Install a plastic tie strap around the harness and the plastic carrier at the break-out point (1). 17. Install the new harness edge clip (1) 10 mm (0.4 in) further from the connectors and the existing harness clip. Ensure the clip is installed in the orientation shown. 18. Install the harness with the new harness clip in the location shown (1). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Fan: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 16453 19. Reinstall the harness connectors (1) to the MSM. 20. Reinstall the seat to the vehicle. Heated and Cooled Seats (RPO KB6) Follow the steps below to correct the concern with the heated and cooled seats. 1. Inspect the ventilation heating and cooling module for a concern with the TED. Refer to Seat Heating and Cooling, Diagnostic Information and Procedures in SI. Note If the heated and cooled seat function is inoperative, but the heat switch indicators are On, the MSM is functioning properly and the concern is with the TED. 2. If the TED is found to be the concern, replace the seat cushion or seat back ventilation heating and cooling module. Refer to Driver or Passenger Seat Back Ventilation Heating and Cooling Blower Replacement or Driver or Passenger Seat Cushion Ventilation Heating and Cooling Blower Replacement in SI. If the TED is not the concern, follow normal diagnostics and repair in SI. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Use the appropriate Labor Operation based on the repair completed. Heated Seats (RPO AN3, KA1) For vehicles repaired under warranty, use: Heated and Cooled Seats (RPO KB6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Fan: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 16454 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions Seat Fan: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Schematic Symbols Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16457 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16458 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16459 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16460 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16461 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16462 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16463 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16464 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16465 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16466 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16467 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16468 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16469 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16470 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16471 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16472 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16473 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16474 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16475 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16476 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16477 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16478 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16479 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16480 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16481 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16482 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16483 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16484 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16485 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16486 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16487 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16488 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16489 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16490 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16491 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16492 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16493 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16494 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16495 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16496 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16497 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16498 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16499 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16500 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16501 Seat Fan: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed with Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16502 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16503 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Connector Test Adapters) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16504 Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Test Lamp) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Fused Jumper Wires) * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage Drop) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Frequency) * Testing Ground and Low Reference Circuits (See: Testing and Inspection/Component Tests and General Diagnostics/Testing Ground and Low Reference Circuits) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fuses) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Circuit Breakers) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fusible Links) Troubleshooting with a Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Testing for a Short to Voltage Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16505 Testing for a Short to Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure tests for a short to voltage in a circuit. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the Digital Multimeter (DMM) to the V (DC) position. 4. Connect the positive lead of the DMM to one end of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. Turn ON the ignition and operate all accessories. 7. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Special Tools J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure). Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents). Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16506 The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the frequency of a signal. Note: Connecting the Digital Multimeter (DMM) to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Set to Hz on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16507 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the Digital Multimeter (DMM). 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the difference in voltage potential between 2 points. 1. Set the Digital Multimeter (DMM) to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16508 Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Backprobe Note: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16509 (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for Continuity Testing for Continuity Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures verify good continuity in a circuit. With a Digital Multimeter (DMM) 1. Set the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Select the MIN MAX function on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16510 Testing for Electrical Intermittents Testing for Electrical Intermittents Special Tools J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. Note: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions). 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16511 visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing for Terminal Fretting Some intermittent conditions can be caused by wire terminal fretting corrosion. Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can pile up enough at the electrical contact spots that the electrical resistance across the connection increases. Movement between the contacting surfaces as small as 10 to 100 microns can cause fretting. To put this in perspective, a sheet of paper is about 100 microns thick, so fretting motion is small and hard to see. Vibration and thermal expansion/contraction are the main sources that create fretting motion. Since vehicles vibrate and can experience large temperature swings, they are a good source for fretting motion. Tin, copper, nickel, and iron surfaces are all susceptible to fretting corrosion. Fretting corrosion can be difficult to see but it looks like small, dark smudges on the terminals contact surface. To correct a fretting condition disconnect the suspect connector and add Nyogel lubricant 760G (dielectric grease) to both sides of the connector terminals. Then reconnect the connector and wipe away any excess lubricant. This will correct the additional terminal contact resistance due to the terminal fretting corrosion. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16512 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics). * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Ground Distribution Schematics). Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Checking Aftermarket Accessories). * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16513 Note: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures test for a short to ground in a circuit. With a Digital Multimeter (DMM) 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohms position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Danger: High voltage circuits should only be tested using a digital multimeter (DMM) and test leads with at least a CAT III rating, such as the J 39200-A Digital Multimeter. Failure to follow the procedures exactly as written may result in serious injury or death. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Digital Multimeter (DMM) Basic Requirements Service information is validated using digital multimeters that meet or exceed the following requirements. Using a multimeter that does not meet these basic requirements may give inaccurate readings which could lead to an incorrect diagnosis. Display and Settings 1. Four digits displayed 2. Voltage, amperage, resistance, frequency, diode test settings, and min-max function 3. Display positive and negative values Voltage 1. Have at least 10 M ohm input impedance Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16514 2. Test a DC voltage range of 0.1-1000 V. 3. Test an AC voltage range of 0.1-1000 V. Amperage 1. Test a DC amperage range of 0.1µA-10 A. 2. Test an AC amperage range of 0.1µA-10 A. Resistance Test a resistance range of 0.1 ohm-40 Mohm and displays infinite for a value greater than 40 M ohm (O.L. (Over-load)) Frequency Test for a frequency range of 0.5 HZ-199 K HZ Diode Test 1. Apply at least 1 mA when performing the diode bias test 2. Display the break over voltage drop (0-3 V) of a forward biased diode 3. Display infinite (O.L. (Over-load)) when a diode is reverse biased Min-Max Readings 1. Can update at a 1 ms sample rate 2. Saves and displays minimum and maximum values Note: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Probe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors). * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the EL-38125-580 GM Approved Terminal Release Tool Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the EL-38125-580 GM Approved Terminal Release Tool Kit , ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the EL-38125-580 GM Approved Terminal Release Tool Kit label on the inside of the EL-38125-580 GM Approved Terminal Release Tool Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16515 Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/EPC Connectors AFL/EPC Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16516 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 3. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16517 View showing depressing of the lever lock release tab. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16518 6. Release the rear lower half of the wiredress cover. 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16519 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16520 Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Bosch Connectors (ECM) Bosch Connectors (ECM) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16521 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. 2. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16522 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-bladed tool to release the locking tabs and remove the dress cover. 4. The terminal positive assurance (TPA) is located in the front of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16523 5. Use a small flat-blade tool to remove TPA from the connector. 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16524 Note: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16525 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16526 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Terminal Replacement Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16527 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16528 5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Position Assurance Locks) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Terminal Position Assurance Locks) * AFL/EPC Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/AFL/EPC Connectors) * Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (BSK))Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (0.64))Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (2.8 JPT))Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (ECM)) * Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Weather Pack))Delphi Connectors (Push To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Push to Seat))Delphi Connectors Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16529 (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Pull to Seat))Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro-Pack 100W))Delphi Connectors (Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro .64))Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (12-Way)) * FCI Connectors (Lever Lock) (See: General Electrical Diagnostic Procedures/Connector Repairs/FCI Connectors (Lever Lock)) * JST Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/JST Connectors) * Kostal Connectors (Glow Plug Control Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Glow Plug Control Module))Kostal Connectors (Transmission) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Transmission)) * Molex Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Molex Connectors) * Sumitomo Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Sumitomo Connectors) * Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (CM 42-Way))Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Sensor))Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (0.25 Cap))Tyco/AMP Connectors (43-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (43-Way))Tyco/AMP Connectors (Door Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Door Module))Tyco/AMP Connectors (102-Way Inline) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (102-Way Inline))Tyco/AMP Connectors (Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Seat))Tyco/AMP Connectors (SIR) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (SIR)) * Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (2-Way))Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (16-Way)) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16530 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16531 * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16532 * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16533 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16534 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16535 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Push to Seat) Delphi Connectors (Push To Seat) Special Tools J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16536 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs). 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Terminated Lead Repair 1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice sleeves depending on the gauge size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Delphi Connectors (Pull to Seat) Delphi Connectors (Pull To Seat) Special Tools Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16537 J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Note: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16538 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. View of a typical Micro 64 connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16539 Depress the lock and pull the lever over and past the lock. View of the connector when released from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16540 View of another type of Micro 64 connector. Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16541 View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16542 Note: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16543 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16544 Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Note: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16545 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16546 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16547 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16548 1. Cut the wire as close to the terminal as possible. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16549 Terminal Replacement Procedure After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Special Tools J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Note: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals). 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12-Way) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16550 Delphi Connectors (12-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16551 4. Release the lower wire dress cover locking tab. 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16552 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16553 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors (Lever Lock) FCI Connectors (Lever Lock) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16554 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. The release tab is located on the top of the wiredress cover. 3. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16555 6. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16556 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16557 1. While depressing the lock, remove the connector from the component. 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16558 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. 4. View of the TPA when removed from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16559 5. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Glow Plug Control Module) Kostal Connectors (Glow Plug Control Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16560 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16561 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16562 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. Note: The front TPA cannot be removed from the connector. Only move it to the preset position. 6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm). 7. Use a small flat-blade tool to completely remove the rear TPA from the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16563 8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Transmission) Kostal Connectors (Transmission) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16564 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16565 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Terminal Replacement Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16566 After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16567 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16568 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16569 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16570 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16571 3. To assemble the connector, reverse the connector disassembly procedure. Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16572 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16573 7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16574 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16575 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16576 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16577 Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16578 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16579 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16580 6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (102-Way Inline) Tyco/AMP Connectors (102-Way Inline) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16581 View of a typical connector in the assembled position. 1. Pull the locking lever to the 90 degree position from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16582 2. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal. 3. Slide the male connector body out away from the guide plates. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16583 Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 4. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. 5. Using terminal release tool J 38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16584 6. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 7. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16585 8. The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool J-38125-11A or equivalent to release the locking tab and slide the connector off the female body. 9. Move the locking lever 180 degrees from the connected position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16586 10. With the locking lever in the 180 degree position the guide plates can be removed from the connector body. Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 11. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16587 12. Using terminal release tool J 38125-216, lift the terminal plate past the terminals and out of the connector body cavity. 13. Terminal plate will bind slightly on each corner. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16588 14. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 15. Using terminal release tool J 38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16589 16. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 17. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16590 18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever. 19. Slide the male connector body back inward toward the guide plates. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16591 20. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly. 21. Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Seat) Tyco/AMP Connectors (Seat) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16592 Removal Procedure 1. Grasp the locking slide lever and pull outward from the end of the connector. 2. As the slide lever is pulled out the mating connector is lifted from the seated position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16593 Note: TPA is keyed and can only be inserted in one direction. 3. Using terminal release tool J 38125-11A or equivalent, push the TPA tabs into the connector body. 4. Pull the TPA from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16594 5. Using terminal release tool J 38125-11A or equivalent, release the connector wire dress cover locking tab. 6. With the lock tab released, lift the connector wire dress cover from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16595 7. Using terminal release tool J 38125-212, press the prongs into the holes each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 8. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16596 9. Using terminal release tool J 38125-556, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (SIR) Tyco/AMP Connectors (SIR) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16597 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16598 3. Using terminal tool J-38125-11A or equivalent, release the wire dress cover locking tabs. 4. Pivot connector wire dress cover while removing from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16599 5. Using terminal tool J-38125-11A or equivalent, remove the TPA by lifting straight off the connector body. 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals Repairing Connector Terminals Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16600 Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gauge size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16601 2. Disconnect the connector from the component. 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16602 4. Relieve the tension on the nose piece retainers by inserting J 38125-12A into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. 5. Once the nose piece retainers are relaxed, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16603 6. On the opposite side of the nose piece, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16604 8. Insert the J 38125-553 tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16605 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. If the TPA is removed, be sure to reinstall it before reconnecting the connector. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16606 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Special Tools Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16607 J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Note: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16608 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16609 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16610 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16611 1. While depressing the lock, pull the two connector halves apart. Note: The TPA is fragile and may break if not done carefully. 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. 3. View of the male half of the connector with female terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16612 4. View of the female half of the connector with male terminals. 5. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. View of the female half of the connector with male terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16613 7. View of the male half of the connector with female terminals. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16614 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are a one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine if the element in the fuse is broken (2). If not broken (1), also check for continuity using a Digital Multimeter (DMM) or a continuity tester. If the element is broken or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a Digital Multimeter (DMM) at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gauge size. Repairing a Fusible Link Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16615 Flat Wire Repairs The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Special Tools J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool * J 38125-5 Ultra Torch Special Tool The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Note: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation). GMLAN Connector Terminal Repair Note: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) for the appropriate connector repair procedure. GMLAN Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16616 Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16617 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Special Tools J-38125 Terminal Repair Kit Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16618 repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs High Temperature Wiring Repairs Special Tools J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gauge size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16619 splice. Note: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16620 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16621 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the wire insulation has been chafed, or broken, enough to show the conductive portion of the wire, and the wire is not damaged, determine the length of insulation that needs to be repaired. If the repair is less than 280 mm (11 in), cut the wire within the damaged area. Then slide the appropriate heat shrink tubing (listed below) over the wire, and repair the wire by splicing the wires together. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Once the wire is spliced together slide heat shrink tubing over the damaged area and apply heat to seal the repaired wire. If the wire is damaged, or the damaged area is larger than 280 mm (11 in), then replace the damaged wire by splicing in a new section of wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16622 SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Special Tools J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16623 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16624 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16625 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Special Tools J-38125 Terminal Repair Kit Note: Use only DuraSeal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use DuraSeal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use DuraSeal splice sleeves where there are special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16626 * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16627 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16628 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the instructions for Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Staggering the splices by 65 mm (2.5 in) is recommended. Note: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product AL-36FR to replace the damaged mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Flat Wire Repairs) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/GMLAN Wiring Repairs) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Heated Oxygen Sensor Wiring Repairs) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves) * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Twisted or Shielded Cable) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Inline Harness Diodes) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/SIR/SRS Wiring Repairs) US English/Metric Conversion US English/Metric Conversion Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16629 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16630 Testing Ground and Low Reference Circuits Testing Ground and Low Reference Circuits Because a test lamp can light with up to 200 ohm in a ground or low reference circuit they are not recommended to be used for this type of test. A low impedance test lamp can light and indicate the circuit is good when there is as much as 20-30 ohm present, while a high impedance test lamp can light with up to 200 ohm present in the circuit. This is why the Digital Multi-Meter (DMM) is used when validating a ground or low reference circuit continuity. When using the DMM there are many vehicle conditions that can affect the ground and low reference continuity testing. If these conditions are not met, a ground or low reference circuit test can fail on a good circuit. This may cause longer diagnosis time and incorrect component replacement. Any current flow through a ground or low reference circuit, while being tested, will skew the DMM continuity reading, or display a reading higher than when there is no current flowing. Performing a ground or low reference circuit continuity test, in reference to the vehicles battery negative terminal, will have the highest risk of failing a good ground or low reference circuit test than any other ground reference point. The best ground test points would be a control module housing (if the control modules housing is metal and grounded), door jamb striker (if attached to metal), under dash metal frame work, engine block, or body ground studs (other than where the negative battery cable is attached). A typical DMM ground or low reference circuit continuity reading can be as high as 100 ohm with the ignition ON, and drop to 15-25 ohm after the ignition is turned OFF. The reading will drop below 10 ohm after 30-40 seconds, then below 5 ohm after 60 seconds. Once the vehicle completely goes to sleep (generally 3-10 minutes) the reading will drop below 0.3 ohm. The following list of conditions may need to be met to ensure a valid continuity reading on a ground or low reference circuit: * Ignition OFF * Key out of the ignition switch (when not equipped with keyless entry and remote start) * Retained Accessory Power (RAP) OFF (open and close the driver door after ignition OFF) * Battery charger set at a 2 A or less charge rate * Scan tool not communicating with any vehicle control module (in some cases it may need to be disconnected from the DLC) * All entry doors closed * Headlamps OFF (auto headlamps disabled) * Any delay lighting OFF * HVAC after blow OFF * Any accessory that can work when the ignition is OFF * Wait up to 60 seconds (after all other listed conditions are met) Activating the DOOR LOCK function with a key fob can greatly reduce the time to achieve a valid ground or low reference continuity test result. Terminal Removal Terminal Removal Special Tools * EL-38125-580 - Terminal Release Tool Kit * EL-35616 - Connector Test Adapter Kit For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repair procedures. 1. Find the appropriate connector end view within the connector end view section. The connector end view has the following information: Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16631 * Diagnostic probe tool * Terminal release tool * Terminal/terminated lead part numbers Note: Not using the proper test kit probe may cause damage to the terminal(s) that are probed. 2. Determine if a terminal is damaged. * Locate the diagnostic probe tool from the connector end view. The connector end view describes the color and part number to help the technician find and use the correct tool. * Connect the probe tool to the Digital Multimeter. * Insert the probe tool into the cavity and follow the procedures from the Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter). 3. Disconnect the connector body to perform the repair. 4. Use the following procedure to remove the terminal from the connector body. Note: Several procedures for specific connector bodies are called out in the Wiring Repairs section. * The terminal position assurance (TPA) and connector position assurance (CPA) should be removed before releasing the terminal for the connector body. * Look at the connector end view to locate the cavity of the damaged terminal and find the proper terminal release tool from the terminal release tool kit. Note: Using the incorrect terminal release tool can damage the connector body. * Insert the terminal release tool into the cavity. Note: Some terminals have a lever that must be disengaged before the terminal can be released. 5. Gently pull the wire out of the back of the connector. 6. Repair the terminal by following the Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) procedure. 7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminated Lead Repair Terminated Lead Repair Special Tools * J-38125-8 - Splice Sleeve Crimp Tool Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16632 * J-38125-5 - Ultra Torch For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) procedures. Terminated leads are terminals that are crimped onto wires. The terminated lead can be used throughout the vehicle since it is designed for temperatures up to 150°C. The length of the wire is 450 mm. The DuraSeal splice sleeve has the following 2 critical features: * A special heat shrink tubing that environmentally seals the splice. The shrink tubing contains a sealing adhesive inside the shrink tubing. * A cross hatched (knurled) core crimp that provides the necessary contact integrity for sensitive low energy circuits. 1. Use the connector end view to identify the correct terminated lead. 2. The terminated lead package should include a DuraSeal splice sleeve. If not, use the chart to identify the correct part. 3. Open the harness by removing any tape: Use a sewing seam ripper, or a comparable tool, to cut open the harness, to avoid wire insulation damage. 4. Depending on how many terminals need repairs, cut the terminal and wire back at least 40 mm. Try to keep the harness wire length the same. If more than one terminated lead is required, stagger the lengths by 40 mm. This helps reduce the bundle size of the wire harness. 5. Use the EL-38125-10 - tool in order to position the DuraSeal splice sleeve in the proper color nest of the splice sleeve crimp tool. The crimp tool has four nests, one for each color. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16633 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the J-38125-5 - ultra torch , apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16634 Seat Fan: Electrical Diagrams Heated/Cooled Seat Schematics Heated Seat - Driver (AN3 without KB6) Heated Seat - Passenger (AN3 without KB6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16635 Heated/Cooled Seat Module Power and Ground (KB6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16636 Heated/Cooled Seat - Driver (KB6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16637 Heated/Cooled Seat - Passenger (KB6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16638 Heated Seat - Driver (SPO Heated Seats) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16639 Heated Seat - Passenger (SPO Heated Seats) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Fan > Component Information > Diagrams > Diagram Information and Instructions > Page 16640 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm Seat Heater: Customer Interest Seats - Driver/Passenger Heated Seats Inop./Slow to Warm TECHNICAL Bulletin No.: 10-08-50-008B Date: January 13, 2011 Subject: Driver or Passenger Heated Seat Inoperative, Slow to Warm, DTC(s) Set (Repair Connector, Re-Route Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Silverado, Suburban, Tahoe 2011 Chevrolet Silverado Heavy Duty 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2011 GMC Sierra Heavy Duty All Equipped with Heated Front Seat (RPO AN3, KA1) or Heated and Cooled Seat (RPO KB6) and/or Luxury Package (RPO PCK) Supercede: This bulletin is being revised to update the RPOs. Please discard Corporate Bulletin Number 10-08-50-008A (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger heated seat system exhibits the following symptoms: - Heated seat turns on and then turns off within 1 to 10 minutes (at any 60 second interval). - The system doesn't get warm enough, or gets warm very slowly. - The heated seat system is completely inoperative. Upon further review, DTCs B2430 0D and/or B2180 0D may be set as a current or history code if the vehicle is equipped with heated seats only (RPO KA1). Also, the LED indicator for the heated seats may come On and then flash after approximately 1 minute, then go out. If the vehicle is equipped with heated and cooled seats (KB6), the switch LED indicator may stay On, but the heated and cooled seat is inoperative. The fan will continue to blow air. Cause Heated Seats (RPO AN3, KA1) The heated seat control circuit terminal and/or ground terminal in harness connector X1 to the memory seat module (MSM) may have lost tension and is loose. The reduced terminal tension increases resistance in the connector, which may result in the symptoms described above. Heated and Cooled Seats (RPO KB6) The thermo-electric device (TED) in the seat cushion/seat back ventilation heating and cooling module may have become inoperative. Correction Heated Seats (RPO AN3, KA1) Follow the steps below to correct the concern with the heated seats. Note This repair requires a unique anti-abrasion electrical tape and harness clip from Kent Automotive. Refer to the Parts Information below. 1. Access and remove the seat bolts/nuts. 2. Adjust the seat rearward about halfway. Adjust the seat recline full forward. 3. Tilt the seat backward to access the bottom of the seat. Prop the seat up with a suitable tool if required. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 16649 4. Disconnect seat harness connectors (1) X1, X2, X3 and X4 from the MSM. 5. Identify connector X1. Refer to Component Connector End Views in SI. 6. Perform a terminal drag test on connector X1, paying special attention to terminals 1, 4, 6, 11 and 14. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Refer to Testing for Intermittent Conditions and Poor Connections in SI. 7. Replace any terminal in question including connector X1 terminals 1, 4, 6, 11 and 14 if necessary. Refer to Repairing Connector Terminals in SI. 8. Identify connector X4. Refer to Component Connector End Views in SI. 9. Perform the terminal drag test described in step 6, paying special attention to terminal 14. 10. Replace any terminal in question including connector X4 terminal 14 if necessary. Refer to Repairing Connector Terminals in SI. 11. Remove the harness clip (1) from the plastic carrier. 12. Cut the electrical tape holding the harness in the plastic carrier using a sharp utility knife in the area shown (1). 13. Free the harness from the carrier back to the area shown (1). 14. Obtain "*Woven Polyester (PET) Electrical Tape" (Special Order P/N RZ97156A00) from Kent Automotive. Refer to Parts Information below. Important Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 16650 DO NOT substitute with vinyl electrical tape or friction tape. Use only the tape specified above. 15. Tape the harness starting at the MSM connectors (1) extending back to the new break-out location (2) in the plastic carrier. 16. Install a plastic tie strap around the harness and the plastic carrier at the break-out point (1). 17. Install the new harness edge clip (1) 10 mm (0.4 in) further from the connectors and the existing harness clip. Ensure the clip is installed in the orientation shown. 18. Install the harness with the new harness clip in the location shown (1). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 16651 19. Reinstall the harness connectors (1) to the MSM. 20. Reinstall the seat to the vehicle. Heated and Cooled Seats (RPO KB6) Follow the steps below to correct the concern with the heated and cooled seats. 1. Inspect the ventilation heating and cooling module for a concern with the TED. Refer to Seat Heating and Cooling, Diagnostic Information and Procedures in SI. Note If the heated and cooled seat function is inoperative, but the heat switch indicators are On, the MSM is functioning properly and the concern is with the TED. 2. If the TED is found to be the concern, replace the seat cushion or seat back ventilation heating and cooling module. Refer to Driver or Passenger Seat Back Ventilation Heating and Cooling Blower Replacement or Driver or Passenger Seat Cushion Ventilation Heating and Cooling Blower Replacement in SI. If the TED is not the concern, follow normal diagnostics and repair in SI. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Use the appropriate Labor Operation based on the repair completed. Heated Seats (RPO AN3, KA1) For vehicles repaired under warranty, use: Heated and Cooled Seats (RPO KB6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 16652 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm Seat Heater: All Technical Service Bulletins Seats - Driver/Passenger Heated Seats Inop./Slow to Warm TECHNICAL Bulletin No.: 10-08-50-008B Date: January 13, 2011 Subject: Driver or Passenger Heated Seat Inoperative, Slow to Warm, DTC(s) Set (Repair Connector, Re-Route Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Silverado, Suburban, Tahoe 2011 Chevrolet Silverado Heavy Duty 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2011 GMC Sierra Heavy Duty All Equipped with Heated Front Seat (RPO AN3, KA1) or Heated and Cooled Seat (RPO KB6) and/or Luxury Package (RPO PCK) Supercede: This bulletin is being revised to update the RPOs. Please discard Corporate Bulletin Number 10-08-50-008A (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger heated seat system exhibits the following symptoms: - Heated seat turns on and then turns off within 1 to 10 minutes (at any 60 second interval). - The system doesn't get warm enough, or gets warm very slowly. - The heated seat system is completely inoperative. Upon further review, DTCs B2430 0D and/or B2180 0D may be set as a current or history code if the vehicle is equipped with heated seats only (RPO KA1). Also, the LED indicator for the heated seats may come On and then flash after approximately 1 minute, then go out. If the vehicle is equipped with heated and cooled seats (KB6), the switch LED indicator may stay On, but the heated and cooled seat is inoperative. The fan will continue to blow air. Cause Heated Seats (RPO AN3, KA1) The heated seat control circuit terminal and/or ground terminal in harness connector X1 to the memory seat module (MSM) may have lost tension and is loose. The reduced terminal tension increases resistance in the connector, which may result in the symptoms described above. Heated and Cooled Seats (RPO KB6) The thermo-electric device (TED) in the seat cushion/seat back ventilation heating and cooling module may have become inoperative. Correction Heated Seats (RPO AN3, KA1) Follow the steps below to correct the concern with the heated seats. Note This repair requires a unique anti-abrasion electrical tape and harness clip from Kent Automotive. Refer to the Parts Information below. 1. Access and remove the seat bolts/nuts. 2. Adjust the seat rearward about halfway. Adjust the seat recline full forward. 3. Tilt the seat backward to access the bottom of the seat. Prop the seat up with a suitable tool if required. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 16658 4. Disconnect seat harness connectors (1) X1, X2, X3 and X4 from the MSM. 5. Identify connector X1. Refer to Component Connector End Views in SI. 6. Perform a terminal drag test on connector X1, paying special attention to terminals 1, 4, 6, 11 and 14. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Refer to Testing for Intermittent Conditions and Poor Connections in SI. 7. Replace any terminal in question including connector X1 terminals 1, 4, 6, 11 and 14 if necessary. Refer to Repairing Connector Terminals in SI. 8. Identify connector X4. Refer to Component Connector End Views in SI. 9. Perform the terminal drag test described in step 6, paying special attention to terminal 14. 10. Replace any terminal in question including connector X4 terminal 14 if necessary. Refer to Repairing Connector Terminals in SI. 11. Remove the harness clip (1) from the plastic carrier. 12. Cut the electrical tape holding the harness in the plastic carrier using a sharp utility knife in the area shown (1). 13. Free the harness from the carrier back to the area shown (1). 14. Obtain "*Woven Polyester (PET) Electrical Tape" (Special Order P/N RZ97156A00) from Kent Automotive. Refer to Parts Information below. Important Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 16659 DO NOT substitute with vinyl electrical tape or friction tape. Use only the tape specified above. 15. Tape the harness starting at the MSM connectors (1) extending back to the new break-out location (2) in the plastic carrier. 16. Install a plastic tie strap around the harness and the plastic carrier at the break-out point (1). 17. Install the new harness edge clip (1) 10 mm (0.4 in) further from the connectors and the existing harness clip. Ensure the clip is installed in the orientation shown. 18. Install the harness with the new harness clip in the location shown (1). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 16660 19. Reinstall the harness connectors (1) to the MSM. 20. Reinstall the seat to the vehicle. Heated and Cooled Seats (RPO KB6) Follow the steps below to correct the concern with the heated and cooled seats. 1. Inspect the ventilation heating and cooling module for a concern with the TED. Refer to Seat Heating and Cooling, Diagnostic Information and Procedures in SI. Note If the heated and cooled seat function is inoperative, but the heat switch indicators are On, the MSM is functioning properly and the concern is with the TED. 2. If the TED is found to be the concern, replace the seat cushion or seat back ventilation heating and cooling module. Refer to Driver or Passenger Seat Back Ventilation Heating and Cooling Blower Replacement or Driver or Passenger Seat Cushion Ventilation Heating and Cooling Blower Replacement in SI. If the TED is not the concern, follow normal diagnostics and repair in SI. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Use the appropriate Labor Operation based on the repair completed. Heated Seats (RPO AN3, KA1) For vehicles repaired under warranty, use: Heated and Cooled Seats (RPO KB6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 16661 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service Bulletins > Page 16662 Seat Heater: Specifications Fastener Tightening Specifications Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions Seat Heater: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Schematic Symbols Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16665 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16666 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16667 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16668 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16669 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16670 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16671 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16672 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16673 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16674 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16675 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16676 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16677 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16678 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16679 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16680 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16681 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16682 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16683 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16684 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16685 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16686 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16687 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16688 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16689 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16690 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16691 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16692 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16693 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16694 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16695 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16696 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16697 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16698 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16699 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16700 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16701 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16702 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16703 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16704 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16705 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16706 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16707 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16708 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16709 Seat Heater: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed with Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16710 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16711 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Connector Test Adapters) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16712 Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Test Lamp) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Fused Jumper Wires) * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage Drop) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Frequency) * Testing Ground and Low Reference Circuits (See: Testing and Inspection/Component Tests and General Diagnostics/Testing Ground and Low Reference Circuits) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fuses) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Circuit Breakers) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fusible Links) Troubleshooting with a Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Testing for a Short to Voltage Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16713 Testing for a Short to Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure tests for a short to voltage in a circuit. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the Digital Multimeter (DMM) to the V (DC) position. 4. Connect the positive lead of the DMM to one end of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. Turn ON the ignition and operate all accessories. 7. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Special Tools J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure). Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents). Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16714 The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the frequency of a signal. Note: Connecting the Digital Multimeter (DMM) to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Set to Hz on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16715 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the Digital Multimeter (DMM). 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the difference in voltage potential between 2 points. 1. Set the Digital Multimeter (DMM) to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16716 Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Backprobe Note: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16717 (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for Continuity Testing for Continuity Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures verify good continuity in a circuit. With a Digital Multimeter (DMM) 1. Set the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Select the MIN MAX function on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16718 Testing for Electrical Intermittents Testing for Electrical Intermittents Special Tools J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. Note: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions). 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16719 visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing for Terminal Fretting Some intermittent conditions can be caused by wire terminal fretting corrosion. Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can pile up enough at the electrical contact spots that the electrical resistance across the connection increases. Movement between the contacting surfaces as small as 10 to 100 microns can cause fretting. To put this in perspective, a sheet of paper is about 100 microns thick, so fretting motion is small and hard to see. Vibration and thermal expansion/contraction are the main sources that create fretting motion. Since vehicles vibrate and can experience large temperature swings, they are a good source for fretting motion. Tin, copper, nickel, and iron surfaces are all susceptible to fretting corrosion. Fretting corrosion can be difficult to see but it looks like small, dark smudges on the terminals contact surface. To correct a fretting condition disconnect the suspect connector and add Nyogel lubricant 760G (dielectric grease) to both sides of the connector terminals. Then reconnect the connector and wipe away any excess lubricant. This will correct the additional terminal contact resistance due to the terminal fretting corrosion. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16720 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics). * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Ground Distribution Schematics). Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Checking Aftermarket Accessories). * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16721 Note: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures test for a short to ground in a circuit. With a Digital Multimeter (DMM) 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohms position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Danger: High voltage circuits should only be tested using a digital multimeter (DMM) and test leads with at least a CAT III rating, such as the J 39200-A Digital Multimeter. Failure to follow the procedures exactly as written may result in serious injury or death. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Digital Multimeter (DMM) Basic Requirements Service information is validated using digital multimeters that meet or exceed the following requirements. Using a multimeter that does not meet these basic requirements may give inaccurate readings which could lead to an incorrect diagnosis. Display and Settings 1. Four digits displayed 2. Voltage, amperage, resistance, frequency, diode test settings, and min-max function 3. Display positive and negative values Voltage 1. Have at least 10 M ohm input impedance Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16722 2. Test a DC voltage range of 0.1-1000 V. 3. Test an AC voltage range of 0.1-1000 V. Amperage 1. Test a DC amperage range of 0.1µA-10 A. 2. Test an AC amperage range of 0.1µA-10 A. Resistance Test a resistance range of 0.1 ohm-40 Mohm and displays infinite for a value greater than 40 M ohm (O.L. (Over-load)) Frequency Test for a frequency range of 0.5 HZ-199 K HZ Diode Test 1. Apply at least 1 mA when performing the diode bias test 2. Display the break over voltage drop (0-3 V) of a forward biased diode 3. Display infinite (O.L. (Over-load)) when a diode is reverse biased Min-Max Readings 1. Can update at a 1 ms sample rate 2. Saves and displays minimum and maximum values Note: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Probe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors). * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the EL-38125-580 GM Approved Terminal Release Tool Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the EL-38125-580 GM Approved Terminal Release Tool Kit , ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the EL-38125-580 GM Approved Terminal Release Tool Kit label on the inside of the EL-38125-580 GM Approved Terminal Release Tool Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16723 Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/EPC Connectors AFL/EPC Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16724 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 3. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16725 View showing depressing of the lever lock release tab. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16726 6. Release the rear lower half of the wiredress cover. 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16727 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16728 Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Bosch Connectors (ECM) Bosch Connectors (ECM) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16729 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. 2. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16730 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-bladed tool to release the locking tabs and remove the dress cover. 4. The terminal positive assurance (TPA) is located in the front of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16731 5. Use a small flat-blade tool to remove TPA from the connector. 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16732 Note: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16733 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16734 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Terminal Replacement Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16735 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16736 5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Position Assurance Locks) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Terminal Position Assurance Locks) * AFL/EPC Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/AFL/EPC Connectors) * Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (BSK))Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (0.64))Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (2.8 JPT))Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (ECM)) * Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Weather Pack))Delphi Connectors (Push To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Push to Seat))Delphi Connectors Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16737 (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Pull to Seat))Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro-Pack 100W))Delphi Connectors (Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro .64))Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (12-Way)) * FCI Connectors (Lever Lock) (See: General Electrical Diagnostic Procedures/Connector Repairs/FCI Connectors (Lever Lock)) * JST Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/JST Connectors) * Kostal Connectors (Glow Plug Control Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Glow Plug Control Module))Kostal Connectors (Transmission) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Transmission)) * Molex Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Molex Connectors) * Sumitomo Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Sumitomo Connectors) * Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (CM 42-Way))Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Sensor))Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (0.25 Cap))Tyco/AMP Connectors (43-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (43-Way))Tyco/AMP Connectors (Door Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Door Module))Tyco/AMP Connectors (102-Way Inline) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (102-Way Inline))Tyco/AMP Connectors (Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Seat))Tyco/AMP Connectors (SIR) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (SIR)) * Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (2-Way))Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (16-Way)) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16738 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16739 * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16740 * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16741 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16742 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16743 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Push to Seat) Delphi Connectors (Push To Seat) Special Tools J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16744 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs). 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Terminated Lead Repair 1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice sleeves depending on the gauge size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Delphi Connectors (Pull to Seat) Delphi Connectors (Pull To Seat) Special Tools Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16745 J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Note: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16746 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. View of a typical Micro 64 connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16747 Depress the lock and pull the lever over and past the lock. View of the connector when released from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16748 View of another type of Micro 64 connector. Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16749 View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16750 Note: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16751 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16752 Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Note: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16753 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16754 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16755 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16756 1. Cut the wire as close to the terminal as possible. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16757 Terminal Replacement Procedure After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Special Tools J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Note: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals). 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12-Way) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16758 Delphi Connectors (12-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16759 4. Release the lower wire dress cover locking tab. 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16760 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16761 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors (Lever Lock) FCI Connectors (Lever Lock) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16762 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. The release tab is located on the top of the wiredress cover. 3. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16763 6. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16764 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16765 1. While depressing the lock, remove the connector from the component. 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16766 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. 4. View of the TPA when removed from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16767 5. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Glow Plug Control Module) Kostal Connectors (Glow Plug Control Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16768 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16769 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16770 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. Note: The front TPA cannot be removed from the connector. Only move it to the preset position. 6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm). 7. Use a small flat-blade tool to completely remove the rear TPA from the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16771 8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Transmission) Kostal Connectors (Transmission) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16772 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16773 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Terminal Replacement Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16774 After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16775 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16776 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16777 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16778 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16779 3. To assemble the connector, reverse the connector disassembly procedure. Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16780 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16781 7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16782 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16783 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16784 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16785 Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16786 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16787 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16788 6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (102-Way Inline) Tyco/AMP Connectors (102-Way Inline) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16789 View of a typical connector in the assembled position. 1. Pull the locking lever to the 90 degree position from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16790 2. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal. 3. Slide the male connector body out away from the guide plates. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16791 Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 4. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. 5. Using terminal release tool J 38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16792 6. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 7. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16793 8. The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool J-38125-11A or equivalent to release the locking tab and slide the connector off the female body. 9. Move the locking lever 180 degrees from the connected position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16794 10. With the locking lever in the 180 degree position the guide plates can be removed from the connector body. Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 11. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16795 12. Using terminal release tool J 38125-216, lift the terminal plate past the terminals and out of the connector body cavity. 13. Terminal plate will bind slightly on each corner. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16796 14. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 15. Using terminal release tool J 38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16797 16. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 17. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16798 18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever. 19. Slide the male connector body back inward toward the guide plates. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16799 20. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly. 21. Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Seat) Tyco/AMP Connectors (Seat) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16800 Removal Procedure 1. Grasp the locking slide lever and pull outward from the end of the connector. 2. As the slide lever is pulled out the mating connector is lifted from the seated position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16801 Note: TPA is keyed and can only be inserted in one direction. 3. Using terminal release tool J 38125-11A or equivalent, push the TPA tabs into the connector body. 4. Pull the TPA from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16802 5. Using terminal release tool J 38125-11A or equivalent, release the connector wire dress cover locking tab. 6. With the lock tab released, lift the connector wire dress cover from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16803 7. Using terminal release tool J 38125-212, press the prongs into the holes each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 8. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16804 9. Using terminal release tool J 38125-556, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (SIR) Tyco/AMP Connectors (SIR) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16805 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16806 3. Using terminal tool J-38125-11A or equivalent, release the wire dress cover locking tabs. 4. Pivot connector wire dress cover while removing from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16807 5. Using terminal tool J-38125-11A or equivalent, remove the TPA by lifting straight off the connector body. 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals Repairing Connector Terminals Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16808 Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gauge size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16809 2. Disconnect the connector from the component. 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16810 4. Relieve the tension on the nose piece retainers by inserting J 38125-12A into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. 5. Once the nose piece retainers are relaxed, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16811 6. On the opposite side of the nose piece, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16812 8. Insert the J 38125-553 tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16813 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. If the TPA is removed, be sure to reinstall it before reconnecting the connector. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16814 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Special Tools Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16815 J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Note: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16816 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16817 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16818 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16819 1. While depressing the lock, pull the two connector halves apart. Note: The TPA is fragile and may break if not done carefully. 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. 3. View of the male half of the connector with female terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16820 4. View of the female half of the connector with male terminals. 5. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. View of the female half of the connector with male terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16821 7. View of the male half of the connector with female terminals. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16822 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are a one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine if the element in the fuse is broken (2). If not broken (1), also check for continuity using a Digital Multimeter (DMM) or a continuity tester. If the element is broken or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a Digital Multimeter (DMM) at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gauge size. Repairing a Fusible Link Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16823 Flat Wire Repairs The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Special Tools J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool * J 38125-5 Ultra Torch Special Tool The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Note: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation). GMLAN Connector Terminal Repair Note: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) for the appropriate connector repair procedure. GMLAN Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16824 Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16825 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Special Tools J-38125 Terminal Repair Kit Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16826 repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs High Temperature Wiring Repairs Special Tools J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gauge size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16827 splice. Note: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16828 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16829 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the wire insulation has been chafed, or broken, enough to show the conductive portion of the wire, and the wire is not damaged, determine the length of insulation that needs to be repaired. If the repair is less than 280 mm (11 in), cut the wire within the damaged area. Then slide the appropriate heat shrink tubing (listed below) over the wire, and repair the wire by splicing the wires together. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Once the wire is spliced together slide heat shrink tubing over the damaged area and apply heat to seal the repaired wire. If the wire is damaged, or the damaged area is larger than 280 mm (11 in), then replace the damaged wire by splicing in a new section of wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16830 SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Special Tools J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16831 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16832 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16833 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Special Tools J-38125 Terminal Repair Kit Note: Use only DuraSeal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use DuraSeal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use DuraSeal splice sleeves where there are special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16834 * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16835 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16836 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the instructions for Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Staggering the splices by 65 mm (2.5 in) is recommended. Note: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product AL-36FR to replace the damaged mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Flat Wire Repairs) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/GMLAN Wiring Repairs) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Heated Oxygen Sensor Wiring Repairs) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves) * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Twisted or Shielded Cable) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Inline Harness Diodes) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/SIR/SRS Wiring Repairs) US English/Metric Conversion US English/Metric Conversion Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16837 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16838 Testing Ground and Low Reference Circuits Testing Ground and Low Reference Circuits Because a test lamp can light with up to 200 ohm in a ground or low reference circuit they are not recommended to be used for this type of test. A low impedance test lamp can light and indicate the circuit is good when there is as much as 20-30 ohm present, while a high impedance test lamp can light with up to 200 ohm present in the circuit. This is why the Digital Multi-Meter (DMM) is used when validating a ground or low reference circuit continuity. When using the DMM there are many vehicle conditions that can affect the ground and low reference continuity testing. If these conditions are not met, a ground or low reference circuit test can fail on a good circuit. This may cause longer diagnosis time and incorrect component replacement. Any current flow through a ground or low reference circuit, while being tested, will skew the DMM continuity reading, or display a reading higher than when there is no current flowing. Performing a ground or low reference circuit continuity test, in reference to the vehicles battery negative terminal, will have the highest risk of failing a good ground or low reference circuit test than any other ground reference point. The best ground test points would be a control module housing (if the control modules housing is metal and grounded), door jamb striker (if attached to metal), under dash metal frame work, engine block, or body ground studs (other than where the negative battery cable is attached). A typical DMM ground or low reference circuit continuity reading can be as high as 100 ohm with the ignition ON, and drop to 15-25 ohm after the ignition is turned OFF. The reading will drop below 10 ohm after 30-40 seconds, then below 5 ohm after 60 seconds. Once the vehicle completely goes to sleep (generally 3-10 minutes) the reading will drop below 0.3 ohm. The following list of conditions may need to be met to ensure a valid continuity reading on a ground or low reference circuit: * Ignition OFF * Key out of the ignition switch (when not equipped with keyless entry and remote start) * Retained Accessory Power (RAP) OFF (open and close the driver door after ignition OFF) * Battery charger set at a 2 A or less charge rate * Scan tool not communicating with any vehicle control module (in some cases it may need to be disconnected from the DLC) * All entry doors closed * Headlamps OFF (auto headlamps disabled) * Any delay lighting OFF * HVAC after blow OFF * Any accessory that can work when the ignition is OFF * Wait up to 60 seconds (after all other listed conditions are met) Activating the DOOR LOCK function with a key fob can greatly reduce the time to achieve a valid ground or low reference continuity test result. Terminal Removal Terminal Removal Special Tools * EL-38125-580 - Terminal Release Tool Kit * EL-35616 - Connector Test Adapter Kit For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repair procedures. 1. Find the appropriate connector end view within the connector end view section. The connector end view has the following information: Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16839 * Diagnostic probe tool * Terminal release tool * Terminal/terminated lead part numbers Note: Not using the proper test kit probe may cause damage to the terminal(s) that are probed. 2. Determine if a terminal is damaged. * Locate the diagnostic probe tool from the connector end view. The connector end view describes the color and part number to help the technician find and use the correct tool. * Connect the probe tool to the Digital Multimeter. * Insert the probe tool into the cavity and follow the procedures from the Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter). 3. Disconnect the connector body to perform the repair. 4. Use the following procedure to remove the terminal from the connector body. Note: Several procedures for specific connector bodies are called out in the Wiring Repairs section. * The terminal position assurance (TPA) and connector position assurance (CPA) should be removed before releasing the terminal for the connector body. * Look at the connector end view to locate the cavity of the damaged terminal and find the proper terminal release tool from the terminal release tool kit. Note: Using the incorrect terminal release tool can damage the connector body. * Insert the terminal release tool into the cavity. Note: Some terminals have a lever that must be disengaged before the terminal can be released. 5. Gently pull the wire out of the back of the connector. 6. Repair the terminal by following the Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) procedure. 7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminated Lead Repair Terminated Lead Repair Special Tools * J-38125-8 - Splice Sleeve Crimp Tool Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16840 * J-38125-5 - Ultra Torch For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) procedures. Terminated leads are terminals that are crimped onto wires. The terminated lead can be used throughout the vehicle since it is designed for temperatures up to 150°C. The length of the wire is 450 mm. The DuraSeal splice sleeve has the following 2 critical features: * A special heat shrink tubing that environmentally seals the splice. The shrink tubing contains a sealing adhesive inside the shrink tubing. * A cross hatched (knurled) core crimp that provides the necessary contact integrity for sensitive low energy circuits. 1. Use the connector end view to identify the correct terminated lead. 2. The terminated lead package should include a DuraSeal splice sleeve. If not, use the chart to identify the correct part. 3. Open the harness by removing any tape: Use a sewing seam ripper, or a comparable tool, to cut open the harness, to avoid wire insulation damage. 4. Depending on how many terminals need repairs, cut the terminal and wire back at least 40 mm. Try to keep the harness wire length the same. If more than one terminated lead is required, stagger the lengths by 40 mm. This helps reduce the bundle size of the wire harness. 5. Use the EL-38125-10 - tool in order to position the DuraSeal splice sleeve in the proper color nest of the splice sleeve crimp tool. The crimp tool has four nests, one for each color. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16841 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the J-38125-5 - ultra torch , apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16842 Seat Heater: Connector Views Component Connector End Views Heated Seat Element - Driver Back (AN3 without KB6) Heated Seat Element - Driver Back (SPO Heated Seats) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16843 Heated Seat Element - Driver Cushion (AN3 without KB6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16844 Heated Seat Element - Driver Cushion (SPO Heated Seats) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16845 Heated Seat Element - Passenger Back (AN3 without KB6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16846 Heated Seat Element - Passenger Back (SPO Heated Seats) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16847 Heated Seat Element - Passenger Cushion (AN3 without KB6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16848 Heated Seat Element - Passenger Cushion (SPO Heated Seats) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16849 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16850 Seat Heater: Electrical Diagrams Heated/Cooled Seat Schematics Heated Seat - Driver (AN3 without KB6) Heated Seat - Passenger (AN3 without KB6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16851 Heated/Cooled Seat Module Power and Ground (KB6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16852 Heated/Cooled Seat - Driver (KB6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16853 Heated/Cooled Seat - Passenger (KB6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16854 Heated Seat - Driver (SPO Heated Seats) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16855 Heated Seat - Passenger (SPO Heated Seats) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 16856 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Description and Operation > Heated Seat Seat Heater: Description and Operation Heated Seat Heated Seats Description and Operation Heated Seat Components The driver and passenger heated seat system consists of the following components: * Heated seat switch * Door lock/window switch * Memory seat module (factory installed system) * Heated seat module (dealer installed system) * Seat cushion heating element * Seat back heating element * Seat cushion temperature sensor * Seat back temperature sensor Modes of Operation The memory seat module (MSM)/heated seat module (HSM) controls heated seat operation for both the driver and passenger seats. There are 2 modes of operation available for heated seats; both the seat cushion and seat back heat, or seat back only heat. When a heated seat temperature signal request is received, the MSM/HSM will activate both the seat cushion and seat back heating elements. When the heated seat BACK ONLY mode button is pressed once the MSM/HSM will deactivate the seat cushion heating element and leave the seat back heating element ON. Factory Installed Heated Seat System Operation The driver and passenger heated seats are controlled by separate heated seat switches located in the door panels. Ground is supplied to the heated seat switches through the switch low reference circuits from their respective door lock/window switches. The door lock/window switches also control the heated seat switch heat mode and temperature indicators. The memory seat module (MSM) controls the heated seat operation for both front heated seats. The following describes the sequence of operation and how the MSM responds to each of the switch inputs. * High Temperature-When the heated seat switch is pressed once, ground is applied through the switch contacts and the switch signal circuit to the door lock/window switch indicating the high heat request. In response to this signal, the door lock/window switch applies a low current voltage through the 3 temperature indicator control circuits illuminating all 3 LEDs indicating the high temperature mode. The switch then sends a message via the GMLAN serial data line to the MSM indicating the heated seat request. The MSM then applies battery voltage through the heating element supply voltage circuit to the seat cushion and seat back heating elements. At the same time, it supplies a ground through the element low reference circuits to the seat heating elements. * Medium Temperature-When the switch is pressed a second time, the MSM sets the temperature level to medium heat. The door lock/window switch removes the voltage from the high temperature indicator leaving 2 LEDs illuminated indicating the medium temperature mode. * Low Temperature-When the switch is pressed a third time, the MSM sets the temperature level to low heat. The door lock/window switch removes the voltage from the medium temperature indicator leaving 1 LED illuminated indicating the low temperature mode. * System OFF State-When the switch is pressed a fourth time, the MSM removes the battery voltage and grounds from the heating elements. The door lock/window switch removes the voltage from the low temperature indicator, indicating the system OFF state. * Back Only Mode-When the heated seat is ON and the BACK ONLY mode button is pressed, ground is applied through the switch contacts and the heated seat back only mode signal circuit to the door lock/window switch. In response to this signal, the door lock/window switch sends a GMLAN message to the MSM indicating the back only mode request. The MSM then opens the ground path to the seat cushion heater element, leaving the seat back heater active. The door lock/window switch turns OFF the seat cushion/back mode indicator, then applies a low current voltage through the heated seat back only mode indicator control circuit illuminating the back only mode indicator. Dealer Installed Heated Seat System Operation The dealer installed driver and passenger heated seats are controlled by separate heated seat switches located in the instrument panel trim plate on the right side of the HVAC controls. The following describes the sequence of operation and how the heated seat module (HSM) responds to each of the switch inputs. * High Temperature-When the heated seat switch is pressed once, ground is applied through the switch contacts and the switch signal circuit to the HSM indicating the high heat request. In response to this signal, the HSM applies battery voltage through the heating element supply voltage circuit and ground through the element low reference circuits to the seat cushion and seat back heating elements. At the same time, the HSM applies a low current voltage through the 3 temperature indicator control circuits illuminating all 3 LEDs indicating the high temperature mode. * Medium Temperature-When the switch is pressed a second time, the HSM sets the temperature level to medium heat and removes the voltage from the high temperature indicator leaving 2 LEDs illuminated indicating the medium temperature mode. * Low Temperature-When the switch is pressed a third time, the HSM sets the temperature level to low heat and removes the voltage from the Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Description and Operation > Heated Seat > Page 16859 medium temperature indicator leaving 1 LED illuminated indicating the low temperature mode. * System OFF State-When the switch is pressed a fourth time, the HSM removes the battery voltage and grounds from the heating elements and the voltage from the low temperature indicator, indicating the system OFF state. * Back Only Mode-When the heated seat is ON and the BACK ONLY mode button is pressed, ground is applied through the switch contacts and the heated seat back only mode signal circuit to the HSM. In response to this signal, the HSM opens the ground path to the seat cushion heater element, leaving just the seat back heater active. At the same time, the HSM turns OFF the seat cushion/back mode indicator, then applies a low current voltage through the heated seat back only mode indicator control circuit illuminating the back only mode indicator. Temperature Regulation The heated seat system is designed to warm the seat cushion and seat back to 3 different temperature settings; High, MED, and Low. The MSM/HSM monitors the seat temperature through the temperature sensor signal circuits and the temperature sensors (thermistor) that are located in the seat cushion and the seat back. The temperature sensors are variable resistors, their resistance varies as the temperature of the seat changes. When the temperature sensor resistance indicates to the MSM/HSM that the seat has reached the desired temperature, the module opens the ground path of the seat heating elements through the heated seat element control circuit. The module will then cycle the element control circuit open and closed in order to maintain the desired temperature. Load Management The electrical power management function is designed to monitor the vehicle electrical load and determine when the battery is potentially in a high discharge condition. The heated seat system is one of the vehicle loads that is subject to reduction during a battery discharge condition. For more information on load management refer to Electrical Power Management Description and Operation (See: Starting and Charging/Description and Operation). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Description and Operation > Heated Seat > Page 16860 Seat Heater: Description and Operation Heated/Cooled Seats Heated/Cooled Seats Description and Operation The driver and front passenger heated cooled seat system consist of the following components: * Seat cushion heat/cool ventilation module * Seat back heat/cool ventilation module * Climate control seat module * Memory seat module * Heated and cooled seat switch * Door lock/window switch Air Circulation When the heated/cool seat switch is pressed to initiate operation of the climate control seat system, cabin air is drawn through the heated/cool ventilation module air filter, then directed through passages in the foam of the seat cushion and seat back to the seat's occupant. In order for the climate control seat system to operate to its optimum performance, it is crucial to have unrestricted air flow through the system. A dirty or restricted air filter, the blockage of an exhaust air duct, a misaligned heated/cool ventilation module, or incorrect foam installation of the seat cushion or seat back will all have negative effects on climate control seat system operation. Seat Heat/Cool Ventilation Module Each heated/cool seat has 2 ventilation modules, one located under the seat cushion and one located in the seat back. These modules are controlled by the climate control seat module (CCSM). Each ventilation module contains a thermo-electric device (TED), a temperature sensor, and a blower motor. The TED and temperature sensor are mounted downstream of the blower motor. Each TED consists of a circuit of positive and negative connections sandwiched between 2 ceramic plates. Each ceramic plate is equipped with copper fins for heat exchange. The air flowing past these fins is either directed as conditioned air into the seat cushion and seat back, or directed into the cabin as waste air. TED is essentially a solid state heat pump that is used to heat or cool the air supply to the seat cushion and seat back. When voltage is applied to a TED, one side releases energy as heat, while the opposite side absorbs energy and gets cold. When the polarity of the current flow to the TEDs is switched, the hot and cool sides of the TED reverse. During the following climate control seat system description and operation, the TEDs, blower motors, and temperature sensors will be referenced independently even though they are all packaged together as a module. Climate Control Seat System The climate control seat system consists of two heated/cool ventilation modules and one CCSM that controls both the driver and passenger heated/cool seats systems. The CCSM is mounted below the front passenger seat cushion. Once a climate control seat system is activated, cabin air is drawn through the seat blower motors and directed across the fins of each of the TED located under the seat cushion and in the seat back. The air is either heated or cooled as it passes over the TEDs. This conditioned air is then directed through channels in the foam of the seat pad and through small holes in the seat cover to the occupant. Once the system is activated, the CCSM uses a set of algorithms to control the temperature of the selected heating or cooling modes. Climate Control Seat Module Power and Ground Battery positive voltage is supplied at all times to the CCSM through the battery positive voltage circuit and a 30 A fuse that is located in the I/P fuse block. This voltage is used by the CCSM to supply power to the TEDs and the blower motors. Ignition voltage is also supplied to the CCSM through the ignition voltage circuit and a 10 A fuse located in the underhood fuse block. The ignition voltage is used to power up the CCSM and allows the climate control seat system to operate only with the ignition in the ON position. The CCSM is grounded through the module ground circuit and G304. Climate Control Seat Module The CCSM is located under the passenger seat and controls 4 individual driver and passenger seat heat/cool ventilation blowers. When the CCSM receives a heated cooled seat command through the left or right heated/cooled seat mode signal circuit, the appropriate seat heat/cool ventilation blowers will be operated by the CCSM. Memory Seat Module The memory seat module (MSM) monitors the heated cooled seat switches through serial data message inputs and determines the heated cooled seat operating modes and temperature levels. The MSM controls the operating mode of the CCSM through 2 pulse width modulation (PWM) signal circuits. The left and right heated/cooled seat mode signal circuits are referenced from battery voltage by the CCSM and pulsed low by the MSM. Each heated Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Description and Operation > Heated Seat > Page 16861 cooled seat is capable of operating in 3 modes with 3 temperature levels so the MSM uses 9 PWM frequencies for each signal circuit to command the heated cooled seat modes to the CCSM. Modes of Operation There are 3 modes available for climate control seat system operation, heated seat, cool seat, and back only heat operation. When a heat or cool seat mode signal request is received, the CCSM will activate both the seat cushion and seat back ventilation modules. When the seat BACK ONLY mode button is pressed once, the CCSM will deactivate the seat cushion ventilation module and leave the seat back ventilation module ON. Press the BACK ONLY mode button a second time and the CCSM will re-activate the seat cushion ventilation module. Heated/Cooled Seat Switch and Door Module The heated and cooled seat system is controlled through the heated and cooled seat switches that are located on the door panels. Ground is supplied to the heated/cool seat switch through the low reference circuit and the respective door module. The door module plays an important part of the climate control seat operation, first by relaying the selected switch inputs to the MSM, and second, by controlling the mode and temperature indicators of the heated/cool seat switch. When either a heat or cool seat switch is pressed, ground is applied through the switch contacts and the switch signal circuit to the door lock/window switch. In response to this signal, the door lock/window switch sends a serial data message to the MSM indicating the switch input. In response to this message, the MSM then sends a pulse width modulation (PWM) signal through the appropriate heated/cool seat mode signal circuit to the CCSM indicating the heated or cooled seat request. The door lock/window switch then applies a ground through the appropriate heat or cool seat indicator control circuit to the switch illuminating the selected heat or cool mode indicator. At the same time, the door lock/window switch also applies a ground through the appropriate high, medium, or low temperature indicator control circuits illuminating temperature mode indicators. Temperature Sensors As mentioned above in the heated/cool ventilation module description, the seat cushion and seat back temperature sensors are each packaged with a TED and blower motor as an assembly. The seat temperature sensors are thermistors which are attached directly to the fins of each TED. The CCSM supplies a 5 V reference voltage through the temperature sensor signal circuit and ground through the temperature sensor low reference circuit to the respective seat cushion and seat back temperature sensors. As the temperature of the TED changes, the resistance of the thermistor varies changing the feedback voltage of the temperature sensor signal circuit. This voltage varies from 0.5 - 4 V. The CCSM monitors this voltage signal to determine the fin temperature so that it can adjust and maintain the seat temperature to the selected switch input. Blower Motors Also, as mentioned above in the heated/cool ventilation module description, the seat cushion and seat back blower motors are each packaged with a TED and temperature sensor as an assembly. Each blower motor contains logic that will allow for the blower to operate only when the ignition is in the ON position. When the ignition is ON and the CCSM is powered up, the module supplies battery positive voltage through the blower supply voltage circuit to the logic of the blower motors. When the heated/cool seat switch is pressed, the CCSM applies a pre-determined voltage through the blower speed control circuits to the blower motors. The module also supplies each blower motor with a ground path through the blower low reference circuits. With the climate control seat system, the speed of the blower motor is not related directly to the High, Med, or Low input from the heated/cool seat switch. The speed of the blower motor is related directly to TED temperature as described below in heated and cooled seat operation. Heated Seat Operation When the heated seat switch is pressed for High Heat, the CCSM will transition to the HEAT state. In the heat state, the CCSM applies a pre-determined voltage through the ventilation module heat control circuits to the heat side of the TEDs, while providing a ground through the ventilation module cool control circuit to the cool side of the TEDs. A pre-determined voltage is also applied to the blower motors. The CCSM uses the following sequence beginning with the Heat SoftStart Mode to achieve the set point temperature before it can enter the Control Heat Mode. If the seat temperature is already above the Temperature Set Point, the CCSM will skip the Heat SoftStart Mode and proceed to the Control Heat Mode. * Heat SoftStart Mode - While in transition to the heat mode, the CCSM will initiate the SoftStart Mode. The intent of the Heat SoftStart Mode is for the module to bring the ventilation module fin temperature up to the pre-determined Temperature Set Point of the Max Heat Mode. The module does this by setting the blower motor speed control to a pre-determined voltage while ramping up the ventilation module voltage from 0 V to the maximum voltage, not to exceed 5 seconds, at which point the system transitions to Max Heat Mode. The Heat SoftStart Mode will only be attempted once per ignition cycle. * Max Heat Mode - Upon completion of the Heat SoftStart Mode, the CCSM will initiate Max Heat Mode. The intent of the MAX Heat Mode is to maintain the fin temperature to the pre-determined Temperature Set Point in order for the CCSM to go into the Control Heat Mode. The CCSM does this by maintaining the TED at the maximum voltage while maintaining the minimum required airflow across the fins. After max heat duration has been reached, or upon achieving the pre-determined Temperature Set Point, the system transitions to the Control Heat Mode. * Control Heat Mode - At the completion of Max Heat Mode, the CCSM will initiate Control Heat Mode. The intent of the Control Heat Mode is to maintain the desired fin temperature or the set point temperature. The CCSM does this in two ways; first by adjusting the voltage supply to the blower motor to control blower motor speed, then secondly by controlling the voltage supplied to the TED. The CCSM updates these voltages once every second. Increasing the blower motor speed will decrease the fin temperature. If the maximum blower motor speed is achieved and the fin temperature is still above the set point of high heat, the CCSM will then begin to control the TED voltage to achieve Temperature Set Point. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Description and Operation > Heated Seat > Page 16862 Decreasing the TED voltage decreases the fin temperature. If the CCSM is trying to raise the fin temperature to set point by using TED voltage, and the fin temperature cannot be raised because the TED voltage is at the maximum, the CCSM reduces the blower motor speed to achieve the Temperature Set Point. Cooled Seat Operation When the cool seat switch is pressed for High Cool, the CCSM will transition to the COOL state. In response to this command, the CCSM applies a pre-determined voltage through the ventilation module cool control circuits to the cool side of the TEDs while providing a ground through the ventilation module heat control circuits to the heat side of the TEDs. A pre-determined voltage is also applied to the blower motors. The CCSM uses the following sequence, beginning with the Cool SoftStart Mode, to achieve the set point temperature before it can enter the Open Loop Cool Mode. * Cool SoftStart Mode - The intent of the Cool SoftStart Mode is for the CCSM to bring the TED fin temperature to maximum cool temperate. The CCSM does this by setting the blower motor speed control voltage to 0 V, while ramping up the TED voltage duty cycle from 0 V to maximum voltage duty cycle over a period not to exceed 5 seconds. Then, with the TEDs at maximum voltage, the CCSM will increase the blower speed to maximum voltage, and keep these settings for the MAX COOL DURATION. After which the system transitions to the Open Loop Cool Mode. * Open Loop Cool Mode - At the completion of Cool SoftStart Mode, the CCSM will initiate Open Loop Cool Mode. The intent of this mode is to maintain the set point fin temperature based on the input of the cool seat switch. First, by controlling the speed of the blower motor, then secondly, by controlling TED voltage. The CCSM updates these voltages once every second. Fault State The climate control seat system will operate normally in the battery voltage range of 9 - 16 V. If the system voltage falls outside of this voltage range, the module will shut down all outputs until the system returns to its normal operating voltage range. The system will also transition to the fault state per the conditions listed below, by shutting down all outputs for the seat in which the fault occurred. High Temperature Fault State During the heating or cooling modes, if the TED temperatures listed below are exceeded for more than 4 seconds, the system will enter the High Temperature Fault State. At which time the CCSM will set the TED voltage duty cycle to 0%, set the blower speed control to maximum voltage to blow ambient air over the TEDs, attempting to reduce the TED temperature below the listed maximums. The system will operate in this mode for 30 seconds. If the over temperature fault still exists after 30 seconds, the system will transition to the FAULT state for the remainder of the ignition cycle. If the over temperature fault clears, the system will then transition to the appropriate heat or cool softstart mode. The following temperatures are based upon individual readings of either sensor: * Heat mode TED temperature exceeds 230°F (110°C). * Cool mode TED temperature exceeds 149°F (65°C). Temperature Delta Fault During the heating or cooling modes, if the CCSM detects a temperature difference between the seat cushion and seat back TED temperature sensors exceeding the delta temperature listed below for more than 4 seconds, the system will enter the Temperature Delta Fault state. At which time the CCSM will set the TED voltage duty cycle to 0%, set the blower speed control to maximum voltage to blow ambient air over the TEDs, attempting to reduce the delta temperature to less than 68°F. The system will operate in this mode for 30 seconds. If the delta temperature fault still exists after 30 seconds, the system will transition to the FAULT state and remain there until the ignition has been set to OFF. * Delta between the seat cushion and seat back temperature sensors is 104°F (40°C). * This fault state is disabled in the back only mode. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Testing and Inspection > Symptoms - Seat Heating and Cooling Seat Heater: Testing and Inspection Symptoms - Seat Heating and Cooling Symptoms - Seat Heating and Cooling Important: The following steps must be completed before using the symptom tables. 1. Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) before using the Symptom Tables in order to verify that all of the following are true: * There are no DTCs set. * The control modules can communicate via the serial data link. 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Heated Seats Description and Operation (See: Description and Operation). Visual/Physical Inspection * Inspect for aftermarket devices which could affect the operation of the system. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Checking Aftermarket Accessories). * Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom. Intermittent Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections ( See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections). Symptom List Refer to Heated Seat Inoperative (Factory Installed, KA1) (See: Heated Seat Inoperative (Factory Installed, KA1))Heated Seat Inoperative (Dealer Installed, KA1) (See: Heated Seat Inoperative (Dealer Installed, KA1)) in order to diagnose the symptom. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Testing and Inspection > Symptoms - Seat Heating and Cooling > Page 16865 Seat Heater: Testing and Inspection Heated Seat Inoperative (Factory Installed, KA1) Heated Seat Inoperative (Factory Installed, KA1) Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Circuit/System Description The driver and front passenger heated seats are controlled by separate heated seat switches located on the door panels. When a heated seat switch is pressed, ground is momentarily applied through the switch contacts and the switch signal circuit to the door lock/window switch. In response to this signal, the door lock/window switch sends a serial message to the memory seat module (MSM) indicating the heat seat request. The MSM then applied battery voltage to the seat cushion and seat back heater elements through a common voltage supply circuit. Each individual heater element is grounded by the module through separate low side drive control circuits. The heater element control circuits are pulse width modulated (PWM) to ground by the module in order to control the seat temperatures by regulating the current flow through the heater elements. The MSM relies on 4 independent inputs from temperature sensors (thermistors) located in the seat back and seat cushion of the driver and passenger seats. The temperature sensor resistance varies based on the temperature of the heating element causing the signal circuit voltage to change. Once the seat reaches the switch set temperature, the MSM will then cycle the control circuits of the heating elements ON and OFF in order to maintain the desired seat temperature based on the feedback voltage from the sensors. The MSM then monitors the current flow through the heating elements and the of rate change of the temperature sensor to verify correct heated seat operation. Reference Information Schematic Reference Heated/Cooled Seat Schematics (See: Diagrams/Electrical Diagrams) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views) Description and Operation Heated Seats Description and Operation (See: Description and Operation) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning) for scan tool information Circuit/System Verification 1. Ignition ON, observe the appropriate scan tool Driver Door Switch or Passenger Door Switch parameters listed below while pressing and releasing the appropriate switch. The readings should change between Inactive and Active. * Seat Back Heat Mode Sw. * Seat Heat Mode Sw. ‹› If not the specified values, refer to the Heated Seat Switch component test. If the heated seat switch tests normal, replace the appropriate door lock/window switch. 2. If all scan tool parameters test normal and there are no DTCs set, replace the MSM. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Testing and Inspection > Symptoms - Seat Heating and Cooling > Page 16866 3. If all heated seat functions operate normal and the heated seat switch indicators do not illuminate, refer to the Heated Seat Switch Indicators component test. Component Testing Heated Seat Switch 1. Ignition OFF, disconnect the X4 harness connector at the appropriate door lock/window switch. 2. Test for infinite resistance between the signal circuits listed below and the low reference circuit terminal 4 with the switch in the open position. * Seat back and cushion heat mode terminal 6 * Seat back only mode terminal 7 ‹› If not the specified value, replace the heated seat switch. 3. Test for less than 2 Ohms between the signal circuits listed below and the low reference circuit terminal 4 with the switch in the closed position. * Seat back and cushion heat mode terminal 6 * Seat back only mode terminal 7 ‹› If greater than the specified range for any of the tests, replace the heated seat switch. Heated Seat Switch Indicators 1. Ignition OFF, disconnect the X4 harness connector at the appropriate door lock/window switch. 2. Connect a 3 A fused jumper wire between the low reference circuit terminal 4 and ground. 3. Connect a test lamp between B+ and each control circuit listed below. The appropriate indicator should illuminate. * Seat back and cushion mode indicator terminal 10 * Seat back only mode indicator terminal 11 * Low heat indicator terminal 9 * Medium heat indicator terminal 1 * High heat indicator terminal 2 ‹› If any indicator does not illuminate, replace the heated seat switch. 4. If all indicators illuminate, replace the door lock/window switch. Repair Instructions Perform the Diagnostic Repair Verification (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. * Front Seat Heater Switch Replacement (See: Seat Heater Switch/Service and Repair/Front Seat Heater Switch Replacement) * Control Module References (See: Testing and Inspection/Programming and Relearning) for MSM and door lock/window switch replacement, programming, and setup Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Testing and Inspection > Symptoms - Seat Heating and Cooling > Page 16867 Seat Heater: Testing and Inspection Heated Seat Inoperative (Dealer Installed, KA1) Heated Seat Inoperative (Dealer Installed, KA1) Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions )provides an overview of each diagnostic category. Diagnostic Fault Information Circuit/System Description The driver and front passenger heated seats are controlled by separate heated seat switches. When a heated seat switch is pressed, ground is momentarily applied through the switch contacts and the switch signal circuit to the heated seat module (HSM). In response to this signal, the module then applies battery voltage through the element supply voltage circuits to the seat cushion and seat back heating elements. The HSM then supplies a ground through the appropriate indicator control circuits to the heated seat switch illuminating the switch indicators. Reference Information Schematic Reference Heated/Cooled Seat Schematics (See: Diagrams/Electrical Diagrams) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views) Description and Operation Heated Seats Description and Operation (See: Description and Operation) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Testing and Inspection > Symptoms - Seat Heating and Cooling > Page 16868 Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning)for scan tool information Circuit/System Verification 1. Ignition ON, observe the appropriate scan tool Heated Seat Module parameter listed below while pressing and releasing the heated seat back and cushion switch. The readings should change between Off and Back & Cushion. * Driver Seat HVC Mode * Passenger Seat HVC Mode ‹› If not the specified value, refer to Heated Seat Switch Malfunction. 2. Ignition ON, observe the appropriate scan tool Heated Seat Module parameter listed below while pressing and releasing the heated seat back only switch. The readings should change between Off and Back Only. * Driver Seat HVC Mode * Passenger Seat HVC Mode ‹› If not the specified value, refer to Heated Seat Switch Malfunction. 3. If all heated seat switch functions operate OK, but, one or more of the heated seat switch indicators is inoperative or always ON, refer to Heated Seat Switch Indicator Malfunction. 4. If all scan tool parameters test normal and there are no DTCs set, replace the HSM. Circuit/System Testing Heated Seat Switch Malfunction 1. Ignition OFF, disconnect the harness connector at the appropriate heated seat switch. 2. Test for less than 10 Ohms between the ground circuit terminal 7 and ground. ‹› If greater than the specified range, test the ground circuit for an open/high resistance. 3. Ignition ON, verify the appropriate scan tool Heated Seat Module parameter listed below is Off. * Driver Seat HVC Mode * Passenger Seat HVC Mode ‹› If not the specified value, test the signal circuits listed below for a short to ground. If the circuits test normal, replace the HSM. * Seat cushion and back signal terminal 4 * Seat back only signal terminal 5 4. Install a 3 A fused jumper wire between the signal circuit terminal 4 and ground. Verify the appropriate scan tool Heated Seat Module parameter listed below is Back & Cushion. * Driver Seat HVC Mode * Passenger Seat HVC Mode ‹› If not the specified value, test the signal circuit for a short to voltage an open/high resistance. If the circuit tests normal, replace the HSM. 5. Install a 3 A fused jumper wire between the signal circuit terminal 5 and ground. Verify the appropriate scan tool Heated Seat Module parameter listed below is Back Only. * Driver Seat HVC Mode * Passenger Seat HVC Mode ‹› If not the specified value, test the signal circuit for a short to voltage or an open/high resistance. If the circuit tests normal, replace the HSM. 6. If all circuits test normal, test or replace the heated seat switch. Heated Seat Switch Indicator Malfunction 1. Ignition OFF, disconnect the harness connector at the appropriate heated seat switch. 2. Ignition ON, verify that a test lamp illuminates between the control circuit terminal 2 and ground. If the test lamp does not illuminate, refer to Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Testing and Inspection > Symptoms - Seat Heating and Cooling > Page 16869 Interior Backlighting Malfunction (w/AN3) (See: Lighting and Horns/Testing and Inspection/Interior Backlighting Malfunction (w/AN3))Interior Backlighting Malfunction (w/o AN3) (See: Lighting and Horns/Testing and Inspection/Interior Backlighting Malfunction (w/o AN3)). 3. Ignition OFF, connect the harness connector at the heated seat switch. 4. Disconnect the X3, X4 harness connectors at the heated seat module. 5. Ignition ON, connect a test lamp between the control circuits listed below and ground. The appropriate indicator should turn ON and OFF when the test lamp is connected and disconnected. * Driver seat high heat indicator terminal 5 X3 * Driver seat medium heat indicator terminal 16 X4 * Driver seat low heat indicator terminal 4 X3 * Driver seat back and cushion heat indicator terminal 17 X4 * Driver seat back heat indicator terminal 15 X4 * Passenger seat high heat indicator terminal 10 X3 * Passenger seat medium heat indicator terminal 6 X4 * Passenger seat low heat indicator terminal 9 X3 * Passenger seat back and cushion heat indicator terminal 7 X4 * Passenger seat back heat indicator terminal 18 X4 ‹› If the test lamp is always ON, test the appropriate control circuit for a short to ground. If the circuit tests normal, test or replace the heated seat switch. ‹› If the test lamp is always OFF, test the appropriate control circuit for a short to voltage or an open/high resistance. If the circuit tests normal, test or replace the heated seat switch. 6. If all circuits test normal, replace the HSM. Component Testing Heated Seat Switch 1. Ignition OFF, disconnect the harness connector at the heated seat switch switch. 2. Test for infinite resistance between the signal terminal 4 and the ground terminal 7 with the back and cushion switch in the open position. ‹› If not the specified value, replace the heated seat switch switch. 3. Test for infinite resistance between the signal terminal 5 and the ground terminal 7 with the back only switch in the open position. ‹› If not the specified value, replace the heated seat switch switch. 4. Test for less than 5 Ohms between the signal terminal 4 and the ground terminal 7 with the back and cushion switch in the closed position. ‹› If greater than the specified value, replace the heated seat switch. 5. Test for less than 5 Ohms between the signal terminal 5 and the ground terminal 7 with the back only switch in the closed position. ‹› If greater than the specified value, replace the heated seat switch. 6. Install a 3 A fused jumper wire between the control terminal 2 and B+. 7. Connect a test lamp between the control circuits listed below and ground. The selected indicator should illuminate. * Back and cushion heat indicator terminal 1 * Low heat indicator terminal 6 * Medium heat indicator terminal 8 * Back only heat indicator terminal 9 * High heat indicator terminal 10 ‹› If any indicator does not illuminate, replace the heated seat switch. Repair Instructions Perform the Diagnostic Repair Verification (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. Control Module References (See: Testing and Inspection/Programming and Relearning)for heated seat control module replacement, setup, and programming Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Testing and Inspection > Symptoms - Seat Heating and Cooling > Page 16870 Seat Heater: Testing and Inspection Heated/Cooled Seats Inoperative (KB6) Heated/Cooled Seats Inoperative (KB6) Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Diagnostic Fault Information Circuit/System Description The heat and cool seat functions for the driver and passenger seats are controlled by the climate control seat module (CCSM) that is located under the Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Testing and Inspection > Symptoms - Seat Heating and Cooling > Page 16871 passenger seat cushion. When a driver or passenger heat or cool seat switch is pressed, a low reference signal is applied through the switch signal circuit to the door lock/window switch. In response to the switch input, the door lock/window switch simultaneously illuminates the appropriate heated/cooled switch indicators and sends a serial data message to the memory seat module (MSM) indicating the heat or cool seat request. The MSM then sends a pulse width modulation (PWM) signal through the appropriate heated/cooled seat mode signal circuit to the CCSM. The CCSM then applies battery positive voltage to the seat cushion and seat back thermal electronic devices (TEDs) and a pre-determined voltage to the blower motors. To determine seat temperature, the CCSM supplies a 5 V signal and a low reference to the temperature sensors that are attached to each TED. The temperature sensors are variable resistors, their resistance changes as the temperature of the seat changes. Then based on the seat temperature, the CCSM controls the voltage level that it applies to the TEDs and blower motors. Diagnostic Aids The following conditions must be met in order to perform valid tests when diagnosing the climate control seat system: * The ignition must be cycled OFF then ON between each test in order to reset the CCSM. * Most circuit faults will set a DTC within 1.5 minutes. However, some circuit faults may cause a performance problem in one mode and be inoperative and set a DTC in another mode. In some cases it may take 5 minutes or more for a DTC to set. Operate the heated/cooled seat in each of the three modes for 5 minutes or more then check for DTCs. * The engine must be running in order to supply the CCSM with the amount of current needed to operate the heated/cool seat system. Reference Information Schematic Reference Heated/Cooled Seat Schematics (See: Diagrams/Electrical Diagrams) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views) Description and Operation Heated/Cooled Seats Description and Operation (See: Description and Operation/Heated/Cooled Seats) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning) for scan tool information Circuit/System Verification 1. If both, the driver and passenger heated and cooled seats are inoperative, refer to Driver and Passenger Heated/Cool Seats Inoperative. 2. Ignition ON, observe the scan tool Driver Door Switch parameters listed below while pressing and releasing the appropriate switch. The readings should change between Inactive and Active or Off and ON. * Seat Back Heat Mode Sw. * Seat Cool Mode Switch * Seat Heat Mode Sw. ‹› If the reading does not change between Inactive and Active or Off and ON, refer to the Heated and Cooled Seat Switch component test. If the switch tests normal, replace the driver door lock/window switch. ‹› If the readings test normal, but the driver heat/cool seat is inoperative, refer to Driver Heated/Cool Seat Circuit System Test. 3. Observe the scan tool Passenger Door Switch parameters listed below while pressing and releasing the appropriate switch. The readings should change between Inactive and Active or Off and ON. * Seat Back Heat Mode Sw. * Seat Cool Mode Switch * Seat Heat Mode Sw. ‹› If the reading does not change between Inactive and Active or Off and ON, refer to the Heated and Cooled Seat Switch component test. If the Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Testing and Inspection > Symptoms - Seat Heating and Cooling > Page 16872 switch tests normal, replace the front passenger door lock/window switch. ‹› If the readings test normal, but the passenger heat/cool seat is inoperative, refer to Passenger Heated/Cool Seat Circuit System Test. 4. If all heated and cooled seat functions operate normal, but the heated/cooled seat switch indicators do not illuminate or are always ON, refer to the Heated and Cooled Seat Switch component test. If the switch tests normal, replace the appropriate door lock/window switch. Circuit/System Testing Driver and Passenger Heated/Cool Seats Inoperative 1. Ignition OFF, disconnect the X1 harness connector at the CCSM. 2. Verify that a test lamp illuminates between the ground circuit terminal M and B+. ‹› If the test lamp does not illuminate, test the ground circuit for an open/high resistance. 3. Verify that a test lamp illuminates between the B+ circuit terminal E and ground. ‹› If the test lamp does not illuminate, test the B+ circuit for a short to ground or an open/high resistance. 4. Disconnect the X2 harness connector at the CCSM. 5. Ignition ON, verify that a test lamp illuminates between the ignition circuit terminal 1 and ground. ‹› If the test lamp does not illuminate, test the ignition circuit for a short to ground or an open/high resistance. 6. If all circuits test normal, replace the CCSM. Driver Heated/Cool Seat Circuit System Test 1. Ignition OFF, disconnect the X3 harness connector at the CCSM. 2. Connect a test lamp between the signal circuit terminal 14 and B+. 3. Ignition ON, press the HEAT or COOL seat switch through the high, medium, and low positions to OFF. The test lamp should illuminate until the OFF position is reached. ‹› If the test lamp does not illuminate, test the signal circuit for a short to voltage or an open/high resistance. If the circuit tests normal, replace the MSM. ‹› If the test lamp remains ON with the switch in the OFF position, test the signal circuit for a short to ground. If the circuit tests normal, replace the MSM. 4. Connect the X3 harness connector at the CCSM. 5. Disconnect the harness connector at the seat cushion ventilation heating and cooling module. 6. Test for less than 5 Ohms between the low reference circuit terminal 4 and ground. ‹› If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the CCSM. 7. Ignition ON, test for 4.8 - 5.2 V between the signal circuit terminal 5 and ground. ‹› If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the CCSM. ‹› If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the CCSM. Note: The ignition must be cycled OFF then ON between each test in order to reset the CCSM. 8. Ignition OFF then ON, connect a test lamp between the control circuits listed below and ground. Press the HEAT switch when testing the heat control circuit and the COOL switch when testing the cool control circuit. The test lamp should illuminate or slowly illuminate for approximately 2 - 4 seconds after the switch is pressed. On the heat control circuit, the test lamp may exhibit a 4 second delay before it starts to illuminate. * Seat cushion heat control circuit terminal 1 * Seat cushion cool control circuit terminal 3 ‹› If the test lamp does not illuminate, test the appropriate control circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the CCSM. ‹› If the test lamp is always ON, test the appropriate control circuit for a short to voltage. If the circuit tests normal, replace the CCSM. Note: The ignition must be cycled OFF then ON between each test in order to reset the CCSM. 9. Ignition OFF then ON, connect a test lamp between the circuits listed below and ground. The test lamp should illuminate or slowly illuminate for approximately 5 seconds after pressing the HEAT switch. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Testing and Inspection > Symptoms - Seat Heating and Cooling > Page 16873 * Seat cushion blower control circuit terminal 2 * Seat cushion blower speed control circuit terminal 7 ‹› If the test lamp does not illuminate, test the appropriate circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the CCSM. ‹› If the test lamp is always ON, test the appropriate circuit for a short to voltage. If the circuit tests normal, replace the CCSM. 10. Ignition OFF, connect the harness connector to the seat cushion ventilation heating and cooling module. 11. Disconnect the harness connector at the seat back ventilation heating and cooling module. 12. Test for less than 5 Ohms between the low reference circuit terminal 4 and ground. ‹› If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the CCSM. 13. Ignition ON, test for 4.8 - 5.2 V between the signal circuit terminal 5 and ground. ‹› If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the CCSM. ‹› If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the CCSM. Note: The ignition must be cycled OFF then ON between each test in order to reset the CCSM. 14. Ignition OFF then ON, connect a test lamp between the control circuits listed below and ground. Press the HEAT switch when testing the heat control circuit and the COOL switch when testing the cool control circuit. The test lamp should illuminate or slowly illuminate for approximately 4 seconds after the switch is pressed. On the heat control circuit, the test lamp may exhibit a 4 second delay before it starts to illuminate. * Seat back heat control circuit terminal 1 * Seat back cool control circuit terminal 3 ‹› If the test lamp does not illuminate, test the appropriate control circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the CCSM. ‹› If the test lamp is always ON, test the appropriate control circuit for a short to voltage. If the circuit tests normal, replace the CCSM. Note: The ignition must be cycled OFF then ON between each test in order to reset the CCSM. 15. Ignition OFF then ON, connect a test lamp between the circuits listed below and ground. The test lamp should illuminate or slowly illuminate for approximately 5 seconds after pressing the HEAT switch. * Seat back blower control circuit terminal 2 * Seat cushion blower speed control circuit terminal 7 ‹› If the test lamp does not illuminate, test the appropriate circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the CCSM. ‹› If the test lamp is always ON, test the appropriate circuit for a short to voltage. If the circuit tests normal, replace the CCSM. 16. If all circuits test normal, test or replace the appropriate seat cushion or seat back ventilation heating and cooling module. Passenger Heated/Cool Seat Circuit System Test 1. Ignition OFF, disconnect the X3 harness connector at the CCSM. 2. Connect a test lamp between the signal circuit terminal 6 and B+. 3. Ignition ON, press the HEAT or COOL seat switch through the high, medium, and low positions to OFF. The test lamp should illuminate until the OFF position is reached. ‹› If the test lamp does not illuminate, test the signal circuit for a short to voltage or an open/high resistance. If the circuit tests normal, replace the MSM. ‹› If the test lamp remains ON with the switch in the OFF position, test the signal circuit for a short to ground. If the circuit tests normal, replace the MSM. 4. Connect the X3 harness connector at the CCSM. 5. Disconnect the harness connector at the seat cushion ventilation heating and cooling module. 6. Test for less than 5 Ohms between the low reference circuit terminal 4 and ground. ‹› If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the CCSM. 7. Ignition ON, test for 4.8 - 5.2 V between the signal circuit terminal 5 and ground. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Testing and Inspection > Symptoms - Seat Heating and Cooling > Page 16874 ‹› If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the CCSM. ‹› If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the CCSM. Note: The ignition must be cycled OFF then ON between each test in order to reset the CCSM. 8. Ignition OFF then ON, connect a test lamp between the control circuits listed below and ground. Press the HEAT switch when testing the heat control circuit and the COOL switch when testing the cool control circuit. The test lamp should illuminate or slowly illuminate for approximately 2 - 4 seconds after the switch is pressed. On the heat control circuit, the test lamp may exhibit a 4 second delay before it starts to illuminate. * Seat cushion heat control circuit terminal 1 * Seat cushion cool control circuit terminal 3 ‹› If the test lamp does not illuminate, test the appropriate control circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the CCSM. ‹› If the test lamp is always ON, test the appropriate control circuit for a short to voltage. If the circuit tests normal, replace the CCSM. Note: The ignition must be cycled OFF then ON between each test in order to reset the CCSM. 9. Ignition OFF then ON, connect a test lamp between the circuits listed below and ground. The test lamp should illuminate or slowly illuminate for approximately 5 seconds after pressing the HEAT switch. * Seat cushion blower control circuit terminal 2 * Seat cushion blower speed control circuit terminal 7 ‹› If the test lamp does not illuminate, test the appropriate circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the CCSM. ‹› If the test lamp is always ON, test the appropriate circuit for a short to voltage. If the circuit tests normal, replace the CCSM. 10. Ignition OFF, connect the harness connector to the seat cushion ventilation heating and cooling module. 11. Disconnect the harness connector at the seat back ventilation heating and cooling module. 12. Test for less than 5 Ohms between the low reference circuit terminal 4 and ground. ‹› If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the CCSM. 13. Ignition ON, test for 4.8 - 5.2 V between the signal circuit terminal 5 and ground. ‹› If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the CCSM. ‹› If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the CCSM. Note: The ignition must be cycled OFF then ON between each test in order to reset the CCSM. 14. Ignition OFF then ON, connect a test lamp between the control circuits listed below and ground. Press the HEAT switch when testing the heat control circuit and the COOL switch when testing the cool control circuit. The test lamp should illuminate or slowly illuminate for approximately 4 seconds after the switch is pressed. On the heat control circuit, the test lamp may exhibit a 4 second delay before it starts to illuminate. * Seat back heat control circuit terminal 1 * Seat back cool control circuit terminal 3 ‹› If the test lamp does not illuminate, test the appropriate control circuit for a short to ground or an open high resistance. If the circuit tests normal, replace the CCSM. ‹› If the test lamp is always ON, test the appropriate control circuit for a short to voltage. If the circuit tests normal, replace the CCSM. Note: The ignition must be cycled OFF then ON between each test in order to reset the CCSM. 15. Ignition OFF then ON, connect a test lamp between the circuits listed below and ground. The test lamp should illuminate or slowly illuminate for approximately 5 seconds after pressing the HEAT switch. * Seat back blower control circuit terminal 2 * Seat back blower speed control circuit terminal 7 ‹› If the test lamp does not illuminate, test the appropriate circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the CCSM. ‹› If the test lamp is always ON, test the appropriate circuit for a short to voltage. If the circuit tests normal, replace the CCSM. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Testing and Inspection > Symptoms - Seat Heating and Cooling > Page 16875 16. If all circuits test normal, test or replace the appropriate seat cushion or seat back ventilation heating and cooling module. Component Testing Heated and Cooled Seat Switch 1. Ignition OFF, disconnect the X4 harness connector at the appropriate door lock/window switch. 2. Test for infinite resistance between the low reference circuit terminal 4 and the signal terminals listed below the with the switch in the open position. * Seat back only mode switch terminal 7 * Seat back cushion heat switch terminal 6 * Seat cool switch terminal 3 ‹› If not the specified value, replace the heated and cooled seat switch. 3. Test for less than 2 Ohms between the low reference circuit terminal 4 and the signal terminals listed below with the appropriate switch in the closed position. * Seat back only mode switch terminal 7 * Seat back cushion heat switch terminal 6 * Seat cool switch terminal 3 ‹› If greater than the specified range, replace the heated and cooled seat switch. 4. Connect a 3 A fused jumper wire between the low reference circuit terminal 4 and ground. 5. Connect a test lamp between B+ and each control terminal listed below. The appropriate indicator should illuminate. * Seat back only mode indicator terminal 11 * Seat cool mode indicator terminal 12 * Seat back and cushion indicator terminal 10 * Low temperature indicator terminal 9 * Medium temperature indicator terminal 1 * High temperature indicator terminal 2 ‹› If any indicator does not illuminate, replace the heated and cooled seat switch. Ventilation Heat and Cool Module 1. Ignition OFF, disconnect the harness connectors at the seat cushion and seat back ventilation heat and cool modules. Note: If the resistance is measured with the seat still warm or cool, the resistance values will vary. At 68°F (20°C), the nominal resistance value is 1200 Ohms ±5 percent. For warmer or cooler ambient temperatures, refer to the Temperature vs Resistance table below. The delta resistance values between the seat cushion and seat back temperature sensors should not be greater than 2000 Ohms. 2. Test for 300 Ohms - 18 kOhms between the temperature sensor signal circuit terminal 5 and the low reference circuit terminal 8. ‹› If not within the specified range, replace the ventilation heat and cool module. Note: The test leads must be connected in the correct polarity, otherwise lower out of range values will appear. Use the Positive Lead for the COOL control circuit and the Negative Lead for the HEAT control circuit. If the resistance is measured with the seat still warm or cool, the resistance values will vary even if the system was powered up for just a few seconds. The TED must be allowed to stabilize to room temperature prior to a measurement. The conditions listed below will change the resistance to out of range values: * The test leads are incorrectly connected. * Air blowing across the TED * Measuring the resistance at other than room temperature of 70°F * Holding the TED portion of the heated and cool ventilation module in your hand In warmer or cooler climates where room temperature conditions of 70°F (21°C) may be unattainable, resistance values may read above the specified range. Use a heat gun or a blower to warm or cool the TED while measuring the resistance. The resistance values should slowly lower toward the specified range. 3. Test for 0.9 - 10 Ohms between the heat control circuit terminal 1 and the cool control circuit terminal 3. ‹› If not within the specified range, replace the ventilation heat and cool module. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Testing and Inspection > Symptoms - Seat Heating and Cooling > Page 16876 Note: The test leads must be connected in the correct polarity, otherwise higher out of range values will appear. Use the Positive Lead for the control circuit and the Negative Lead for the ground circuit. 4. Test for 6 k - 9 kOhms between blower motor control circuit terminal 2 and the low reference circuit terminal 4. ‹› If not within the specified range, replace the ventilation heat and cool module. Note: The test leads need to be connected in the correct polarity, otherwise higher out of range values will appear. Use the Positive Lead for the speed control circuit and the Negative Lead for the ground circuit. 5. Test for 290 k - 420 kOhms between blower motor speed control circuit terminal 7 and the low reference circuit terminal 4. ‹› If not within the specified range, replace the ventilation heat and cool module. Repair Instructions Perform the Diagnostic Repair Verification (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. * Driver or Passenger Seat Back Ventilation Heating and Cooling Blower Replacement (Denali with KB6) (See: Service and Repair/Driver or Passenger Seat Back Ventilation Heating and Cooling Blower Replacement (Denali with KB6)) * Driver or Passenger Seat Cushion Ventilation Heating and Cooling Blower Replacement (Denali with KB6) (See: Service and Repair/Driver or Passenger Seat Cushion Ventilation Heating and Cooling Blower Replacement (Denali with KB6)) * Control Module References (See: Testing and Inspection/Programming and Relearning) for the MSM, CCSM, and door lock/window switch replacement, setup, and programming Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Service and Repair > Driver or Passenger Seat Back Cushion Heater Replacement Seat Heater: Service and Repair Driver or Passenger Seat Back Cushion Heater Replacement Driver or Passenger Seat Back Cushion Heater Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Service and Repair > Driver or Passenger Seat Back Cushion Heater Replacement > Page 16879 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Service and Repair > Driver or Passenger Seat Back Cushion Heater Replacement > Page 16880 Seat Heater: Service and Repair Driver or Passenger Seat Cushion Heater Replacement Driver or Passenger Seat Cushion Heater Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Service and Repair > Driver or Passenger Seat Back Cushion Heater Replacement > Page 16881 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Service and Repair > Driver or Passenger Seat Back Cushion Heater Replacement > Page 16882 Seat Heater: Service and Repair Driver or Passenger Seat Back Ventilation Heating and Cooling Blower Replacement (Denali with KB6) Driver or Passenger Seat Back Ventilation Heating and Cooling Blower Replacement (Denali with KB6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Service and Repair > Driver or Passenger Seat Back Cushion Heater Replacement > Page 16883 Seat Heater: Service and Repair Driver or Passenger Seat Cushion Ventilation Heating and Cooling Blower Replacement (Denali with KB6) Driver or Passenger Seat Cushion Ventilation Heating and Cooling Blower Replacement (Denali with KB6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Service and Repair > Driver or Passenger Seat Back Cushion Heater Replacement > Page 16884 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Control Module: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm Seat Heater Control Module: All Technical Service Bulletins Seats - Driver/Passenger Heated Seats Inop./Slow to Warm TECHNICAL Bulletin No.: 10-08-50-008B Date: January 13, 2011 Subject: Driver or Passenger Heated Seat Inoperative, Slow to Warm, DTC(s) Set (Repair Connector, Re-Route Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Silverado, Suburban, Tahoe 2011 Chevrolet Silverado Heavy Duty 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2011 GMC Sierra Heavy Duty All Equipped with Heated Front Seat (RPO AN3, KA1) or Heated and Cooled Seat (RPO KB6) and/or Luxury Package (RPO PCK) Supercede: This bulletin is being revised to update the RPOs. Please discard Corporate Bulletin Number 10-08-50-008A (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger heated seat system exhibits the following symptoms: - Heated seat turns on and then turns off within 1 to 10 minutes (at any 60 second interval). - The system doesn't get warm enough, or gets warm very slowly. - The heated seat system is completely inoperative. Upon further review, DTCs B2430 0D and/or B2180 0D may be set as a current or history code if the vehicle is equipped with heated seats only (RPO KA1). Also, the LED indicator for the heated seats may come On and then flash after approximately 1 minute, then go out. If the vehicle is equipped with heated and cooled seats (KB6), the switch LED indicator may stay On, but the heated and cooled seat is inoperative. The fan will continue to blow air. Cause Heated Seats (RPO AN3, KA1) The heated seat control circuit terminal and/or ground terminal in harness connector X1 to the memory seat module (MSM) may have lost tension and is loose. The reduced terminal tension increases resistance in the connector, which may result in the symptoms described above. Heated and Cooled Seats (RPO KB6) The thermo-electric device (TED) in the seat cushion/seat back ventilation heating and cooling module may have become inoperative. Correction Heated Seats (RPO AN3, KA1) Follow the steps below to correct the concern with the heated seats. Note This repair requires a unique anti-abrasion electrical tape and harness clip from Kent Automotive. Refer to the Parts Information below. 1. Access and remove the seat bolts/nuts. 2. Adjust the seat rearward about halfway. Adjust the seat recline full forward. 3. Tilt the seat backward to access the bottom of the seat. Prop the seat up with a suitable tool if required. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Control Module: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 16893 4. Disconnect seat harness connectors (1) X1, X2, X3 and X4 from the MSM. 5. Identify connector X1. Refer to Component Connector End Views in SI. 6. Perform a terminal drag test on connector X1, paying special attention to terminals 1, 4, 6, 11 and 14. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Refer to Testing for Intermittent Conditions and Poor Connections in SI. 7. Replace any terminal in question including connector X1 terminals 1, 4, 6, 11 and 14 if necessary. Refer to Repairing Connector Terminals in SI. 8. Identify connector X4. Refer to Component Connector End Views in SI. 9. Perform the terminal drag test described in step 6, paying special attention to terminal 14. 10. Replace any terminal in question including connector X4 terminal 14 if necessary. Refer to Repairing Connector Terminals in SI. 11. Remove the harness clip (1) from the plastic carrier. 12. Cut the electrical tape holding the harness in the plastic carrier using a sharp utility knife in the area shown (1). 13. Free the harness from the carrier back to the area shown (1). 14. Obtain "*Woven Polyester (PET) Electrical Tape" (Special Order P/N RZ97156A00) from Kent Automotive. Refer to Parts Information below. Important Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Control Module: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 16894 DO NOT substitute with vinyl electrical tape or friction tape. Use only the tape specified above. 15. Tape the harness starting at the MSM connectors (1) extending back to the new break-out location (2) in the plastic carrier. 16. Install a plastic tie strap around the harness and the plastic carrier at the break-out point (1). 17. Install the new harness edge clip (1) 10 mm (0.4 in) further from the connectors and the existing harness clip. Ensure the clip is installed in the orientation shown. 18. Install the harness with the new harness clip in the location shown (1). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Control Module: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 16895 19. Reinstall the harness connectors (1) to the MSM. 20. Reinstall the seat to the vehicle. Heated and Cooled Seats (RPO KB6) Follow the steps below to correct the concern with the heated and cooled seats. 1. Inspect the ventilation heating and cooling module for a concern with the TED. Refer to Seat Heating and Cooling, Diagnostic Information and Procedures in SI. Note If the heated and cooled seat function is inoperative, but the heat switch indicators are On, the MSM is functioning properly and the concern is with the TED. 2. If the TED is found to be the concern, replace the seat cushion or seat back ventilation heating and cooling module. Refer to Driver or Passenger Seat Back Ventilation Heating and Cooling Blower Replacement or Driver or Passenger Seat Cushion Ventilation Heating and Cooling Blower Replacement in SI. If the TED is not the concern, follow normal diagnostics and repair in SI. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Use the appropriate Labor Operation based on the repair completed. Heated Seats (RPO AN3, KA1) For vehicles repaired under warranty, use: Heated and Cooled Seats (RPO KB6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Heater Control Module: > 10-08-50-008B > Jan > 11 > Seats - Driver/Passenger Heated Seats Inop./Slow to Warm > Page 16896 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 10-08-50-008B > Jan > 11 > Seats Driver/Passenger Heated Seats Inop./Slow to Warm Seat Heater Control Module: Customer Interest Seats - Driver/Passenger Heated Seats Inop./Slow to Warm TECHNICAL Bulletin No.: 10-08-50-008B Date: January 13, 2011 Subject: Driver or Passenger Heated Seat Inoperative, Slow to Warm, DTC(s) Set (Repair Connector, Re-Route Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Silverado, Suburban, Tahoe 2011 Chevrolet Silverado Heavy Duty 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2011 GMC Sierra Heavy Duty All Equipped with Heated Front Seat (RPO AN3, KA1) or Heated and Cooled Seat (RPO KB6) and/or Luxury Package (RPO PCK) Supercede: This bulletin is being revised to update the RPOs. Please discard Corporate Bulletin Number 10-08-50-008A (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger heated seat system exhibits the following symptoms: - Heated seat turns on and then turns off within 1 to 10 minutes (at any 60 second interval). - The system doesn't get warm enough, or gets warm very slowly. - The heated seat system is completely inoperative. Upon further review, DTCs B2430 0D and/or B2180 0D may be set as a current or history code if the vehicle is equipped with heated seats only (RPO KA1). Also, the LED indicator for the heated seats may come On and then flash after approximately 1 minute, then go out. If the vehicle is equipped with heated and cooled seats (KB6), the switch LED indicator may stay On, but the heated and cooled seat is inoperative. The fan will continue to blow air. Cause Heated Seats (RPO AN3, KA1) The heated seat control circuit terminal and/or ground terminal in harness connector X1 to the memory seat module (MSM) may have lost tension and is loose. The reduced terminal tension increases resistance in the connector, which may result in the symptoms described above. Heated and Cooled Seats (RPO KB6) The thermo-electric device (TED) in the seat cushion/seat back ventilation heating and cooling module may have become inoperative. Correction Heated Seats (RPO AN3, KA1) Follow the steps below to correct the concern with the heated seats. Note This repair requires a unique anti-abrasion electrical tape and harness clip from Kent Automotive. Refer to the Parts Information below. 1. Access and remove the seat bolts/nuts. 2. Adjust the seat rearward about halfway. Adjust the seat recline full forward. 3. Tilt the seat backward to access the bottom of the seat. Prop the seat up with a suitable tool if required. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 10-08-50-008B > Jan > 11 > Seats Driver/Passenger Heated Seats Inop./Slow to Warm > Page 16902 4. Disconnect seat harness connectors (1) X1, X2, X3 and X4 from the MSM. 5. Identify connector X1. Refer to Component Connector End Views in SI. 6. Perform a terminal drag test on connector X1, paying special attention to terminals 1, 4, 6, 11 and 14. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Refer to Testing for Intermittent Conditions and Poor Connections in SI. 7. Replace any terminal in question including connector X1 terminals 1, 4, 6, 11 and 14 if necessary. Refer to Repairing Connector Terminals in SI. 8. Identify connector X4. Refer to Component Connector End Views in SI. 9. Perform the terminal drag test described in step 6, paying special attention to terminal 14. 10. Replace any terminal in question including connector X4 terminal 14 if necessary. Refer to Repairing Connector Terminals in SI. 11. Remove the harness clip (1) from the plastic carrier. 12. Cut the electrical tape holding the harness in the plastic carrier using a sharp utility knife in the area shown (1). 13. Free the harness from the carrier back to the area shown (1). 14. Obtain "*Woven Polyester (PET) Electrical Tape" (Special Order P/N RZ97156A00) from Kent Automotive. Refer to Parts Information below. Important Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 10-08-50-008B > Jan > 11 > Seats Driver/Passenger Heated Seats Inop./Slow to Warm > Page 16903 DO NOT substitute with vinyl electrical tape or friction tape. Use only the tape specified above. 15. Tape the harness starting at the MSM connectors (1) extending back to the new break-out location (2) in the plastic carrier. 16. Install a plastic tie strap around the harness and the plastic carrier at the break-out point (1). 17. Install the new harness edge clip (1) 10 mm (0.4 in) further from the connectors and the existing harness clip. Ensure the clip is installed in the orientation shown. 18. Install the harness with the new harness clip in the location shown (1). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 10-08-50-008B > Jan > 11 > Seats Driver/Passenger Heated Seats Inop./Slow to Warm > Page 16904 19. Reinstall the harness connectors (1) to the MSM. 20. Reinstall the seat to the vehicle. Heated and Cooled Seats (RPO KB6) Follow the steps below to correct the concern with the heated and cooled seats. 1. Inspect the ventilation heating and cooling module for a concern with the TED. Refer to Seat Heating and Cooling, Diagnostic Information and Procedures in SI. Note If the heated and cooled seat function is inoperative, but the heat switch indicators are On, the MSM is functioning properly and the concern is with the TED. 2. If the TED is found to be the concern, replace the seat cushion or seat back ventilation heating and cooling module. Refer to Driver or Passenger Seat Back Ventilation Heating and Cooling Blower Replacement or Driver or Passenger Seat Cushion Ventilation Heating and Cooling Blower Replacement in SI. If the TED is not the concern, follow normal diagnostics and repair in SI. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Use the appropriate Labor Operation based on the repair completed. Heated Seats (RPO AN3, KA1) For vehicles repaired under warranty, use: Heated and Cooled Seats (RPO KB6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical Service Bulletins > Customer Interest for Seat Heater Control Module: > 10-08-50-008B > Jan > 11 > Seats Driver/Passenger Heated Seats Inop./Slow to Warm > Page 16905 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 16906 Seat Heater Control Module: Diagrams Component Connector End Views Seat Back Ventilation Heating and Cooling Module - Driver (KB6) Seat Back Ventilation Heating and Cooling Module - Passenger (KB6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 16907 Seat Climate Control Module X1 (KB6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 16908 Seat Climate Control Module X2 (KB6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 16909 Seat Climate Control Module X3 (KB6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 16910 Seat Cushion Ventilation Heating and Cooling Module - Driver (KB6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 16911 Seat Cushion Ventilation Heating and Cooling Module - Passenger (KB6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 16912 Heated Seat Control Module X1 (SPO Heated Seats) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 16913 Heated Seat Control Module X2 (SPO Heated Seats) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 16914 Heated Seat Control Module X3 (SPO Heated Seats) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 16915 Heated Seat Control Module X4 (SPO Heated Seats) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Technical Service Bulletins > Page 16916 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Service and Repair > Front Seat Heater Control Module Seat Heater Control Module: Service and Repair Front Seat Heater Control Module Front Seat Heater Control Module Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Service and Repair > Front Seat Heater Control Module > Page 16919 Seat Heater Control Module: Service and Repair Module Replacement - Seat Climate Control Front Seat (Denali with KB6) Module Replacement - Seat Climate Control - Front Seat (Denali with KB6) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Diagrams Seat Heater Switch: Diagrams Component Connector End Views Heated Seat Switch - Driver (SPO Heated Seats) Heated Seat Switch - Passenger (SPO Heated Seats) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Diagrams > Page 16923 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair > Front Seat Heater Switch Replacement Seat Heater Switch: Service and Repair Front Seat Heater Switch Replacement Front Seat Heater Switch Replacement Removal Procedure 1. Remove door upper trim panel. Refer to Upper Extension Trim Panel Replacement (See: Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair). 2. Pull the door trim panel away from the door and support the bottom of the trim panel on the door panel hooks. Refer to Front Side Door Trim Panel Replacement (SLT, A95) (See: Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair)Front Side Door Trim Panel Replacement (Except YE9 or SLT) (See: Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair). 3. Disconnect the electrical connector. 4. Remove the front side door heater switch fasteners (1). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair > Front Seat Heater Switch Replacement > Page 16926 5. Remove the front side door heater switch assembly (2). Installation Procedure 1. Install the front side door heater switch assembly (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the front side door heater switch fasteners and tighten to 2 Nm (18 lb in). 3. Connect the electrical connector. 4. Install the door trim panel. Refer to Front Side Door Trim Panel Replacement (SLT, A95) (See: Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair)Front Side Door Trim Panel Replacement (Except YE9 or SLT) (See: Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Service and Repair > Rear Seat Latch Replacement (Extended Cab with AM7) Seat Latch: Service and Repair Rear Seat Latch Replacement (Extended Cab with AM7) Rear Seat Latch Replacement (Extended Cab with AM7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Service and Repair > Rear Seat Latch Replacement (Extended Cab with AM7) > Page 16931 Seat Latch: Service and Repair Rear Seat Latch Replacement (Extended Cab with A68) Rear Seat Latch Replacement (Extended Cab with A68) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Service and Repair > Rear Seat Latch Replacement (Extended Cab with AM7) > Page 16932 Seat Latch: Service and Repair Rear Seat Latch Replacement (Crew Cab with A68) Rear Seat Latch Replacement (Crew Cab with A68) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Service and Repair > Rear Seat Latch Replacement (Extended Cab with AM7) > Page 16933 Seat Latch: Service and Repair Front Seat Center Latch Side Belt Replacement Front Seat Center Latch Side Belt Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Service and Repair > Rear Seat Latch Replacement (Extended Cab with AM7) > Page 16934 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Diagrams Hood Sensor/Switch (For Alarm): Diagrams Component Connector End Views Hood Ajar Switch (AP3, AP8 or PTO) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Pedal Positioning Sensor > Component Information > Service and Repair Pedal Positioning Sensor: Service and Repair Brake and Accelerator Pedal Adjuster Position Sensor Replacement (With Memory Seats) Removal Procedure 1. Turn the ignition switch to the OFF position. 2. Remove the driver knee bolster. Refer to Knee Bolster Replacement (With SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (With SLT))Knee Bolster Replacement (Without SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (Without SLT)). 3. Disconnect the adjustable pedal position sensor jumper harness electrical connector (1). 4. Remove the adjustable pedal position sensor bolts (1). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Pedal Positioning Sensor > Component Information > Service and Repair > Page 16943 5. Remove the brake and accelerator pedal adjuster position sensor (1). Installation Procedure 1. Install the brake and accelerator pedal adjuster position sensor (1). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Pedal Positioning Sensor > Component Information > Service and Repair > Page 16944 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the adjustable pedal position sensor bolts (1) and tighten to 2 Nm (18 lb in). 3. Connect the adjustable pedal position sensor jumper harness electrical connector (1). 4. Install the driver knee bolster. Refer to Knee Bolster Replacement (With SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (With SLT))Knee Bolster Replacement (Without SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (Without SLT)). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams Power Door Lock Switch: Diagrams Component Connector End Views Door Lock Switch - Driver (AU3 without AN3 or DL3) Door Lock Switch - Passenger (AU3 without AN3 or DL3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 16948 Door Lock/Window Switch - Driver X1 (AN3 or DL3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 16949 Door Lock/Window Switch - Driver X2 (AN3 or DL3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 16950 Door Lock/Window Switch - Driver X3 (AN3 or DL3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 16951 Door Lock/Window Switch - Driver X4 (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 16952 Door Lock/Window Switch - Driver X7 (AN3 or DL3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 16953 Door Lock/Window Switch - Passenger X1 (AN3 or DL3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 16954 Door Lock/Window Switch - Passenger X2 (AN3 or DL3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 16955 Door Lock/Window Switch - Passenger X3 (AN3 or DL3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 16956 Door Lock/Window Switch - Passenger X4 (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 16957 Door Lock/Window Switch - Passenger X7 (AN3 or DL3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 16958 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Door Lock Switch Replacement - Front (with DL8 and without SLT) Power Door Lock Switch: Service and Repair Door Lock Switch Replacement - Front (with DL8 and without SLT) Door Lock Switch Replacement - Front (with DL8 and without SLT) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Door Lock Switch Replacement - Front (with DL8 and without SLT) > Page 16961 Power Door Lock Switch: Service and Repair Door Lock and Side Window Switch Replacement Driver Side Door Lock and Side Window Switch Replacement - Driver Side Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Door Lock Switch Replacement - Front (with DL8 and without SLT) > Page 16962 Power Door Lock Switch: Service and Repair Door Lock and Side Window Switch Replacement Passenger Side Door Lock and Side Window Switch Replacement - Passenger Side Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Position Switch/Sensor > Component Information > Technical Service Bulletins > Customer Interest for Power Mirror Position Switch/Sensor: > 06-08-64-027I > Apr > 11 > Body - LH/RH Outside Rearview Mirror Glass Shake/Flutter Power Mirror Position Switch/Sensor: Customer Interest Body - LH/RH Outside Rearview Mirror Glass Shake/Flutter TECHNICAL Bulletin No.: 06-08-64-027I Date: April 12, 2011 Subject: Left or Right Outside Rearview Mirror Glass Shake or Flutter (Relearn Power Mirrors and Replace Mirror, If Necessary) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon XL, Yukon Denali All Equipped with Power Folding Mirrors RPO DL3 Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 06-08-64-027H (Section 08 - Body and Accessories). Condition Some customers may comment that the left or right outside rearview mirror glass shakes or flutters at normal driving speeds. Cause - The mirror may have been accidentally pushed in manually or obstructed while folding. - The mirror actuator screws may be loose, allowing the mirror to move. - The metal spring may not have enough tension to hold the mirror from moving. Correction Follow the procedure below to correct this condition. 1. The power folding mirrors should be cycled three complete times to relearn the mirror positions. Then perform a road test and check the mirror glass for stability. If stability is not corrected, proceed to Step 2. 2. Remove the mirror glass. Refer to Mirror Face Replacement in SI. 3. Verify the torque on the four retaining screws on the actuator. Tighten Tighten the screws to 1.13-1.6 Nm (10-14 lb in). 4. Bend the metal spring up to increase the tension engagement to the mirror housing 13 mm (1/2 in). 5. Install the glass assembly by pressing firmly, taking care not to allow the spring finger to unseat from its intended track in the mirror housing. Road test the vehicle. If stability is not improved, replace the mirror assembly. Refer to Power Mirror Replacement in SI. Parts Information If replacing the mirror assembly, see Mirror in Group 16.068 of the appropriate Parts Catalog for part numbers and usage. Warranty Information Important Only one Labor Operation should be claimed depending on the actual repair. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Position Switch/Sensor > Component Information > Technical Service Bulletins > Customer Interest for Power Mirror Position Switch/Sensor: > 06-08-64-027I > Apr > 11 > Body - LH/RH Outside Rearview Mirror Glass Shake/Flutter > Page 16971 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Position Switch/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Mirror Position Switch/Sensor: > 06-08-64-027I > Apr > 11 > Body - LH/RH Outside Rearview Mirror Glass Shake/Flutter Power Mirror Position Switch/Sensor: All Technical Service Bulletins Body - LH/RH Outside Rearview Mirror Glass Shake/Flutter TECHNICAL Bulletin No.: 06-08-64-027I Date: April 12, 2011 Subject: Left or Right Outside Rearview Mirror Glass Shake or Flutter (Relearn Power Mirrors and Replace Mirror, If Necessary) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon XL, Yukon Denali All Equipped with Power Folding Mirrors RPO DL3 Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 06-08-64-027H (Section 08 - Body and Accessories). Condition Some customers may comment that the left or right outside rearview mirror glass shakes or flutters at normal driving speeds. Cause - The mirror may have been accidentally pushed in manually or obstructed while folding. - The mirror actuator screws may be loose, allowing the mirror to move. - The metal spring may not have enough tension to hold the mirror from moving. Correction Follow the procedure below to correct this condition. 1. The power folding mirrors should be cycled three complete times to relearn the mirror positions. Then perform a road test and check the mirror glass for stability. If stability is not corrected, proceed to Step 2. 2. Remove the mirror glass. Refer to Mirror Face Replacement in SI. 3. Verify the torque on the four retaining screws on the actuator. Tighten Tighten the screws to 1.13-1.6 Nm (10-14 lb in). 4. Bend the metal spring up to increase the tension engagement to the mirror housing 13 mm (1/2 in). 5. Install the glass assembly by pressing firmly, taking care not to allow the spring finger to unseat from its intended track in the mirror housing. Road test the vehicle. If stability is not improved, replace the mirror assembly. Refer to Power Mirror Replacement in SI. Parts Information If replacing the mirror assembly, see Mirror in Group 16.068 of the appropriate Parts Catalog for part numbers and usage. Warranty Information Important Only one Labor Operation should be claimed depending on the actual repair. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Position Switch/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Mirror Position Switch/Sensor: > 06-08-64-027I > Apr > 11 > Body - LH/RH Outside Rearview Mirror Glass Shake/Flutter > Page 16977 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Diagrams Power Mirror Switch: Diagrams Component Connector End Views Outside Rearview Mirror Switch (DL8 or DPN) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Diagrams > Page 16981 Power Mirror Switch: Service and Repair Power Mirror Switch Replacement (with DL8 and without SLT) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Locations Power Seat Motor Position Sensor: Locations Harness Routing Views Driver Seat Harness Routing 1 - Seat Recline Motor - Driver (AN3) 2 - Seat Lumbar Vertical Motor Position Sensor - Driver (AN3) 3 - Seat Lumbar Vertical Motor - Driver (AN3) 4 - X324 (AN3) 5 - Seat Lumbar Horizontal Motor - Driver (AN3) 6 - Seat Lumbar Horizontal Motor Position Sensor - Driver (AN3) 7 - Seat Recline Position Sensor - Driver (AN3) 8 - Seat Lumbar Switch - Driver (AN3) 9 - Seat Adjuster Switch - Driver (AG1) 10 - Memory Seat Module (MSM) (AN3) 11 - Inflatable Restraint Seat Position Sensor (SPS) - Driver (10 Series) 12 - Seat Adjuster Motor Assembly - Driver (AG1) 13 Seat Belt Buckle - Driver Passenger Seat Harness Routing Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Locations > Page 16985 1 - Seat Frame 2 - X325 (AN3) 3 - Seat Lumbar Vertical Motor - Passenger (AN3) 4 - Seat Adjuster Switch - Passenger (AG2) 5 - Seat Lumbar Switch - Passenger (AN3) 6 - Seat Belt Buckle Passenger 7 - Inflatable Restraint Passenger Presence System (PPS) Module (AL0) 8 - Seat Adjuster Motor Assembly - Passenger (AG2) 9 - Inflatable Restraint Passenger Presence System (PPS) Sensor (AL0) 10 - Seat Recline Motor - Passenger (AN3) 11 - Seat Lumbar Horizontal Motor - Passenger (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Locations > Page 16986 Power Seat Motor Position Sensor: Diagrams Component Connector End Views Seat Lumbar Horizontal Motor Position Sensor - Driver (AN3) Seat Lumbar Vertical Motor Position Sensor - Driver (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Locations > Page 16987 Seat Recline Position Sensor - Driver (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Locations > Page 16988 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Customer Interest for Power Seat Switch: > 09-08-50-011A > Apr > 11 > Body - Sticking/Binding Door Mounted Seat Switches Power Seat Switch: Customer Interest Body - Sticking/Binding Door Mounted Seat Switches TECHNICAL Bulletin No.: 09-08-50-011A Date: April 13, 2011 Subject: Sticking/Binding Door Mounted Seat Switches (Align Switch) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon XL Denali All Equipped with RPOs AN3, KA1, KB6 Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 09-08-50-011 (Section 08 - Body and Accessories). Condition Some customers may comment that the door mounted memory/ heated/ cool seat switch buttons are sticking or binding. Cause This condition may be caused by the switch being out of alignment in the bezel, creating a hard contact between the switch button and the inside release handle bezel. Correction 1. Remove the door trim. Refer to Front Side Door Trim Panel Replacement in SI. 2. Loosen both screws (1) holding the switch to the inside release handle bezel. 3. Using a flat-bladed tool (1), carefully shift the position of the switch to create a nominal gap all around its perimeter within the bezel. Tighten the two screws holding the switch. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Customer Interest for Power Seat Switch: > 09-08-50-011A > Apr > 11 > Body - Sticking/Binding Door Mounted Seat Switches > Page 16997 4. Confirm that the switch buttons are free moving, and there is a nominal gap (1) all around its perimeter within the bezel. 5. Reinstall the door trim. Refer to Front Side Door Trim Panel Replacement in SI. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Seat Switch: > 09-08-50-011A > Apr > 11 > Body - Sticking/Binding Door Mounted Seat Switches Power Seat Switch: All Technical Service Bulletins Body - Sticking/Binding Door Mounted Seat Switches TECHNICAL Bulletin No.: 09-08-50-011A Date: April 13, 2011 Subject: Sticking/Binding Door Mounted Seat Switches (Align Switch) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon XL Denali All Equipped with RPOs AN3, KA1, KB6 Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 09-08-50-011 (Section 08 - Body and Accessories). Condition Some customers may comment that the door mounted memory/ heated/ cool seat switch buttons are sticking or binding. Cause This condition may be caused by the switch being out of alignment in the bezel, creating a hard contact between the switch button and the inside release handle bezel. Correction 1. Remove the door trim. Refer to Front Side Door Trim Panel Replacement in SI. 2. Loosen both screws (1) holding the switch to the inside release handle bezel. 3. Using a flat-bladed tool (1), carefully shift the position of the switch to create a nominal gap all around its perimeter within the bezel. Tighten the two screws holding the switch. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Seat Switch: > 09-08-50-011A > Apr > 11 > Body - Sticking/Binding Door Mounted Seat Switches > Page 17003 4. Confirm that the switch buttons are free moving, and there is a nominal gap (1) all around its perimeter within the bezel. 5. Reinstall the door trim. Refer to Front Side Door Trim Panel Replacement in SI. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Page 17004 Power Seat Switch: Locations Harness Routing Views Driver Seat Harness Routing 1 - Seat Recline Motor - Driver (AN3) 2 - Seat Lumbar Vertical Motor Position Sensor - Driver (AN3) 3 - Seat Lumbar Vertical Motor - Driver (AN3) 4 - X324 (AN3) 5 - Seat Lumbar Horizontal Motor - Driver (AN3) 6 - Seat Lumbar Horizontal Motor Position Sensor - Driver (AN3) 7 - Seat Recline Position Sensor - Driver (AN3) 8 - Seat Lumbar Switch - Driver (AN3) 9 - Seat Adjuster Switch - Driver (AG1) 10 - Memory Seat Module (MSM) (AN3) 11 - Inflatable Restraint Seat Position Sensor (SPS) - Driver (10 Series) 12 - Seat Adjuster Motor Assembly - Driver (AG1) 13 Seat Belt Buckle - Driver Passenger Seat Harness Routing Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Page 17005 1 - Seat Frame 2 - X325 (AN3) 3 - Seat Lumbar Vertical Motor - Passenger (AN3) 4 - Seat Adjuster Switch - Passenger (AG2) 5 - Seat Lumbar Switch - Passenger (AN3) 6 - Seat Belt Buckle Passenger 7 - Inflatable Restraint Passenger Presence System (PPS) Module (AL0) 8 - Seat Adjuster Motor Assembly - Passenger (AG2) 9 - Inflatable Restraint Passenger Presence System (PPS) Sensor (AL0) 10 - Seat Recline Motor - Passenger (AN3) 11 - Seat Lumbar Horizontal Motor - Passenger (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Page 17006 Power Seat Switch: Diagrams Component Connector End Views Seat Adjuster Switch - Driver (AG1 without AN3) Seat Adjuster Switch - Driver (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Page 17007 Seat Adjuster Switch - Passenger (AG2 without AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Page 17008 Seat Adjuster Switch - Passenger (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Page 17009 Seat Lumbar Switch - Driver (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Technical Service Bulletins > Page 17010 Seat Lumbar Switch - Passenger (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Driver or Passenger Seat Adjuster Switch Knob Replacement Power Seat Switch: Service and Repair Driver or Passenger Seat Adjuster Switch Knob Replacement Driver or Passenger Seat Adjuster Switch Knob Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Driver or Passenger Seat Adjuster Switch Knob Replacement > Page 17013 Power Seat Switch: Service and Repair Power Seat Switch Replacement Power Seat Switch Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Driver or Passenger Seat Adjuster Switch Knob Replacement > Page 17014 Power Seat Switch: Service and Repair Lumbar Switch Replacement Lumbar Switch Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Diagrams Seat Heater Switch: Diagrams Component Connector End Views Heated Seat Switch - Driver (SPO Heated Seats) Heated Seat Switch - Passenger (SPO Heated Seats) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Diagrams > Page 17018 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Front Seat Heater Switch Replacement Seat Heater Switch: Service and Repair Front Seat Heater Switch Replacement Front Seat Heater Switch Replacement Removal Procedure 1. Remove door upper trim panel. Refer to Upper Extension Trim Panel Replacement (See: Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair). 2. Pull the door trim panel away from the door and support the bottom of the trim panel on the door panel hooks. Refer to Front Side Door Trim Panel Replacement (SLT, A95) (See: Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair)Front Side Door Trim Panel Replacement (Except YE9 or SLT) (See: Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair). 3. Disconnect the electrical connector. 4. Remove the front side door heater switch fasteners (1). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Front Seat Heater Switch Replacement > Page 17021 5. Remove the front side door heater switch assembly (2). Installation Procedure 1. Install the front side door heater switch assembly (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the front side door heater switch fasteners and tighten to 2 Nm (18 lb in). 3. Connect the electrical connector. 4. Install the door trim panel. Refer to Front Side Door Trim Panel Replacement (SLT, A95) (See: Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair)Front Side Door Trim Panel Replacement (Except YE9 or SLT) (See: Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Locations Seat Memory Switch: Locations Harness Routing Views Driver Seat Harness Routing 1 - Seat Recline Motor - Driver (AN3) 2 - Seat Lumbar Vertical Motor Position Sensor - Driver (AN3) 3 - Seat Lumbar Vertical Motor - Driver (AN3) 4 - X324 (AN3) 5 - Seat Lumbar Horizontal Motor - Driver (AN3) 6 - Seat Lumbar Horizontal Motor Position Sensor - Driver (AN3) 7 - Seat Recline Position Sensor - Driver (AN3) 8 - Seat Lumbar Switch - Driver (AN3) 9 - Seat Adjuster Switch - Driver (AG1) 10 - Memory Seat Module (MSM) (AN3) 11 - Inflatable Restraint Seat Position Sensor (SPS) - Driver (10 Series) 12 - Seat Adjuster Motor Assembly - Driver (AG1) 13 Seat Belt Buckle - Driver Passenger Seat Harness Routing Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Locations > Page 17025 1 - Seat Frame 2 - X325 (AN3) 3 - Seat Lumbar Vertical Motor - Passenger (AN3) 4 - Seat Adjuster Switch - Passenger (AG2) 5 - Seat Lumbar Switch - Passenger (AN3) 6 - Seat Belt Buckle Passenger 7 - Inflatable Restraint Passenger Presence System (PPS) Module (AL0) 8 - Seat Adjuster Motor Assembly - Passenger (AG2) 9 - Inflatable Restraint Passenger Presence System (PPS) Sensor (AL0) 10 - Seat Recline Motor - Passenger (AN3) 11 - Seat Lumbar Horizontal Motor - Passenger (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Locations > Page 17026 Seat Memory Switch: Service and Repair Driver Seat Adjuster Memory Switch Replacement (Crew Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams Sunroof / Moonroof Switch: Diagrams Component Connector End Views Sunroof Switch (CF5) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Page 17030 Sunroof / Moonroof Switch: Service and Repair Sunroof Switch Replacement (Crew Cab) Removal Procedure 1. Remove the overhead console in order to access the sunroof switch. Refer to Roof Console Replacement (See: Interior Moulding / Trim/Console/Service and Repair/Roof Console Replacement). 2. Disconnect the electrical connector from the sunroof switch. 3. With a flat-bladed tool, carefully release the tabs that retain the sunroof switch to the overhead console. 4. Remove the sunroof switch from the overhead console. Installation Procedure 1. Position the sunroof switch alignment tabs to the slots in the console. 2. Install the sunroof switch into the console, ensuring that the retaining tabs are fully seated. 3. Connect the electrical connector to the sunroof switch. 4. Install the overhead console to the roof. Refer to Roof Console Replacement (See: Interior Moulding / Trim/Console/Service and Repair/Roof Console Replacement). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Technical Service Bulletins > Customer Interest for Sound Proofing / Insulation: > 10-08-58-001E > Mar > 11 > Interior - Excessive Wind Noise In Interior Of Vehicle Sound Proofing / Insulation: Customer Interest Interior - Excessive Wind Noise In Interior Of Vehicle TECHNICAL Bulletin No.: 10-08-58-001E Date: March 08, 2011 Subject: Excessive Wind Noise Coming from Rear Interior of Vehicle (Perform Repair as Outlined) Models: 2007-2011 Chevrolet Silverado Crew Cab and Extended Cab 2007-2011 GMC Sierra Crew Cab and Extended Cab Supercede: This bulletin is being revised to update the repair in the Customer Enthusiasm section and update the Parts Information. Please discard Corporate Bulletin Number 10-08-58-001D (Section 08 - Body and Accessories). Condition Some customers may comment on hearing excessive wind noise coming from the rear interior of the vehicle. Cause #1 This condition may be caused by a void in the body filler within the C-pillar. Cause #2 This condition may be caused by the body rear panel acoustic insulator that is mounted behind the rear seat. There is an access flap (1) in this panel that could cause excessive noise if the flap is not fully seated/closed into the rest of the insulator material. Also, starting in 2010, a new insulator was installed that may allow higher wind/road or other acoustic noise that may be objectionable for some customers. Noise penetration into the cab can be higher than a similarly equipped 2009, or earlier, model. As shown in the graphic above, note that the service part insulator (1) is noticeably thicker than the original 2010 part (2). Correction #1 Note This repair is specific to 2007-2010 model years. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Technical Service Bulletins > Customer Interest for Sound Proofing / Insulation: > 10-08-58-001E > Mar > 11 > Interior - Excessive Wind Noise In Interior Of Vehicle > Page 17039 Important Prior to attempting a repair of the vehicle, it will be necessary to compare it to a like vehicle in similar operating characteristics to determine if it should be considered normal operation or a repairable condition. 1. To properly diagnose the C-pillar body filler issue, complete the following steps: 1. Close the all doors and windows of the vehicle. 2. Without starting the vehicle, turn the vehicle ignition to the ON/RUN position. 3. Press the HVAC selector switch for Outside Air. 4. Turn the HVAC Fan Control to Medium/High. Note The air flow that is felt most commonly exits the lower C-pillar opening shown in the graphic above. 5. Run your hand alongside the lower seam of the body at the base of the C-pillar and feel for air flowing out of the bottom of the body. 6. Compare the air flow on the opposite side of the vehicle. If one side exhibits a distinct higher amount of air flow, continue on to the next step in this procedure to start the process of adding sealer to the C-pillar on that side. If no air flow difference is found, skip ahead to Correction #2. 2. To access the inner C-pillar, remove the rear seat and the body lock pillar trim panel. Refer to Body Lock Pillar Trim Replacement (Crew Cab) or Body Lock Pillar Trim Replacement (Extended Cab) in SI. Figure 1 - Outside View Through C-pillar Figure 2 - Top View, Section Cut Through C-pillar 3. Inspect the inner baffle/foam within the C-pillar for any voids in the body filler. The examples above show an opening (1) in the baffle at the forward, inboard corner of the right side C-pillar. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Technical Service Bulletins > Customer Interest for Sound Proofing / Insulation: > 10-08-58-001E > Mar > 11 > Interior - Excessive Wind Noise In Interior Of Vehicle > Page 17040 4. If a void is found (1), fill it with seam sealer Kent Automotive High-Tech(TM) Clear Sealer, P/N P10200 (5 oz. tube), or equivalent, to eliminate the air flow escape concern. 5. Before reinstalling the trim, inspect the insulator mat that is mounted on the body rear inner panel to ensure the access flap is fully seated/closed as shown above. 6. Reinstall the trim panels and rear seat. Refer to Body Lock Pillar Trim Replacement (Crew Cab) or Body Lock Pillar Trim Replacement (Extended Cab) in SI. Correction #2 Note This repair is ONLY for 2010 models that have the original body rear panel insulator (pictured above) and exhibit a higher noise penetration into the cab, when compared to a similarly equipped 2009, or earlier, model. Note that the insulator shape is flat across the bottom edge. Tip Before any repairs, you can visually verify which insulator the vehicle has by looking under the rear seat on the right or left side. If you can see the body Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Technical Service Bulletins > Customer Interest for Sound Proofing / Insulation: > 10-08-58-001E > Mar > 11 > Interior - Excessive Wind Noise In Interior Of Vehicle > Page 17041 color of the rear inner panel (shown circled above) below the insulator (1), the insulator is the original design, which is trimmed straight across the bottom. Order a service body rear panel insulator (pictured above), referencing the parts table below. Note that the new insulator has an increased thickness and the height was extended on both ends. R & R the rear seat and any necessary trim to replace the body rear panel insulator. Refer to Body Rear Panel Insulator Replacement (Extended Cab/Crew Cab) in SI. Further Repair for Customer Enthusiasm Only in situations when the above repairs are completed and the customer is still commenting on objectionable noise, the following additional steps can be done to sound-proof the body rear panel. This additional sound-proofing should only be done in cases deemed necessary for customer enthusiasm. Note After this procedure has been performed, the vehicle needs to be re-assembled and evaluated with the trim and rear seat fully installed in the vehicle. If the bulletin has been followed properly, the noise should be reduced to a level quieter than stock 2011 models, and no further repairs should be attempted. It has been found that controlling the wind noise at the two pressure relief valve (PRV) locations is the key to quieting the rear cab wind noise. The repair below has been found to be successful in eliminating most of the objectionable noise. 1. R & R the rear seat and any necessary trim to remove the body rear panel insulator. Refer to Body Rear Panel Insulator Replacement (Extended Cab/Crew Cab) in SI. Note GM P/N 12378195 is not available in Canada. However several equivalents such as *Evercoat (Q-Pads) P/N 100116 and *Dominion Sure Seal (Sound Deadener Pads) BSDE Part 110900 are available through NAPA Auto Parts retailers. Information for finding your local retail location can be obtained online at www.napacanada.com. 2. Install noise and vibration sound deadening pads to backside of the body rear panel insulator. Follow the pattern shown above, ensuring they cover the two PRV locations. Use GM P/N 12378195, or equivalents commercially available through *Dynamat(R), Evercoat(R) or Dominion Sure Seal. Important Ensure that the foam tape pattern does not have any gaps in the corners and that it is securely pressed/attached to the inner rear body panel. 3. Install *Duck Brand Weatherstrip Seal (Self Adhesive Foam) P/N 1278750, or equivalent, to the inner body rear end panel following the patterns shown below: Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Technical Service Bulletins > Customer Interest for Sound Proofing / Insulation: > 10-08-58-001E > Mar > 11 > Interior - Excessive Wind Noise In Interior Of Vehicle > Page 17042 Note Ensure that the cross-car adhesive foam is positioned at a height just below the insulator push pin fastener locations so that once the fasteners are installed, the seal is compressed. - Across the inner rear body panel, matching the width of the insulator panel. - Downward from each end of the cross-car foam (left side (1) shown in the graphic above). The length should match the height of the insulator panel. - Partially around the two PRV's. Install the foam down the outboard side (1), underneath (2), partially back up the inboard side (3), then finish with a length extending further inboard (4) from the PRV. Important Ensure that any C-pillar wiring harnesses/connectors are routed forward of the insulator, and not trapped behind it. 4. Position the body rear panel insulator to the inner rear body panel and install the push pin retainers. Caution should be taken to not disturb the foam tape installed previously. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Technical Service Bulletins > Customer Interest for Sound Proofing / Insulation: > 10-08-58-001E > Mar > 11 > Interior - Excessive Wind Noise In Interior Of Vehicle > Page 17043 Important Ensure that the foam is securely wedged between the outboard edges of the insulator and the wiring harnesses/sheet metal, making sure that any C-pillar wiring harnesses/connectors are routed forward of the insulator and foam, and not trapped behind either of them. 5. Install a length of *Duck Brand Window Air Conditioner Insulating Strip Seal P/N 1284075, or equivalent, down each side C-pillar. 6. Complete the installation of the insulator panel and interior trim. Refer to Body Rear Panel Insulator Replacement (Extended Cab/Crew Cab) in SI. * We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Contact Kent Automotive at 1-888-YES-KENT or online at www.kent-automotive.com. Duck Brand products, or equivalent, can be obtained from your local hardware or home improvement store. *GM‹›P/N‹›12378195 is not available in Canada. However several equivalents such as Evercoat (Q-Pads) P/N 100116 and Dominion Sure Seal (Sound Deadener Pads) BSDE Part 110900 are available through NAPA Auto Parts retailers. Information for finding your local retail location can be obtained online at www.napacanada.com. Dominion Sure Seal (Sound Deadener Pads) BSDE Part 110900 can be obtained by contacting Dominion Sure Seal at 1-800-265-0790. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sound Proofing / Insulation: > 10-08-58-001E > Mar > 11 > Interior Excessive Wind Noise In Interior Of Vehicle Sound Proofing / Insulation: All Technical Service Bulletins Interior - Excessive Wind Noise In Interior Of Vehicle TECHNICAL Bulletin No.: 10-08-58-001E Date: March 08, 2011 Subject: Excessive Wind Noise Coming from Rear Interior of Vehicle (Perform Repair as Outlined) Models: 2007-2011 Chevrolet Silverado Crew Cab and Extended Cab 2007-2011 GMC Sierra Crew Cab and Extended Cab Supercede: This bulletin is being revised to update the repair in the Customer Enthusiasm section and update the Parts Information. Please discard Corporate Bulletin Number 10-08-58-001D (Section 08 - Body and Accessories). Condition Some customers may comment on hearing excessive wind noise coming from the rear interior of the vehicle. Cause #1 This condition may be caused by a void in the body filler within the C-pillar. Cause #2 This condition may be caused by the body rear panel acoustic insulator that is mounted behind the rear seat. There is an access flap (1) in this panel that could cause excessive noise if the flap is not fully seated/closed into the rest of the insulator material. Also, starting in 2010, a new insulator was installed that may allow higher wind/road or other acoustic noise that may be objectionable for some customers. Noise penetration into the cab can be higher than a similarly equipped 2009, or earlier, model. As shown in the graphic above, note that the service part insulator (1) is noticeably thicker than the original 2010 part (2). Correction #1 Note This repair is specific to 2007-2010 model years. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sound Proofing / Insulation: > 10-08-58-001E > Mar > 11 > Interior Excessive Wind Noise In Interior Of Vehicle > Page 17049 Important Prior to attempting a repair of the vehicle, it will be necessary to compare it to a like vehicle in similar operating characteristics to determine if it should be considered normal operation or a repairable condition. 1. To properly diagnose the C-pillar body filler issue, complete the following steps: 1. Close the all doors and windows of the vehicle. 2. Without starting the vehicle, turn the vehicle ignition to the ON/RUN position. 3. Press the HVAC selector switch for Outside Air. 4. Turn the HVAC Fan Control to Medium/High. Note The air flow that is felt most commonly exits the lower C-pillar opening shown in the graphic above. 5. Run your hand alongside the lower seam of the body at the base of the C-pillar and feel for air flowing out of the bottom of the body. 6. Compare the air flow on the opposite side of the vehicle. If one side exhibits a distinct higher amount of air flow, continue on to the next step in this procedure to start the process of adding sealer to the C-pillar on that side. If no air flow difference is found, skip ahead to Correction #2. 2. To access the inner C-pillar, remove the rear seat and the body lock pillar trim panel. Refer to Body Lock Pillar Trim Replacement (Crew Cab) or Body Lock Pillar Trim Replacement (Extended Cab) in SI. Figure 1 - Outside View Through C-pillar Figure 2 - Top View, Section Cut Through C-pillar 3. Inspect the inner baffle/foam within the C-pillar for any voids in the body filler. The examples above show an opening (1) in the baffle at the forward, inboard corner of the right side C-pillar. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sound Proofing / Insulation: > 10-08-58-001E > Mar > 11 > Interior Excessive Wind Noise In Interior Of Vehicle > Page 17050 4. If a void is found (1), fill it with seam sealer Kent Automotive High-Tech(TM) Clear Sealer, P/N P10200 (5 oz. tube), or equivalent, to eliminate the air flow escape concern. 5. Before reinstalling the trim, inspect the insulator mat that is mounted on the body rear inner panel to ensure the access flap is fully seated/closed as shown above. 6. Reinstall the trim panels and rear seat. Refer to Body Lock Pillar Trim Replacement (Crew Cab) or Body Lock Pillar Trim Replacement (Extended Cab) in SI. Correction #2 Note This repair is ONLY for 2010 models that have the original body rear panel insulator (pictured above) and exhibit a higher noise penetration into the cab, when compared to a similarly equipped 2009, or earlier, model. Note that the insulator shape is flat across the bottom edge. Tip Before any repairs, you can visually verify which insulator the vehicle has by looking under the rear seat on the right or left side. If you can see the body Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sound Proofing / Insulation: > 10-08-58-001E > Mar > 11 > Interior Excessive Wind Noise In Interior Of Vehicle > Page 17051 color of the rear inner panel (shown circled above) below the insulator (1), the insulator is the original design, which is trimmed straight across the bottom. Order a service body rear panel insulator (pictured above), referencing the parts table below. Note that the new insulator has an increased thickness and the height was extended on both ends. R & R the rear seat and any necessary trim to replace the body rear panel insulator. Refer to Body Rear Panel Insulator Replacement (Extended Cab/Crew Cab) in SI. Further Repair for Customer Enthusiasm Only in situations when the above repairs are completed and the customer is still commenting on objectionable noise, the following additional steps can be done to sound-proof the body rear panel. This additional sound-proofing should only be done in cases deemed necessary for customer enthusiasm. Note After this procedure has been performed, the vehicle needs to be re-assembled and evaluated with the trim and rear seat fully installed in the vehicle. If the bulletin has been followed properly, the noise should be reduced to a level quieter than stock 2011 models, and no further repairs should be attempted. It has been found that controlling the wind noise at the two pressure relief valve (PRV) locations is the key to quieting the rear cab wind noise. The repair below has been found to be successful in eliminating most of the objectionable noise. 1. R & R the rear seat and any necessary trim to remove the body rear panel insulator. Refer to Body Rear Panel Insulator Replacement (Extended Cab/Crew Cab) in SI. Note GM P/N 12378195 is not available in Canada. However several equivalents such as *Evercoat (Q-Pads) P/N 100116 and *Dominion Sure Seal (Sound Deadener Pads) BSDE Part 110900 are available through NAPA Auto Parts retailers. Information for finding your local retail location can be obtained online at www.napacanada.com. 2. Install noise and vibration sound deadening pads to backside of the body rear panel insulator. Follow the pattern shown above, ensuring they cover the two PRV locations. Use GM P/N 12378195, or equivalents commercially available through *Dynamat(R), Evercoat(R) or Dominion Sure Seal. Important Ensure that the foam tape pattern does not have any gaps in the corners and that it is securely pressed/attached to the inner rear body panel. 3. Install *Duck Brand Weatherstrip Seal (Self Adhesive Foam) P/N 1278750, or equivalent, to the inner body rear end panel following the patterns shown below: Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sound Proofing / Insulation: > 10-08-58-001E > Mar > 11 > Interior Excessive Wind Noise In Interior Of Vehicle > Page 17052 Note Ensure that the cross-car adhesive foam is positioned at a height just below the insulator push pin fastener locations so that once the fasteners are installed, the seal is compressed. - Across the inner rear body panel, matching the width of the insulator panel. - Downward from each end of the cross-car foam (left side (1) shown in the graphic above). The length should match the height of the insulator panel. - Partially around the two PRV's. Install the foam down the outboard side (1), underneath (2), partially back up the inboard side (3), then finish with a length extending further inboard (4) from the PRV. Important Ensure that any C-pillar wiring harnesses/connectors are routed forward of the insulator, and not trapped behind it. 4. Position the body rear panel insulator to the inner rear body panel and install the push pin retainers. Caution should be taken to not disturb the foam tape installed previously. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sound Proofing / Insulation: > 10-08-58-001E > Mar > 11 > Interior Excessive Wind Noise In Interior Of Vehicle > Page 17053 Important Ensure that the foam is securely wedged between the outboard edges of the insulator and the wiring harnesses/sheet metal, making sure that any C-pillar wiring harnesses/connectors are routed forward of the insulator and foam, and not trapped behind either of them. 5. Install a length of *Duck Brand Window Air Conditioner Insulating Strip Seal P/N 1284075, or equivalent, down each side C-pillar. 6. Complete the installation of the insulator panel and interior trim. Refer to Body Rear Panel Insulator Replacement (Extended Cab/Crew Cab) in SI. * We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Contact Kent Automotive at 1-888-YES-KENT or online at www.kent-automotive.com. Duck Brand products, or equivalent, can be obtained from your local hardware or home improvement store. *GM‹›P/N‹›12378195 is not available in Canada. However several equivalents such as Evercoat (Q-Pads) P/N 100116 and Dominion Sure Seal (Sound Deadener Pads) BSDE Part 110900 are available through NAPA Auto Parts retailers. Information for finding your local retail location can be obtained online at www.napacanada.com. Dominion Sure Seal (Sound Deadener Pads) BSDE Part 110900 can be obtained by contacting Dominion Sure Seal at 1-800-265-0790. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Splash Guard > Component Information > Service and Repair > Engine Splash Shield Replacement - Left Side Splash Guard: Service and Repair Engine Splash Shield Replacement - Left Side Engine Splash Shield Replacement - Left Side Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Splash Guard > Component Information > Service and Repair > Engine Splash Shield Replacement - Left Side > Page 17058 Splash Guard: Service and Repair Engine Splash Shield Replacement - Right Side Engine Splash Shield Replacement - Right Side Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Spoilers, Flaps, and Air Dams > Air Dam > Component Information > Service and Repair > Front Air Deflector Extension Replacement Air Dam: Service and Repair Front Air Deflector Extension Replacement Front Air Deflector Extension Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Spoilers, Flaps, and Air Dams > Air Dam > Component Information > Service and Repair > Front Air Deflector Extension Replacement > Page 17064 Air Dam: Service and Repair Front Air Deflector Replacement Front Air Deflector Replacement (Chevrolet) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Spoilers, Flaps, and Air Dams > Spoiler > Component Information > Service and Repair > Rear Spoiler Replacement (Avalanche) Spoiler: Service and Repair Rear Spoiler Replacement (Avalanche) Rear Spoiler Replacement (Avalanche) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Spoilers, Flaps, and Air Dams > Spoiler > Component Information > Service and Repair > Rear Spoiler Replacement (Avalanche) > Page 17069 Spoiler: Service and Repair Rear Spoiler Replacement (Sierra / Silverado) Rear Spoiler Replacement (Sierra Silverado) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Hinge > Component Information > Service and Repair > Endgate Torque Rod Replacement Tailgate Hinge: Service and Repair Endgate Torque Rod Replacement Endgate Torque Rod Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Hinge > Component Information > Service and Repair > Endgate Torque Rod Replacement > Page 17075 Tailgate Hinge: Service and Repair Endgate Lower Hinge Replacement - Body Side Endgate Lower Hinge Replacement - Body Side Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Latch > Component Information > Service and Repair > Pickup Box Endgate Latch Rod Replacement (Pickup Box) Tailgate Latch: Service and Repair Pickup Box Endgate Latch Rod Replacement (Pickup Box) Pickup Box Endgate Latch Rod Replacement (Pickup Box) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Latch > Component Information > Service and Repair > Pickup Box Endgate Latch Rod Replacement (Pickup Box) > Page 17080 Tailgate Latch: Service and Repair Pickup Box Endgate Striker Replacement (Pickup Box) Pickup Box Endgate Striker Replacement (Pickup Box) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Latch > Component Information > Service and Repair > Pickup Box Endgate Latch Rod Replacement (Pickup Box) > Page 17081 Tailgate Latch: Service and Repair Endgate Latch Replacement Endgate Latch Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Release Handle > Component Information > Service and Repair Tailgate Release Handle: Service and Repair Endgate Handle Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Shock / Support > Component Information > Service and Repair > Endgate Cable Replacement Tailgate Shock / Support: Service and Repair Endgate Cable Replacement Endgate Cable Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Tailgate > Tailgate Shock / Support > Component Information > Service and Repair > Endgate Cable Replacement > Page 17089 Tailgate Shock / Support: Service and Repair Pickup Box Endgate Cable Bolt Replacement Pickup Box Endgate Cable Bolt Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Tie Down Hook / Bracket > Component Information > Service and Repair Tie Down Hook / Bracket: Service and Repair Pickup Box Tie Down Loop Replacement Removal Procedure Warning: Refer to Approved Equipment for Collision Repair Warning (See: Service Precautions/Technician Safety Information/Approved Equipment for Collision Repair Warning). 1. Locate and drill out the spot welds. 2. Remove the tie down loop. Installation Procedure 1. Prepare all mating surfaces as necessary. 2. Apply GM-approved Weld-Thru coating or equivalent to all mating surfaces. Refer to Anti-Corrosion Treatment and Repair (). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Tie Down Hook / Bracket > Component Information > Service and Repair > Page 17093 3. Position the tie down loop. 4. Plug weld accordingly. 5. Clean and prepare all welded surfaces. 6. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair (). 7. Paint and repair the area. Refer to Basecoat/Clearcoat Paint Systems (See: Paint, Striping and Decals/Paint/Application and ID/Basecoat/Clearcoat Paint Systems). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Towing Hook / Bracket > Component Information > Service and Repair Towing Hook / Bracket: Service and Repair Tow Hook Replacement (2500HD/3500 Series) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Truck Bed > Truck Bed Cover > Truck Bed Cover Latch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Truck Bed Cover Latch: > 09-08-66-004A > Jan > 11 > Body - Soft Tonneau Cover Appears Loose/Won't Latch Truck Bed Cover Latch: All Technical Service Bulletins Body - Soft Tonneau Cover Appears Loose/Won't Latch TECHNICAL Bulletin No.: 09-08-66-004A Date: January 04, 2011 Subject: Roll Up Soft Tonneau Cover Appears Loose or Latch Not Functioning Properly (Adjust Upper Side Rail Clamps and/or Rails and/or Replace Rear Latch) Models: 2007-2011 Chevrolet Silverado 2007-2011 GMC Sierra Attention: This bulletin only applies to vehicles with tonneau part numbers 19213900, 19213901, 19213902, 19213903, 19213904 and 19213905. Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-08-66-004 (Section 08 - Body and Accessories). Condition Some customers may comment that the roll up soft tonneau cover is too loose, or that the tonneau cover latch is disengaging and not staying closed. Two improvements have been implemented since the original release of the tonneau cover. Be sure that the tonneau cover meets the criteria of the items below. Cause #1 The condition may be caused by improper installation of one or more of the upper side rail clamps. Using the outer groove (1) when a molded bed rail protector IS NOT installed may cause a gap (2) between the pad and pickup box. This may also prevent proper latch retention. Correction #1 Note Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Truck Bed > Truck Bed Cover > Truck Bed Cover Latch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Truck Bed Cover Latch: > 09-08-66-004A > Jan > 11 > Body - Soft Tonneau Cover Appears Loose/Won't Latch > Page 17107 A removable insert, shown above, was added to the outer groove of the upper side rail clamp to help prevent improper positioning from unintentionally occurring. Check that the clamps are properly installed using the correct groove in the upper side rail clamp. Correct positioning is detailed in the illustration above. Cause #2 The condition may be caused by the tonneau bows not falling into proper position when the tonneau cover is rolled out. This cause would indicate that repositioning on an upper side rail clamp is needed. Correction #2 Note the position of the bows and use the appropriate repair below: - If bows do not fit between the side rails and additional clearance is required, remove the clamp nearest the interference. Remove the orange strip to allow access to the outer groove of the upper clamp. Reinstall the clamp, using the outer groove of the upper clamp. - If bows are too loose, adjust the clamp nearest the bow with excessive clearance to the inner groove of the upper clamp. Cause #3 This condition may be caused by a misalignment of the tonneau side rails and/or improper adjustment of the forward tension screws. The graphic above shows a misalignment of the tonneau side rail (1) to the front of the pickup box (2). Correction #3 1. Verify that the tonneau side rails are aligned with the front of the pickup box as shown above. 2. Ensure that the side rails are aligned with each other in the same fore/aft position (1) on the vehicle. Note Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Truck Bed > Truck Bed Cover > Truck Bed Cover Latch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Truck Bed Cover Latch: > 09-08-66-004A > Jan > 11 > Body - Soft Tonneau Cover Appears Loose/Won't Latch > Page 17108 Vinyl contains unique thermal properties that cause it to expand in cold conditions and retract during hot conditions. Under recommended install temperatures of 21°C (70°F), the tension screws should be adjusted as shown below. Important Be sure to adjust both sides to the same tension. 3. Inspect and verify that the tension screws are adjusted to the 4.76 mm (3/16 in) gap shown in the illustration above. If adjustment is necessary to tighten, turn the screw clockwise with the 1/4 inch key provided. Cause #4 The condition may be caused by over travel of the latch during operation, causing the latch spring to bind. Correction #4 Note A new design of the latch system now contains a latch stop (1) to limit the travel of the latch during operation. This new latch stop prevents over travel and keeps the spring from binding. Verify that the latch system contains a latch stop, noted in the illustration above. If the stop IS NOT present, replace the latch system with latch spring stop service kit, P/N 19213898 and a new latch assembly service kit, P/N 19201885. Warranty Information Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Truck Bed > Truck Bed Cover > Truck Bed Cover Latch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Truck Bed Cover Latch: > 09-08-66-004A > Jan > 11 > Body - Soft Tonneau Cover Appears Loose/Won't Latch > Page 17109 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Truck Bed > Truck Bed Cover > Truck Bed Cover Latch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Truck Bed Cover Latch: > 09-08-66-003A > Dec > 10 > Body - Tonneau Cover Fits To Loose On Vehicle Truck Bed Cover Latch: All Technical Service Bulletins Body - Tonneau Cover Fits To Loose On Vehicle TECHNICAL Bulletin No.: 09-08-66-003A Date: December 23, 2010 Subject: One-Piece Hard Tonneau Cover Fits Loose on Vehicle or Rear Tonneau Latch Not Functioning Properly (Adjust Rear Latch and Align Tonneau Cover) Models: 2007-2011 Chevrolet Silverado 2007-2011 GMC Sierra Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-08-66-003 (Section 08 - Body and Accessories). Condition Some customers may comment that the hard tonneau rear latch is not functioning properly or that the tonneau cover is loose on the vehicle, causing noticeable movement during vehicle operation. Cause This condition may be caused by both sides of the latch not engaging or releasing at the same time, or the tonneau frame may be misaligned. Correction Note The tonneau cover latches contain multiple design features to accommodate for build variation of the pickup box and tonneau cover. Use the following repair process to obtain proper latch operation: Inspect/Adjust Latch to Striker Loop Interface Side to Side Adjustment 1. Lower the endgate. 2. Slowly lower the tonneau cover from the open to closed position. Use caution not to drop or slam the tonneau cover closed as this may damage the latch assembly. 3. Inspect the fit of the latch into the striker loop just before the U-shaped catch is engaged. The latch should fit into the striker loop without contacting any portion of the rear bracket or striker loop. If contact is observed, proceed with the following steps: 1. Loosen the two nuts of the rotary latch that is making contact to the striker loop assembly with a 7/16 inch wrench. 2. Slide the rotary latch side to side until the latch freely falls into the rear striker loop. 3. Tighten the rotary latch nuts to 2.26 Nm (20 lb in). 4. Inspect the operation of the latches by turning the twist handle. If the latches do not close or release properly, adjust the latch wire per the Inspect/Adjust Latch Release Operation section of this document. Up and Down Adjustment 1. Lower the endgate. 2. Close the tonneau cover by pushing down on the panel near the twist handle on the top of the tonneau cover. 3. Inspect the fit of the tonneau cover side seal to the pickup box. If the seal does not have complete contact, lower the striker loop until the seal has complete contact using the following steps: 1. Loosen the two 1/4 inch nuts that hold the striker plate to the rear bracket. 2. Lower the striker loop. 3. Tighten the 1/4 inch nuts to 13.5 Nm (120 lb in). 4. Inspect for seal contact and repeat procedure as necessary. 4. Close the endgate. 5. Close the tonneau cover by pushing down on the panel near the twist handle on the top of the tonneau cover. 6. Inspect that both latches have engaged by lifting up on the corner of the tonneau. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Truck Bed > Truck Bed Cover > Truck Bed Cover Latch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Truck Bed Cover Latch: > 09-08-66-003A > Dec > 10 > Body - Tonneau Cover Fits To Loose On Vehicle > Page 17114 7. Repeat steps 5 and 6 five more times to look for repeatability. If either one of the sides does not engage, manually close the latch that did not engage and inspect the latch closure of each side by wiggling each corner. Check for the following: 1. If one side is too loose and exhibiting excessive movement, lower the corresponding loop per steps 3.1-3.4 in the Up and Down Adjustment section above. 2. If one side requires excess manual efforts to close, raise the corresponding loop using the following steps: 1. Loosen the two 1/4 inch nuts that hold the striker plate to the rear bracket. 2. Raise the striker loop. 3. Tighten the 1/4 inch nuts to 13.5 Nm (120 lb in). Inspect/Adjust Latch Release Operation 1. Open the tonneau cover. 2. Manually push the U-shaped catches closed for both sides of the vehicle. If either one of the catches does not close, proceed with the following steps: 1. Loosen the set screw of the cable bushing with a 5/64 inch allen wrench. 2. Push the cable inboard from the end of cable to add length to the cable between the latch assembly and the lock assembly. 3. Retighten the set screw. Note Both latches should engage at the same time. 4. Inspect the timing of the latch engagement by manually closing the latches and twisting the lock handle with the cover in the open position. If the latches do not engage at the same time, repeat the above adjustment until they do. 3. Twist the handle and listen for the latches to release. If either one of the catches does not open, proceed with the following steps: 1. Loosen the set screw of the cable bushing with a 5/64 inch allen wrench. 2. Pull the cable outboard from the end of the cable to shorten the length of the cable between the latch assembly and the lock assembly. 3. Retighten the set screw. Note Both latches should release at the same time. 4. Inspect the timing of latch release. Repeat steps 3.1-3.3 above, adjusting the latch that releases second, until both latches are releasing at the same time. Verify that the front frame is centered and squared onto the pickup box 1. Measure from the edge of the front panel sheet metal cross-car to the edge of the hinge clip on both sides. Loosen hardware and adjust the frame position side to side until it's centered. 2. Measure from the stack pocket to the end of the side frame on both sides. Loosen hardware and adjust the frame position until both sides match. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Truck Bed > Truck Bed Cover > Truck Bed Cover Latch > Component Information > Technical Service Bulletins > Customer Interest for Truck Bed Cover Latch: > 09-08-66-004A > Jan > 11 > Body - Soft Tonneau Cover Appears Loose/Won't Latch Truck Bed Cover Latch: Customer Interest Body - Soft Tonneau Cover Appears Loose/Won't Latch TECHNICAL Bulletin No.: 09-08-66-004A Date: January 04, 2011 Subject: Roll Up Soft Tonneau Cover Appears Loose or Latch Not Functioning Properly (Adjust Upper Side Rail Clamps and/or Rails and/or Replace Rear Latch) Models: 2007-2011 Chevrolet Silverado 2007-2011 GMC Sierra Attention: This bulletin only applies to vehicles with tonneau part numbers 19213900, 19213901, 19213902, 19213903, 19213904 and 19213905. Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-08-66-004 (Section 08 - Body and Accessories). Condition Some customers may comment that the roll up soft tonneau cover is too loose, or that the tonneau cover latch is disengaging and not staying closed. Two improvements have been implemented since the original release of the tonneau cover. Be sure that the tonneau cover meets the criteria of the items below. Cause #1 The condition may be caused by improper installation of one or more of the upper side rail clamps. Using the outer groove (1) when a molded bed rail protector IS NOT installed may cause a gap (2) between the pad and pickup box. This may also prevent proper latch retention. Correction #1 Note Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Truck Bed > Truck Bed Cover > Truck Bed Cover Latch > Component Information > Technical Service Bulletins > Customer Interest for Truck Bed Cover Latch: > 09-08-66-004A > Jan > 11 > Body - Soft Tonneau Cover Appears Loose/Won't Latch > Page 17120 A removable insert, shown above, was added to the outer groove of the upper side rail clamp to help prevent improper positioning from unintentionally occurring. Check that the clamps are properly installed using the correct groove in the upper side rail clamp. Correct positioning is detailed in the illustration above. Cause #2 The condition may be caused by the tonneau bows not falling into proper position when the tonneau cover is rolled out. This cause would indicate that repositioning on an upper side rail clamp is needed. Correction #2 Note the position of the bows and use the appropriate repair below: - If bows do not fit between the side rails and additional clearance is required, remove the clamp nearest the interference. Remove the orange strip to allow access to the outer groove of the upper clamp. Reinstall the clamp, using the outer groove of the upper clamp. - If bows are too loose, adjust the clamp nearest the bow with excessive clearance to the inner groove of the upper clamp. Cause #3 This condition may be caused by a misalignment of the tonneau side rails and/or improper adjustment of the forward tension screws. The graphic above shows a misalignment of the tonneau side rail (1) to the front of the pickup box (2). Correction #3 1. Verify that the tonneau side rails are aligned with the front of the pickup box as shown above. 2. Ensure that the side rails are aligned with each other in the same fore/aft position (1) on the vehicle. Note Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Truck Bed > Truck Bed Cover > Truck Bed Cover Latch > Component Information > Technical Service Bulletins > Customer Interest for Truck Bed Cover Latch: > 09-08-66-004A > Jan > 11 > Body - Soft Tonneau Cover Appears Loose/Won't Latch > Page 17121 Vinyl contains unique thermal properties that cause it to expand in cold conditions and retract during hot conditions. Under recommended install temperatures of 21°C (70°F), the tension screws should be adjusted as shown below. Important Be sure to adjust both sides to the same tension. 3. Inspect and verify that the tension screws are adjusted to the 4.76 mm (3/16 in) gap shown in the illustration above. If adjustment is necessary to tighten, turn the screw clockwise with the 1/4 inch key provided. Cause #4 The condition may be caused by over travel of the latch during operation, causing the latch spring to bind. Correction #4 Note A new design of the latch system now contains a latch stop (1) to limit the travel of the latch during operation. This new latch stop prevents over travel and keeps the spring from binding. Verify that the latch system contains a latch stop, noted in the illustration above. If the stop IS NOT present, replace the latch system with latch spring stop service kit, P/N 19213898 and a new latch assembly service kit, P/N 19201885. Warranty Information Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Truck Bed > Truck Bed Cover > Truck Bed Cover Latch > Component Information > Technical Service Bulletins > Customer Interest for Truck Bed Cover Latch: > 09-08-66-004A > Jan > 11 > Body - Soft Tonneau Cover Appears Loose/Won't Latch > Page 17122 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Truck Bed > Truck Bed Cover > Truck Bed Cover Latch > Component Information > Technical Service Bulletins > Customer Interest for Truck Bed Cover Latch: > 09-08-66-003A > Dec > 10 > Body - Tonneau Cover Fits To Loose On Vehicle Truck Bed Cover Latch: Customer Interest Body - Tonneau Cover Fits To Loose On Vehicle TECHNICAL Bulletin No.: 09-08-66-003A Date: December 23, 2010 Subject: One-Piece Hard Tonneau Cover Fits Loose on Vehicle or Rear Tonneau Latch Not Functioning Properly (Adjust Rear Latch and Align Tonneau Cover) Models: 2007-2011 Chevrolet Silverado 2007-2011 GMC Sierra Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-08-66-003 (Section 08 - Body and Accessories). Condition Some customers may comment that the hard tonneau rear latch is not functioning properly or that the tonneau cover is loose on the vehicle, causing noticeable movement during vehicle operation. Cause This condition may be caused by both sides of the latch not engaging or releasing at the same time, or the tonneau frame may be misaligned. Correction Note The tonneau cover latches contain multiple design features to accommodate for build variation of the pickup box and tonneau cover. Use the following repair process to obtain proper latch operation: Inspect/Adjust Latch to Striker Loop Interface Side to Side Adjustment 1. Lower the endgate. 2. Slowly lower the tonneau cover from the open to closed position. Use caution not to drop or slam the tonneau cover closed as this may damage the latch assembly. 3. Inspect the fit of the latch into the striker loop just before the U-shaped catch is engaged. The latch should fit into the striker loop without contacting any portion of the rear bracket or striker loop. If contact is observed, proceed with the following steps: 1. Loosen the two nuts of the rotary latch that is making contact to the striker loop assembly with a 7/16 inch wrench. 2. Slide the rotary latch side to side until the latch freely falls into the rear striker loop. 3. Tighten the rotary latch nuts to 2.26 Nm (20 lb in). 4. Inspect the operation of the latches by turning the twist handle. If the latches do not close or release properly, adjust the latch wire per the Inspect/Adjust Latch Release Operation section of this document. Up and Down Adjustment 1. Lower the endgate. 2. Close the tonneau cover by pushing down on the panel near the twist handle on the top of the tonneau cover. 3. Inspect the fit of the tonneau cover side seal to the pickup box. If the seal does not have complete contact, lower the striker loop until the seal has complete contact using the following steps: 1. Loosen the two 1/4 inch nuts that hold the striker plate to the rear bracket. 2. Lower the striker loop. 3. Tighten the 1/4 inch nuts to 13.5 Nm (120 lb in). 4. Inspect for seal contact and repeat procedure as necessary. 4. Close the endgate. 5. Close the tonneau cover by pushing down on the panel near the twist handle on the top of the tonneau cover. 6. Inspect that both latches have engaged by lifting up on the corner of the tonneau. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Truck Bed > Truck Bed Cover > Truck Bed Cover Latch > Component Information > Technical Service Bulletins > Customer Interest for Truck Bed Cover Latch: > 09-08-66-003A > Dec > 10 > Body - Tonneau Cover Fits To Loose On Vehicle > Page 17127 7. Repeat steps 5 and 6 five more times to look for repeatability. If either one of the sides does not engage, manually close the latch that did not engage and inspect the latch closure of each side by wiggling each corner. Check for the following: 1. If one side is too loose and exhibiting excessive movement, lower the corresponding loop per steps 3.1-3.4 in the Up and Down Adjustment section above. 2. If one side requires excess manual efforts to close, raise the corresponding loop using the following steps: 1. Loosen the two 1/4 inch nuts that hold the striker plate to the rear bracket. 2. Raise the striker loop. 3. Tighten the 1/4 inch nuts to 13.5 Nm (120 lb in). Inspect/Adjust Latch Release Operation 1. Open the tonneau cover. 2. Manually push the U-shaped catches closed for both sides of the vehicle. If either one of the catches does not close, proceed with the following steps: 1. Loosen the set screw of the cable bushing with a 5/64 inch allen wrench. 2. Push the cable inboard from the end of cable to add length to the cable between the latch assembly and the lock assembly. 3. Retighten the set screw. Note Both latches should engage at the same time. 4. Inspect the timing of the latch engagement by manually closing the latches and twisting the lock handle with the cover in the open position. If the latches do not engage at the same time, repeat the above adjustment until they do. 3. Twist the handle and listen for the latches to release. If either one of the catches does not open, proceed with the following steps: 1. Loosen the set screw of the cable bushing with a 5/64 inch allen wrench. 2. Pull the cable outboard from the end of the cable to shorten the length of the cable between the latch assembly and the lock assembly. 3. Retighten the set screw. Note Both latches should release at the same time. 4. Inspect the timing of latch release. Repeat steps 3.1-3.3 above, adjusting the latch that releases second, until both latches are releasing at the same time. Verify that the front frame is centered and squared onto the pickup box 1. Measure from the edge of the front panel sheet metal cross-car to the edge of the hinge clip on both sides. Loosen hardware and adjust the frame position side to side until it's centered. 2. Measure from the stack pocket to the end of the side frame on both sides. Loosen hardware and adjust the frame position until both sides match. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Truck Bed > Truck Bed Storage Compartment > Component Information > Technical Service Bulletins > Accessories - Pick Up Box Accessory Mounting Information Truck Bed Storage Compartment: Technical Service Bulletins Accessories - Pick Up Box Accessory Mounting Information INFORMATION Bulletin No.: 09-08-66-011A Date: October 04, 2010 Subject: Information on Mounting Points for Pickup Box Accessories Models: 2007-2011 Chevrolet Silverado 2007-2011 GMC Sierra Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-08-66-011 (08 - Body and Accessories). The pickup box was designed for the use of add-on equipment. However there are specific mounting points that must be used along with weight restrictions, refer to the following: Chart 1 Weight Restrictions for Pickup Box Add-Ons. Structural members have been added to provide load paths directly to the platform cross-sills and into the vehicle frame. Aftermarket accessories should take advantage of these intended load paths as detailed below in Figures 1-4. Depending on the accessory design, it may be necessary to add some form of a spacer under the accessories at the structural hard points to take up any gap. Do not use the GM Cargo Management Option mounting points for attaching anything other than the GM Cargo Management system as referenced in Figure 5. Figure 1 - Side View - Structural Members Figure 2 - Top View - Structural Members Figure 3 - Top View - Front Structure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Truck Bed > Truck Bed Storage Compartment > Component Information > Technical Service Bulletins > Accessories - Pick Up Box Accessory Mounting Information > Page 17132 Figure 4 - Top View - Rear Structure Figure 5 - GM Cargo Management Points Caution Overloading the vehicle may cause damage. Do not overload the vehicle. When you carry removable items, you may need to put a limit on how many people you carry inside your vehicle. Be sure to weigh your vehicle before you buy and install the new equipment. Remember not to exceed the Gross Axle Weight Rating (GAWR) of the front or rear axle. If the vehicle is damaged due to overloading, repairs would not be covered by the vehicle warranty. The load bearing structural information is also included in the Body Builder's manual at www.gmupfitter.com. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Unibody > Cowl > Cowl Moulding / Trim > System Information > Service and Repair Cowl Moulding / Trim: Service and Repair Air Inlet Grille Panel Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Weatherstrip: > 09-08-64-012C > Nov > 10 > Body - Side Door Body Mounted Weatherstrip Replacement Front Door Weatherstrip: All Technical Service Bulletins Body - Side Door Body Mounted Weatherstrip Replacement INFORMATION Bulletin No.: 09-08-64-012C Date: November 22, 2010 Subject: Information on Side Door Body Mounted Primary Weatherstrip Replacement Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to communicate feedback received from engineering information and add the 2011 model year. Please discard Corporate Bulletin Number 09-08-64-012B (Section 08 - Body and Accessories). Some customers may comment about side door wind noise, water leaks or door fit concerns. These concerns may appear to be related to the body mounted primary door opening weatherstrips. As a result of feedback received from engineering information, we have found that many replacements of the primary door opening weatherstrip are for issues not related to the primary door opening weatherstrip. The instructions below are a guide to help "root cause" the customer's concern and obtain the proper direction for repair. Recommendation Note: If the seal is properly installed, it will not cause a Windnoise. If mis-installed, the seal could create a Windnoise that can be corrected by re-installing the seal. If the condition is for Windnoise, please view the training courses on this subject and follow the proper diagnostics outlined in courses 10210.01D 2010 SKH Seminar Jan Emerging Issues,.02D (Feb),.03D (March) (3 Parts) (Emerging Issues programs available to U.S. dealers only). If the condition is specific to an itch noise, refer to Corporate Bulletin Number 06-08-64-035F to correct that concern. If diagnosing a water leak, please follow information supplied in Corporate Bulletin Number 09-08-57-002B. For door fit concerns, or if the seal is loose or exhibits a poor appearance, inspect for even retention around the door. If the seal pulls off too easily, the channel crimp may be wide/loose as shown between the dashed lines in the graphic above. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Weatherstrip: > 09-08-64-012C > Nov > 10 > Body - Side Door Body Mounted Weatherstrip Replacement > Page 17147 Remove the seal only in the affected area. Inspect the seal's channel crimp and adjust accordingly by pinching the channel together for a tighter retention. Reinstall the portion of the seal that was removed. Warranty Information For vehicles repaired under warranty, use the appropriate labor operation found in the Labor Time Guide (LTG). Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Weatherstrip: > 06-08-64-035G > Jun > 10 > Body - Squeak/Itching Noise in Upper Door Area Front Door Weatherstrip: All Technical Service Bulletins Body - Squeak/Itching Noise in Upper Door Area TECHNICAL Bulletin No.: 06-08-64-035G Date: June 01, 2010 Subject: Squeak/Itching Noise in Upper Door Area (Replace Weatherstrip Assembly) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to update parts description information. Please discard Corporate Bulletin Number 06-08-64-035F (Section 08 - Body and Accessories). Condition Some customers may comment on a squeaking or itching noise in the upper door area when driving. Cause This condition may be caused by the roof drip weatherstrip to door frame contact. This could occur at any or all of the doors. Correction Replace the weatherstrip assembly. Refer to Door Opening Weatherstrip Replacement in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the appropriate labor operation from the Labor Time Guide. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Front Door Weatherstrip: > 09-08-64-012C > Nov > 10 > Body - Side Door Body Mounted Weatherstrip Replacement Front Door Weatherstrip: Customer Interest Body - Side Door Body Mounted Weatherstrip Replacement INFORMATION Bulletin No.: 09-08-64-012C Date: November 22, 2010 Subject: Information on Side Door Body Mounted Primary Weatherstrip Replacement Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to communicate feedback received from engineering information and add the 2011 model year. Please discard Corporate Bulletin Number 09-08-64-012B (Section 08 - Body and Accessories). Some customers may comment about side door wind noise, water leaks or door fit concerns. These concerns may appear to be related to the body mounted primary door opening weatherstrips. As a result of feedback received from engineering information, we have found that many replacements of the primary door opening weatherstrip are for issues not related to the primary door opening weatherstrip. The instructions below are a guide to help "root cause" the customer's concern and obtain the proper direction for repair. Recommendation Note: If the seal is properly installed, it will not cause a Windnoise. If mis-installed, the seal could create a Windnoise that can be corrected by re-installing the seal. If the condition is for Windnoise, please view the training courses on this subject and follow the proper diagnostics outlined in courses 10210.01D 2010 SKH Seminar Jan Emerging Issues,.02D (Feb),.03D (March) (3 Parts) (Emerging Issues programs available to U.S. dealers only). If the condition is specific to an itch noise, refer to Corporate Bulletin Number 06-08-64-035F to correct that concern. If diagnosing a water leak, please follow information supplied in Corporate Bulletin Number 09-08-57-002B. For door fit concerns, or if the seal is loose or exhibits a poor appearance, inspect for even retention around the door. If the seal pulls off too easily, the channel crimp may be wide/loose as shown between the dashed lines in the graphic above. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Front Door Weatherstrip: > 09-08-64-012C > Nov > 10 > Body - Side Door Body Mounted Weatherstrip Replacement > Page 17157 Remove the seal only in the affected area. Inspect the seal's channel crimp and adjust accordingly by pinching the channel together for a tighter retention. Reinstall the portion of the seal that was removed. Warranty Information For vehicles repaired under warranty, use the appropriate labor operation found in the Labor Time Guide (LTG). Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Front Door Weatherstrip: > 06-08-64-035G > Jun > 10 > Body Squeak/Itching Noise in Upper Door Area Front Door Weatherstrip: Customer Interest Body - Squeak/Itching Noise in Upper Door Area TECHNICAL Bulletin No.: 06-08-64-035G Date: June 01, 2010 Subject: Squeak/Itching Noise in Upper Door Area (Replace Weatherstrip Assembly) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to update parts description information. Please discard Corporate Bulletin Number 06-08-64-035F (Section 08 - Body and Accessories). Condition Some customers may comment on a squeaking or itching noise in the upper door area when driving. Cause This condition may be caused by the roof drip weatherstrip to door frame contact. This could occur at any or all of the doors. Correction Replace the weatherstrip assembly. Refer to Door Opening Weatherstrip Replacement in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the appropriate labor operation from the Labor Time Guide. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Front Side Door Window Weatherstrip Replacement Front Door Weatherstrip: Service and Repair Front Side Door Window Weatherstrip Replacement Front Side Door Window Weatherstrip Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Front Side Door Window Weatherstrip Replacement > Page 17164 Front Door Weatherstrip: Service and Repair Front Side Door Roof Drip Weatherstrip Replacement Front Side Door Roof Drip Weatherstrip Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Front Side Door Window Weatherstrip Replacement > Page 17165 Front Door Weatherstrip: Service and Repair Front Door Opening Weatherstrip Replacement (Regular Cab) Front Door Opening Weatherstrip Replacement (Regular Cab) Removal Procedure 1. Remove the front door sill plate. Refer to Front Side Door Sill Trim Plate Replacement (Extended Cab) (See: Interior Moulding / Trim/Scuff Plate/Service and Repair/Front Side Door Sill Trim Plate Replacement (Extended Cab))Front Side Door Sill Trim Plate Replacement (Regular Cab/Crew Cab) (See: Interior Moulding / Trim/Scuff Plate/Service and Repair/Front Side Door Sill Trim Plate Replacement (Regular Cab/Crew Cab)). 2. Remove the weatherstrip from the pinch-weld flange. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Front Side Door Window Weatherstrip Replacement > Page 17166 1. Align the weatherstrip to the door opening with the 2 dots positioned on the upper right and left side. 2. Align the weatherstrip to the door opening with the bond joint positioned at the lower center of the door opening. 3. Install the weatherstrip to the pinch-weld flange. Ensure that the weatherstrip is fully seated. 4. Install the front door sill plate. Refer to Front Side Door Sill Trim Plate Replacement (Extended Cab) (See: Interior Moulding / Trim/Scuff Plate/Service and Repair/Front Side Door Sill Trim Plate Replacement (Extended Cab))Front Side Door Sill Trim Plate Replacement (Regular Cab/Crew Cab) (See: Interior Moulding / Trim/Scuff Plate/Service and Repair/Front Side Door Sill Trim Plate Replacement (Regular Cab/Crew Cab)). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Front Side Door Window Weatherstrip Replacement > Page 17167 Front Door Weatherstrip: Service and Repair Front Door Opening Weatherstrip Replacement (Extended Cab) Front Door Opening Weatherstrip Replacement (Extended Cab) Removal Procedure 1. Open both doors. 2. Remove the front and rear door sill plate. Refer to Front Side Door Sill Trim Plate Replacement (Extended Cab) (See: Interior Moulding / Trim/Scuff Plate/Service and Repair/Front Side Door Sill Trim Plate Replacement (Extended Cab))Front Side Door Sill Trim Plate Replacement (Regular Cab/Crew Cab) (See: Interior Moulding / Trim/Scuff Plate/Service and Repair/Front Side Door Sill Trim Plate Replacement (Regular Cab/Crew Cab)) or Rear Side Door Sill Trim Plate Replacement (Crew Cab) (See: Interior Moulding / Trim/Scuff Plate/Service and Repair/Rear Side Door Sill Trim Plate Replacement (Crew Cab))Rear Side Door Sill Trim Plate Replacement (Extended Cab) (See: Interior Moulding / Trim/Scuff Plate/Service and Repair/Rear Side Door Sill Trim Plate Replacement (Extended Cab)). 3. Remove the hinge pillar trim. Refer to Body Hinge Pillar Trim Panel Replacement (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Body Hinge Pillar Trim Panel Replacement). 4. Remove the body lock pillar trim. Refer to Body Lock Pillar Trim Replacement (Crew Cab) (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Body Lock Pillar Trim Replacement (Crew Cab))Body Lock Pillar Trim Replacement (Extended Cab) (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Body Lock Pillar Trim Replacement (Extended Cab))Body Lock Pillar Trim Replacement (Regular Cab) ( See: Interior Moulding / Trim/Trim Panel/Service and Repair/Body Lock Pillar Trim Replacement (Regular Cab)). 5. Remove the windshield pillar molding. Refer to Windshield Pillar Garnish Molding Replacement (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Windshield Pillar Garnish Molding Replacement). 6. Remove the weatherstrip (1) from the pinch-weld flange (2). Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Front Side Door Window Weatherstrip Replacement > Page 17168 1. Align the weatherstrip to the door opening with the 2 dots positioned on the upper right and left side. 2. Install the weatherstrip (1) to the pinch-weld flange (2). Ensure that the weatherstrip is fully seated around the door opening. 3. Install the windshield pillar molding. Refer to Windshield Pillar Garnish Molding Replacement (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Windshield Pillar Garnish Molding Replacement). 4. Install the body lock pillar trim. Refer to Body Lock Pillar Trim Replacement (Crew Cab) (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Body Lock Pillar Trim Replacement (Crew Cab))Body Lock Pillar Trim Replacement (Extended Cab) (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Body Lock Pillar Trim Replacement (Extended Cab))Body Lock Pillar Trim Replacement (Regular Cab) ( See: Interior Moulding / Trim/Trim Panel/Service and Repair/Body Lock Pillar Trim Replacement (Regular Cab)). 5. Install the hinge pillar trim. Refer to Body Hinge Pillar Trim Panel Replacement (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Body Hinge Pillar Trim Panel Replacement). 6. Install the sill plate. Refer to Front Side Door Sill Trim Plate Replacement (Extended Cab) (See: Interior Moulding / Trim/Scuff Plate/Service and Repair/Front Side Door Sill Trim Plate Replacement (Extended Cab))Front Side Door Sill Trim Plate Replacement (Regular Cab/Crew Cab) (See: Interior Moulding / Trim/Scuff Plate/Service and Repair/Front Side Door Sill Trim Plate Replacement (Regular Cab/Crew Cab)) or Rear Side Door Sill Trim Plate Replacement (Crew Cab) (See: Interior Moulding / Trim/Scuff Plate/Service and Repair/Rear Side Door Sill Trim Plate Replacement (Crew Cab))Rear Side Door Sill Trim Plate Replacement (Extended Cab) (See: Interior Moulding / Trim/Scuff Plate/Service and Repair/Rear Side Door Sill Trim Plate Replacement (Extended Cab)). 7. Inspect the door closing effort and seal to door fit. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Front Side Door Window Weatherstrip Replacement > Page 17169 Front Door Weatherstrip: Service and Repair Front Side Door Bottom Auxiliary Sealing Strip Replacement Front Side Door Bottom Auxiliary Sealing Strip Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Hood Weatherstrip > Component Information > Service and Repair > Hood Front Seal Replacement Hood Weatherstrip: Service and Repair Hood Front Seal Replacement Hood Front Seal Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Hood Weatherstrip > Component Information > Service and Repair > Hood Front Seal Replacement > Page 17174 Hood Weatherstrip: Service and Repair Hood Rear Seal Replacement Hood Rear Seal Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Rear Door Weatherstrip: > 09-08-64-012C > Nov > 10 > Body - Side Door Body Mounted Weatherstrip Replacement Rear Door Weatherstrip: Customer Interest Body - Side Door Body Mounted Weatherstrip Replacement INFORMATION Bulletin No.: 09-08-64-012C Date: November 22, 2010 Subject: Information on Side Door Body Mounted Primary Weatherstrip Replacement Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to communicate feedback received from engineering information and add the 2011 model year. Please discard Corporate Bulletin Number 09-08-64-012B (Section 08 - Body and Accessories). Some customers may comment about side door wind noise, water leaks or door fit concerns. These concerns may appear to be related to the body mounted primary door opening weatherstrips. As a result of feedback received from engineering information, we have found that many replacements of the primary door opening weatherstrip are for issues not related to the primary door opening weatherstrip. The instructions below are a guide to help "root cause" the customer's concern and obtain the proper direction for repair. Recommendation Note: If the seal is properly installed, it will not cause a Windnoise. If mis-installed, the seal could create a Windnoise that can be corrected by re-installing the seal. If the condition is for Windnoise, please view the training courses on this subject and follow the proper diagnostics outlined in courses 10210.01D 2010 SKH Seminar Jan Emerging Issues,.02D (Feb),.03D (March) (3 Parts) (Emerging Issues programs available to U.S. dealers only). If the condition is specific to an itch noise, refer to Corporate Bulletin Number 06-08-64-035F to correct that concern. If diagnosing a water leak, please follow information supplied in Corporate Bulletin Number 09-08-57-002B. For door fit concerns, or if the seal is loose or exhibits a poor appearance, inspect for even retention around the door. If the seal pulls off too easily, the channel crimp may be wide/loose as shown between the dashed lines in the graphic above. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Rear Door Weatherstrip: > 09-08-64-012C > Nov > 10 > Body - Side Door Body Mounted Weatherstrip Replacement > Page 17183 Remove the seal only in the affected area. Inspect the seal's channel crimp and adjust accordingly by pinching the channel together for a tighter retention. Reinstall the portion of the seal that was removed. Warranty Information For vehicles repaired under warranty, use the appropriate labor operation found in the Labor Time Guide (LTG). Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Rear Door Weatherstrip: > 06-08-64-035G > Jun > 10 > Body Squeak/Itching Noise in Upper Door Area Rear Door Weatherstrip: Customer Interest Body - Squeak/Itching Noise in Upper Door Area TECHNICAL Bulletin No.: 06-08-64-035G Date: June 01, 2010 Subject: Squeak/Itching Noise in Upper Door Area (Replace Weatherstrip Assembly) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to update parts description information. Please discard Corporate Bulletin Number 06-08-64-035F (Section 08 - Body and Accessories). Condition Some customers may comment on a squeaking or itching noise in the upper door area when driving. Cause This condition may be caused by the roof drip weatherstrip to door frame contact. This could occur at any or all of the doors. Correction Replace the weatherstrip assembly. Refer to Door Opening Weatherstrip Replacement in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the appropriate labor operation from the Labor Time Guide. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Weatherstrip: > 09-08-64-012C > Nov > 10 > Body - Side Door Body Mounted Weatherstrip Replacement Rear Door Weatherstrip: All Technical Service Bulletins Body - Side Door Body Mounted Weatherstrip Replacement INFORMATION Bulletin No.: 09-08-64-012C Date: November 22, 2010 Subject: Information on Side Door Body Mounted Primary Weatherstrip Replacement Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to communicate feedback received from engineering information and add the 2011 model year. Please discard Corporate Bulletin Number 09-08-64-012B (Section 08 - Body and Accessories). Some customers may comment about side door wind noise, water leaks or door fit concerns. These concerns may appear to be related to the body mounted primary door opening weatherstrips. As a result of feedback received from engineering information, we have found that many replacements of the primary door opening weatherstrip are for issues not related to the primary door opening weatherstrip. The instructions below are a guide to help "root cause" the customer's concern and obtain the proper direction for repair. Recommendation Note: If the seal is properly installed, it will not cause a Windnoise. If mis-installed, the seal could create a Windnoise that can be corrected by re-installing the seal. If the condition is for Windnoise, please view the training courses on this subject and follow the proper diagnostics outlined in courses 10210.01D 2010 SKH Seminar Jan Emerging Issues,.02D (Feb),.03D (March) (3 Parts) (Emerging Issues programs available to U.S. dealers only). If the condition is specific to an itch noise, refer to Corporate Bulletin Number 06-08-64-035F to correct that concern. If diagnosing a water leak, please follow information supplied in Corporate Bulletin Number 09-08-57-002B. For door fit concerns, or if the seal is loose or exhibits a poor appearance, inspect for even retention around the door. If the seal pulls off too easily, the channel crimp may be wide/loose as shown between the dashed lines in the graphic above. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Weatherstrip: > 09-08-64-012C > Nov > 10 > Body - Side Door Body Mounted Weatherstrip Replacement > Page 17193 Remove the seal only in the affected area. Inspect the seal's channel crimp and adjust accordingly by pinching the channel together for a tighter retention. Reinstall the portion of the seal that was removed. Warranty Information For vehicles repaired under warranty, use the appropriate labor operation found in the Labor Time Guide (LTG). Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Weatherstrip: > 06-08-64-035G > Jun > 10 > Body - Squeak/Itching Noise in Upper Door Area Rear Door Weatherstrip: All Technical Service Bulletins Body - Squeak/Itching Noise in Upper Door Area TECHNICAL Bulletin No.: 06-08-64-035G Date: June 01, 2010 Subject: Squeak/Itching Noise in Upper Door Area (Replace Weatherstrip Assembly) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to update parts description information. Please discard Corporate Bulletin Number 06-08-64-035F (Section 08 - Body and Accessories). Condition Some customers may comment on a squeaking or itching noise in the upper door area when driving. Cause This condition may be caused by the roof drip weatherstrip to door frame contact. This could occur at any or all of the doors. Correction Replace the weatherstrip assembly. Refer to Door Opening Weatherstrip Replacement in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the appropriate labor operation from the Labor Time Guide. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement (Crew Cab) Rear Door Weatherstrip: Service and Repair Rear Door Opening Weatherstrip Replacement (Crew Cab) Rear Door Opening Weatherstrip Replacement (Crew Cab) Removal Procedure 1. Remove the rear door sill plate. Refer to Rear Side Door Sill Trim Plate Replacement (Crew Cab) (See: Interior Moulding / Trim/Scuff Plate/Service and Repair/Rear Side Door Sill Trim Plate Replacement (Crew Cab))Rear Side Door Sill Trim Plate Replacement (Extended Cab) ( See: Interior Moulding / Trim/Scuff Plate/Service and Repair/Rear Side Door Sill Trim Plate Replacement (Extended Cab)). 2. Remove the weatherstrip from the pinch-weld flange. Installation Procedure 1. Align the weatherstrip to the door opening with the 2 dots positioned on the upper right and left side. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement (Crew Cab) > Page 17200 2. Align the weatherstrip to the door opening with the bond joint positioned at the lower center of the door opening. 3. Install the weatherstrip to the pinch-weld flange. Ensure that the weatherstrip is fully seated. 4. Install the rear door sill plate. Refer to Rear Side Door Sill Trim Plate Replacement (Crew Cab) (See: Interior Moulding / Trim/Scuff Plate/Service and Repair/Rear Side Door Sill Trim Plate Replacement (Crew Cab))Rear Side Door Sill Trim Plate Replacement (Extended Cab) ( See: Interior Moulding / Trim/Scuff Plate/Service and Repair/Rear Side Door Sill Trim Plate Replacement (Extended Cab)). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement (Crew Cab) > Page 17201 Rear Door Weatherstrip: Service and Repair Rear Side Door Bottom Auxiliary Sealing Strip Replacement (Crew Cab) Rear Side Door Bottom Auxiliary Sealing Strip Replacement (Crew Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement (Crew Cab) > Page 17202 Rear Door Weatherstrip: Service and Repair Rear Side Door Bottom Auxiliary Sealing Strip Replacement (Extended Cab) Rear Side Door Bottom Auxiliary Sealing Strip Replacement (Extended Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement (Crew Cab) > Page 17203 Rear Door Weatherstrip: Service and Repair Rear Side Door Front Auxiliary Weatherstrip Replacement (Crew Cab) Rear Side Door Front Auxiliary Weatherstrip Replacement (Crew Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement (Crew Cab) > Page 17204 Rear Door Weatherstrip: Service and Repair Rear Door Opening Weatherstrip Replacement (Crew Cab) Rear Door Opening Weatherstrip Replacement (Crew Cab) Removal Procedure 1. Remove the rear door sill plate. Refer to Rear Side Door Sill Trim Plate Replacement (Crew Cab) (See: Interior Moulding / Trim/Scuff Plate/Service and Repair/Rear Side Door Sill Trim Plate Replacement (Crew Cab))Rear Side Door Sill Trim Plate Replacement (Extended Cab) ( See: Interior Moulding / Trim/Scuff Plate/Service and Repair/Rear Side Door Sill Trim Plate Replacement (Extended Cab)). 2. Remove the weatherstrip from the pinch-weld flange. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement (Crew Cab) > Page 17205 1. Align the weatherstrip to the door opening with the 2 dots positioned on the upper right and left side. 2. Align the weatherstrip to the door opening with the bond joint positioned at the lower center of the door opening. 3. Install the weatherstrip to the pinch-weld flange. Ensure that the weatherstrip is fully seated. 4. Install the rear door sill plate. Refer to Rear Side Door Sill Trim Plate Replacement (Crew Cab) (See: Interior Moulding / Trim/Scuff Plate/Service and Repair/Rear Side Door Sill Trim Plate Replacement (Crew Cab))Rear Side Door Sill Trim Plate Replacement (Extended Cab) ( See: Interior Moulding / Trim/Scuff Plate/Service and Repair/Rear Side Door Sill Trim Plate Replacement (Extended Cab)). Rear Side Door Bottom Auxiliary Sealing Strip Replacement (Crew Cab) Rear Side Door Bottom Auxiliary Sealing Strip Replacement (Crew Cab) Rear Side Door Bottom Auxiliary Sealing Strip Replacement (Extended Cab) Rear Side Door Bottom Auxiliary Sealing Strip Replacement (Extended Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement (Crew Cab) > Page 17206 Rear Side Door Front Auxiliary Weatherstrip Replacement (Crew Cab) Rear Side Door Front Auxiliary Weatherstrip Replacement (Crew Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement (Crew Cab) > Page 17207 Rear Side Door Front Auxiliary Weatherstrip Replacement (Extended Cab) Rear Side Door Front Auxiliary Weatherstrip Replacement (Extended Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement (Crew Cab) > Page 17208 Rear Side Door Window Weatherstrip Replacement (Crew Cab) Rear Side Door Window Weatherstrip Replacement (Crew Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement (Crew Cab) > Page 17209 Rear Side Door Window Weatherstrip Replacement (Extended Cab) Rear Side Door Window Weatherstrip Replacement (Extended Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Door Opening Weatherstrip Replacement (Crew Cab) > Page 17210 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Weatherstrip: > 08-08-67-006B > Apr > 11 > Body - Headliner Wet/Water Leak Into Cab Past Sunroof Sunroof / Moonroof Weatherstrip: Customer Interest Body - Headliner Wet/Water Leak Into Cab Past Sunroof TECHNICAL Bulletin No.: 08-08-67-006B Date: April 11, 2011 Subject: Headliner Wet, Water Leak into Cab, Water Leak Past Sunroof Glass Weatherstrip/Seal (Inspect Sunroof Weatherstrip/Seal and Replace if Necessary) Models: 2007-2012 Chevrolet Silverado Crew Cab Models 2007-2012 GMC Sierra Crew Cab Models with Sunroof (RPO CF5) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 08-08-67-006A (Section 08 - Body and Accessories). Condition Some customers may comment on the headliner being wet or water leaking into the cab. Cause The sunroof glass weatherstrip/seal may not be completely water tight. The weatherstrip/seal may not be properly secured to the glass panel. Correction Important DO NOT replace the sunroof glass panel. Technicians are to inspect the glass panel seal appearance at the corners and around the glass panel. If the weatherstrip/seal looks depressed or concave in the middle, as shown above, replace the seal. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Weatherstrip: > 08-08-67-006B > Apr > 11 > Body - Headliner Wet/Water Leak Into Cab Past Sunroof > Page 17219 Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Weatherstrip: > 08-08-67-006B > Apr > 11 > Body - Headliner Wet/Water Leak Into Cab Past Sunroof Sunroof / Moonroof Weatherstrip: All Technical Service Bulletins Body - Headliner Wet/Water Leak Into Cab Past Sunroof TECHNICAL Bulletin No.: 08-08-67-006B Date: April 11, 2011 Subject: Headliner Wet, Water Leak into Cab, Water Leak Past Sunroof Glass Weatherstrip/Seal (Inspect Sunroof Weatherstrip/Seal and Replace if Necessary) Models: 2007-2012 Chevrolet Silverado Crew Cab Models 2007-2012 GMC Sierra Crew Cab Models with Sunroof (RPO CF5) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 08-08-67-006A (Section 08 - Body and Accessories). Condition Some customers may comment on the headliner being wet or water leaking into the cab. Cause The sunroof glass weatherstrip/seal may not be completely water tight. The weatherstrip/seal may not be properly secured to the glass panel. Correction Important DO NOT replace the sunroof glass panel. Technicians are to inspect the glass panel seal appearance at the corners and around the glass panel. If the weatherstrip/seal looks depressed or concave in the middle, as shown above, replace the seal. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Weatherstrip: > 08-08-67-006B > Apr > 11 > Body - Headliner Wet/Water Leak Into Cab Past Sunroof > Page 17225 Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component Information > Service and Repair > Sunroof Window Weatherstrip Replacement (Crew Cab) Sunroof / Moonroof Weatherstrip: Service and Repair Sunroof Window Weatherstrip Replacement (Crew Cab) Sunroof Window Weatherstrip Replacement (Crew Cab) Removal Procedure 1. Remove the sunroof window. Refer to Sunroof Window Replacement (Extended Cab) (See: Roof and Associated Components/Sunroof / Moonroof/Sunroof / Moonroof Panel/Service and Repair/Sunroof Window Replacement (Extended Cab))Sunroof Window Replacement (Crew Cab) (See: Roof and Associated Components/Sunroof / Moonroof/Sunroof / Moonroof Panel/Service and Repair/Sunroof Window Replacement (Crew Cab)). 2. Carefully remove the sunroof window weatherstrip from the perimeter of the sunroof window. Installation Procedure 1. Carefully install the sunroof window weatherstrip (2) to the perimeter of the sunroof window (1), ensuring that the weatherstrip is fully seated. 2. Install the sunroof window to the sunroof module assembly. Refer to Sunroof Window Replacement (Extended Cab) (See: Roof and Associated Components/Sunroof / Moonroof/Sunroof / Moonroof Panel/Service and Repair/Sunroof Window Replacement (Extended Cab))Sunroof Window Replacement (Crew Cab) (See: Roof and Associated Components/Sunroof / Moonroof/Sunroof / Moonroof Panel/Service and Repair/Sunroof Window Replacement (Crew Cab)). 3. Ensure that the sunroof does not have any air or waterleaks. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component Information > Service and Repair > Sunroof Window Weatherstrip Replacement (Crew Cab) > Page 17228 Sunroof / Moonroof Weatherstrip: Service and Repair Sunroof Window Weatherstrip Replacement (Extended Cab) Sunroof Window Weatherstrip Replacement (Extended Cab) Removal Procedure 1. Remove the sunroof window. Refer to Sunroof Window Replacement (Extended Cab) (See: Roof and Associated Components/Sunroof / Moonroof/Sunroof / Moonroof Panel/Service and Repair/Sunroof Window Replacement (Extended Cab))Sunroof Window Replacement (Crew Cab) (See: Roof and Associated Components/Sunroof / Moonroof/Sunroof / Moonroof Panel/Service and Repair/Sunroof Window Replacement (Crew Cab)). 2. Carefully remove the sunroof window weatherstrip (2) from the perimeter of the sunroof window (1). Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Sunroof / Moonroof Weatherstrip > Component Information > Service and Repair > Sunroof Window Weatherstrip Replacement (Crew Cab) > Page 17229 1. Carefully install the sunroof window weatherstrip (2) to the perimeter of the sunroof window (1), ensuring that the weatherstrip is fully seated. 2. Install the sunroof window. Refer to Sunroof Window Replacement (Extended Cab) (See: Roof and Associated Components/Sunroof / Moonroof/Sunroof / Moonroof Panel/Service and Repair/Sunroof Window Replacement (Extended Cab))Sunroof Window Replacement (Crew Cab) (See: Roof and Associated Components/Sunroof / Moonroof/Sunroof / Moonroof Panel/Service and Repair/Sunroof Window Replacement (Crew Cab)). 3. Ensure that the sunroof does not have any air or waterleaks. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Technical Service Bulletins > A/T - Shifting/Poor Performance Cruise Control: Technical Service Bulletins A/T - Shifting/Poor Performance INFORMATION Bulletin No.: 01-03-10-010G Date: July 22, 2009 Subject: Inspection of Tire and Wheel Size Prior to Diagnosis of Transmission Shifts, Poor Performance, Speedometer, Cruise Control Concerns Models: 2001-2007 Chevrolet Silverado Pickup (Classic) Models Equipped with Allison(R) Automatic Transmission Only 2001-2007 GMC Sierra Pickup (Classic) Models Equipped with Allison(R) Automatic Transmission Only 2007-2010 Chevrolet Silverado Pickup HD Models 2007-2010 GMC Sierra Pickup HD Models Supercede: This bulletin is being revised to add the 2008-2010 model years, update the tire size information and reference the vehicle tire information label locations. Please discard Corporate Bulletin Number 01-03-10-010F (Section 03 - Suspension). GM has developed and matched specific tires for your vehicle. The original equipment tires and their respective size installed on the vehicle when it was new, were designed to meet General Motors Tire Performance Criteria Specification (TPC Spec) system rating. GM's exclusive TPC Spec system considers over a dozen critical specifications that impact the overall performance of the vehicle. A truck that has different tires and wheels from the original equipment designed for that vehicle will have engine power/performance concerns, transmission shift concerns, speedometer registered speed concerns, cruise control concerns and increased steering effort, especially during parking lot maneuvers at slow speeds. The engine control module (ECM) and transmission control module (TCM) use engine speed (RPM) and vehicle speed sensor (VSS) inputs as operational parameters for engine torque, transmission shifting, cruise control operation and speedometer indicated vehicle speed. Calibrations for different tire/wheel combinations are not available. Therefore, changing of tire and/or wheel size should not be undertaken by dealerships or truck owners. Proper diagnosis of engine, transmission, speedometer and cruise control concerns MUST begin with an inspection of tire/wheel size. Important A vehicle specific Tire and Loading Information label is attached to the center pillar (B-pillar) of the vehicle. With the driver's door open, you will find the label attached below the door lock post (striker). The label shows the size of the original equipment tires and the recommended cold tire inflation pressures.A vehicle specific Certification/Tire label is found on the rear edge of the driver's door. The label shows the size of the original equipment tires and the recommended cold tire inflation pressures. 2001-2007 Pickups (Classic) Equipped with Allison(R) Automatic Transmission Only Inspect the vehicle for the proper tire size as indicated in the following information. - The 2500 series trucks have LT245/75R16E tires as standard equipment. - The 3500 series trucks with single rear wheels have LT265/75R16E tires as standard equipment. - The 3500 series trucks with dual rear wheels have LT215/85R16D tires as standard equipment. 2007 Pickups HD Models (New Design Pickups) Inspect the vehicle for the proper tire size as indicated in the following information. - The 2500 series trucks have LT245/75R16E tires as standard equipment. - The 3500 series trucks with single rear wheels have LT265/75R16E tires as standard equipment. - The 3500 series trucks with dual rear wheels have LT215/85R16E tires as standard equipment. 2008-2010 Pickups HD Models (New Design Pickups) Inspect the vehicle for the proper tire size as indicated in the following information. - The 2500 series trucks have LT245/75R16E tires as standard equipment. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Technical Service Bulletins > A/T - Shifting/Poor Performance > Page 17234 - The 3500 series trucks with single rear wheels have LT265/75R16E tires as standard equipment. - The 3500 series trucks with dual rear wheels have LT225/75R17E tires as standard equipment. If a truck is found to have other than the above listed tire sizes, no further diagnosis should be undertaken until the original size tires and wheels are reinstalled on the truck. Warranty Information Reinstalling the proper wheels and tires on the vehicle, prior to performing any type of diagnosis of the truck, would be considered truck owner responsibility and not a warranty repair. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions Cruise Control: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Schematic Symbols Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17237 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17238 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17239 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17240 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17241 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17242 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17243 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17244 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17245 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17246 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17247 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17248 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17249 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17250 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17251 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17252 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17253 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17254 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17255 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17256 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17257 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17258 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17259 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17260 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17261 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17262 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17263 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17264 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17265 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17266 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17267 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17268 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > 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Information > Diagrams > Diagram Information and Instructions > Page 17279 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17280 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17281 Cruise Control: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed with Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17282 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17283 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Connector Test Adapters) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17284 Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Test Lamp) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Fused Jumper Wires) * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage Drop) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Frequency) * Testing Ground and Low Reference Circuits (See: Testing and Inspection/Component Tests and General Diagnostics/Testing Ground and Low Reference Circuits) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fuses) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Circuit Breakers) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fusible Links) Troubleshooting with a Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Testing for a Short to Voltage Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17285 Testing for a Short to Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure tests for a short to voltage in a circuit. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the Digital Multimeter (DMM) to the V (DC) position. 4. Connect the positive lead of the DMM to one end of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. Turn ON the ignition and operate all accessories. 7. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Special Tools J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure). Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents). Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17286 The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the frequency of a signal. Note: Connecting the Digital Multimeter (DMM) to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Set to Hz on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17287 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the Digital Multimeter (DMM). 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the difference in voltage potential between 2 points. 1. Set the Digital Multimeter (DMM) to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17288 Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Backprobe Note: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17289 (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for Continuity Testing for Continuity Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures verify good continuity in a circuit. With a Digital Multimeter (DMM) 1. Set the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Select the MIN MAX function on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17290 Testing for Electrical Intermittents Testing for Electrical Intermittents Special Tools J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. Note: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions). 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17291 visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing for Terminal Fretting Some intermittent conditions can be caused by wire terminal fretting corrosion. Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can pile up enough at the electrical contact spots that the electrical resistance across the connection increases. Movement between the contacting surfaces as small as 10 to 100 microns can cause fretting. To put this in perspective, a sheet of paper is about 100 microns thick, so fretting motion is small and hard to see. Vibration and thermal expansion/contraction are the main sources that create fretting motion. Since vehicles vibrate and can experience large temperature swings, they are a good source for fretting motion. Tin, copper, nickel, and iron surfaces are all susceptible to fretting corrosion. Fretting corrosion can be difficult to see but it looks like small, dark smudges on the terminals contact surface. To correct a fretting condition disconnect the suspect connector and add Nyogel lubricant 760G (dielectric grease) to both sides of the connector terminals. Then reconnect the connector and wipe away any excess lubricant. This will correct the additional terminal contact resistance due to the terminal fretting corrosion. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17292 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics). * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Ground Distribution Schematics). Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Checking Aftermarket Accessories). * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17293 Note: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures test for a short to ground in a circuit. With a Digital Multimeter (DMM) 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohms position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Danger: High voltage circuits should only be tested using a digital multimeter (DMM) and test leads with at least a CAT III rating, such as the J 39200-A Digital Multimeter. Failure to follow the procedures exactly as written may result in serious injury or death. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Digital Multimeter (DMM) Basic Requirements Service information is validated using digital multimeters that meet or exceed the following requirements. Using a multimeter that does not meet these basic requirements may give inaccurate readings which could lead to an incorrect diagnosis. Display and Settings 1. Four digits displayed 2. Voltage, amperage, resistance, frequency, diode test settings, and min-max function 3. Display positive and negative values Voltage 1. Have at least 10 M ohm input impedance Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17294 2. Test a DC voltage range of 0.1-1000 V. 3. Test an AC voltage range of 0.1-1000 V. Amperage 1. Test a DC amperage range of 0.1µA-10 A. 2. Test an AC amperage range of 0.1µA-10 A. Resistance Test a resistance range of 0.1 ohm-40 Mohm and displays infinite for a value greater than 40 M ohm (O.L. (Over-load)) Frequency Test for a frequency range of 0.5 HZ-199 K HZ Diode Test 1. Apply at least 1 mA when performing the diode bias test 2. Display the break over voltage drop (0-3 V) of a forward biased diode 3. Display infinite (O.L. (Over-load)) when a diode is reverse biased Min-Max Readings 1. Can update at a 1 ms sample rate 2. Saves and displays minimum and maximum values Note: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Probe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors). * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the EL-38125-580 GM Approved Terminal Release Tool Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the EL-38125-580 GM Approved Terminal Release Tool Kit , ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the EL-38125-580 GM Approved Terminal Release Tool Kit label on the inside of the EL-38125-580 GM Approved Terminal Release Tool Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17295 Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/EPC Connectors AFL/EPC Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17296 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 3. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17297 View showing depressing of the lever lock release tab. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17298 6. Release the rear lower half of the wiredress cover. 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17299 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17300 Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Bosch Connectors (ECM) Bosch Connectors (ECM) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17301 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. 2. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17302 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-bladed tool to release the locking tabs and remove the dress cover. 4. The terminal positive assurance (TPA) is located in the front of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17303 5. Use a small flat-blade tool to remove TPA from the connector. 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17304 Note: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17305 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17306 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Terminal Replacement Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17307 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17308 5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Position Assurance Locks) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Terminal Position Assurance Locks) * AFL/EPC Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/AFL/EPC Connectors) * Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (BSK))Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (0.64))Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (2.8 JPT))Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (ECM)) * Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Weather Pack))Delphi Connectors (Push To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Push to Seat))Delphi Connectors Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17309 (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Pull to Seat))Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro-Pack 100W))Delphi Connectors (Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro .64))Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (12-Way)) * FCI Connectors (Lever Lock) (See: General Electrical Diagnostic Procedures/Connector Repairs/FCI Connectors (Lever Lock)) * JST Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/JST Connectors) * Kostal Connectors (Glow Plug Control Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Glow Plug Control Module))Kostal Connectors (Transmission) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Transmission)) * Molex Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Molex Connectors) * Sumitomo Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Sumitomo Connectors) * Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (CM 42-Way))Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Sensor))Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (0.25 Cap))Tyco/AMP Connectors (43-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (43-Way))Tyco/AMP Connectors (Door Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Door Module))Tyco/AMP Connectors (102-Way Inline) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (102-Way Inline))Tyco/AMP Connectors (Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Seat))Tyco/AMP Connectors (SIR) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (SIR)) * Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (2-Way))Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (16-Way)) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17310 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17311 * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17312 * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17313 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17314 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17315 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Push to Seat) Delphi Connectors (Push To Seat) Special Tools J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17316 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs). 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Terminated Lead Repair 1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice sleeves depending on the gauge size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Delphi Connectors (Pull to Seat) Delphi Connectors (Pull To Seat) Special Tools Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17317 J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Note: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17318 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. View of a typical Micro 64 connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17319 Depress the lock and pull the lever over and past the lock. View of the connector when released from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17320 View of another type of Micro 64 connector. Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17321 View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17322 Note: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17323 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17324 Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Note: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17325 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17326 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17327 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17328 1. Cut the wire as close to the terminal as possible. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17329 Terminal Replacement Procedure After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Special Tools J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Note: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals). 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12-Way) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17330 Delphi Connectors (12-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17331 4. Release the lower wire dress cover locking tab. 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17332 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17333 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors (Lever Lock) FCI Connectors (Lever Lock) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17334 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. The release tab is located on the top of the wiredress cover. 3. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17335 6. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17336 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17337 1. While depressing the lock, remove the connector from the component. 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17338 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. 4. View of the TPA when removed from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17339 5. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Glow Plug Control Module) Kostal Connectors (Glow Plug Control Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17340 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17341 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17342 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. Note: The front TPA cannot be removed from the connector. Only move it to the preset position. 6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm). 7. Use a small flat-blade tool to completely remove the rear TPA from the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17343 8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Transmission) Kostal Connectors (Transmission) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17344 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17345 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Terminal Replacement Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17346 After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17347 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17348 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17349 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17350 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17351 3. To assemble the connector, reverse the connector disassembly procedure. Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17352 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17353 7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17354 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17355 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17356 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17357 Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17358 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17359 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17360 6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (102-Way Inline) Tyco/AMP Connectors (102-Way Inline) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17361 View of a typical connector in the assembled position. 1. Pull the locking lever to the 90 degree position from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17362 2. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal. 3. Slide the male connector body out away from the guide plates. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17363 Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 4. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. 5. Using terminal release tool J 38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17364 6. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 7. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17365 8. The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool J-38125-11A or equivalent to release the locking tab and slide the connector off the female body. 9. Move the locking lever 180 degrees from the connected position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17366 10. With the locking lever in the 180 degree position the guide plates can be removed from the connector body. Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 11. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17367 12. Using terminal release tool J 38125-216, lift the terminal plate past the terminals and out of the connector body cavity. 13. Terminal plate will bind slightly on each corner. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17368 14. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 15. Using terminal release tool J 38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17369 16. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 17. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17370 18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever. 19. Slide the male connector body back inward toward the guide plates. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17371 20. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly. 21. Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Seat) Tyco/AMP Connectors (Seat) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17372 Removal Procedure 1. Grasp the locking slide lever and pull outward from the end of the connector. 2. As the slide lever is pulled out the mating connector is lifted from the seated position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17373 Note: TPA is keyed and can only be inserted in one direction. 3. Using terminal release tool J 38125-11A or equivalent, push the TPA tabs into the connector body. 4. Pull the TPA from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17374 5. Using terminal release tool J 38125-11A or equivalent, release the connector wire dress cover locking tab. 6. With the lock tab released, lift the connector wire dress cover from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17375 7. Using terminal release tool J 38125-212, press the prongs into the holes each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 8. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17376 9. Using terminal release tool J 38125-556, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (SIR) Tyco/AMP Connectors (SIR) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17377 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17378 3. Using terminal tool J-38125-11A or equivalent, release the wire dress cover locking tabs. 4. Pivot connector wire dress cover while removing from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17379 5. Using terminal tool J-38125-11A or equivalent, remove the TPA by lifting straight off the connector body. 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals Repairing Connector Terminals Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17380 Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gauge size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17381 2. Disconnect the connector from the component. 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17382 4. Relieve the tension on the nose piece retainers by inserting J 38125-12A into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. 5. Once the nose piece retainers are relaxed, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17383 6. On the opposite side of the nose piece, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17384 8. Insert the J 38125-553 tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17385 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. If the TPA is removed, be sure to reinstall it before reconnecting the connector. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17386 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Special Tools Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17387 J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Note: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17388 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17389 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17390 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17391 1. While depressing the lock, pull the two connector halves apart. Note: The TPA is fragile and may break if not done carefully. 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. 3. View of the male half of the connector with female terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17392 4. View of the female half of the connector with male terminals. 5. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. View of the female half of the connector with male terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17393 7. View of the male half of the connector with female terminals. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17394 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are a one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine if the element in the fuse is broken (2). If not broken (1), also check for continuity using a Digital Multimeter (DMM) or a continuity tester. If the element is broken or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a Digital Multimeter (DMM) at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gauge size. Repairing a Fusible Link Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17395 Flat Wire Repairs The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Special Tools J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool * J 38125-5 Ultra Torch Special Tool The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Note: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation). GMLAN Connector Terminal Repair Note: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) for the appropriate connector repair procedure. GMLAN Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17396 Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17397 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Special Tools J-38125 Terminal Repair Kit Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17398 repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs High Temperature Wiring Repairs Special Tools J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gauge size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17399 splice. Note: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17400 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17401 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the wire insulation has been chafed, or broken, enough to show the conductive portion of the wire, and the wire is not damaged, determine the length of insulation that needs to be repaired. If the repair is less than 280 mm (11 in), cut the wire within the damaged area. Then slide the appropriate heat shrink tubing (listed below) over the wire, and repair the wire by splicing the wires together. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Once the wire is spliced together slide heat shrink tubing over the damaged area and apply heat to seal the repaired wire. If the wire is damaged, or the damaged area is larger than 280 mm (11 in), then replace the damaged wire by splicing in a new section of wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17402 SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Special Tools J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17403 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17404 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17405 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Special Tools J-38125 Terminal Repair Kit Note: Use only DuraSeal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use DuraSeal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use DuraSeal splice sleeves where there are special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17406 * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17407 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17408 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the instructions for Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Staggering the splices by 65 mm (2.5 in) is recommended. Note: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product AL-36FR to replace the damaged mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Flat Wire Repairs) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/GMLAN Wiring Repairs) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Heated Oxygen Sensor Wiring Repairs) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves) * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Twisted or Shielded Cable) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Inline Harness Diodes) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/SIR/SRS Wiring Repairs) US English/Metric Conversion US English/Metric Conversion Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17409 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17410 Testing Ground and Low Reference Circuits Testing Ground and Low Reference Circuits Because a test lamp can light with up to 200 ohm in a ground or low reference circuit they are not recommended to be used for this type of test. A low impedance test lamp can light and indicate the circuit is good when there is as much as 20-30 ohm present, while a high impedance test lamp can light with up to 200 ohm present in the circuit. This is why the Digital Multi-Meter (DMM) is used when validating a ground or low reference circuit continuity. When using the DMM there are many vehicle conditions that can affect the ground and low reference continuity testing. If these conditions are not met, a ground or low reference circuit test can fail on a good circuit. This may cause longer diagnosis time and incorrect component replacement. Any current flow through a ground or low reference circuit, while being tested, will skew the DMM continuity reading, or display a reading higher than when there is no current flowing. Performing a ground or low reference circuit continuity test, in reference to the vehicles battery negative terminal, will have the highest risk of failing a good ground or low reference circuit test than any other ground reference point. The best ground test points would be a control module housing (if the control modules housing is metal and grounded), door jamb striker (if attached to metal), under dash metal frame work, engine block, or body ground studs (other than where the negative battery cable is attached). A typical DMM ground or low reference circuit continuity reading can be as high as 100 ohm with the ignition ON, and drop to 15-25 ohm after the ignition is turned OFF. The reading will drop below 10 ohm after 30-40 seconds, then below 5 ohm after 60 seconds. Once the vehicle completely goes to sleep (generally 3-10 minutes) the reading will drop below 0.3 ohm. The following list of conditions may need to be met to ensure a valid continuity reading on a ground or low reference circuit: * Ignition OFF * Key out of the ignition switch (when not equipped with keyless entry and remote start) * Retained Accessory Power (RAP) OFF (open and close the driver door after ignition OFF) * Battery charger set at a 2 A or less charge rate * Scan tool not communicating with any vehicle control module (in some cases it may need to be disconnected from the DLC) * All entry doors closed * Headlamps OFF (auto headlamps disabled) * Any delay lighting OFF * HVAC after blow OFF * Any accessory that can work when the ignition is OFF * Wait up to 60 seconds (after all other listed conditions are met) Activating the DOOR LOCK function with a key fob can greatly reduce the time to achieve a valid ground or low reference continuity test result. Terminal Removal Terminal Removal Special Tools * EL-38125-580 - Terminal Release Tool Kit * EL-35616 - Connector Test Adapter Kit For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repair procedures. 1. Find the appropriate connector end view within the connector end view section. The connector end view has the following information: Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17411 * Diagnostic probe tool * Terminal release tool * Terminal/terminated lead part numbers Note: Not using the proper test kit probe may cause damage to the terminal(s) that are probed. 2. Determine if a terminal is damaged. * Locate the diagnostic probe tool from the connector end view. The connector end view describes the color and part number to help the technician find and use the correct tool. * Connect the probe tool to the Digital Multimeter. * Insert the probe tool into the cavity and follow the procedures from the Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter). 3. Disconnect the connector body to perform the repair. 4. Use the following procedure to remove the terminal from the connector body. Note: Several procedures for specific connector bodies are called out in the Wiring Repairs section. * The terminal position assurance (TPA) and connector position assurance (CPA) should be removed before releasing the terminal for the connector body. * Look at the connector end view to locate the cavity of the damaged terminal and find the proper terminal release tool from the terminal release tool kit. Note: Using the incorrect terminal release tool can damage the connector body. * Insert the terminal release tool into the cavity. Note: Some terminals have a lever that must be disengaged before the terminal can be released. 5. Gently pull the wire out of the back of the connector. 6. Repair the terminal by following the Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) procedure. 7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminated Lead Repair Terminated Lead Repair Special Tools * J-38125-8 - Splice Sleeve Crimp Tool Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17412 * J-38125-5 - Ultra Torch For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) procedures. Terminated leads are terminals that are crimped onto wires. The terminated lead can be used throughout the vehicle since it is designed for temperatures up to 150°C. The length of the wire is 450 mm. The DuraSeal splice sleeve has the following 2 critical features: * A special heat shrink tubing that environmentally seals the splice. The shrink tubing contains a sealing adhesive inside the shrink tubing. * A cross hatched (knurled) core crimp that provides the necessary contact integrity for sensitive low energy circuits. 1. Use the connector end view to identify the correct terminated lead. 2. The terminated lead package should include a DuraSeal splice sleeve. If not, use the chart to identify the correct part. 3. Open the harness by removing any tape: Use a sewing seam ripper, or a comparable tool, to cut open the harness, to avoid wire insulation damage. 4. Depending on how many terminals need repairs, cut the terminal and wire back at least 40 mm. Try to keep the harness wire length the same. If more than one terminated lead is required, stagger the lengths by 40 mm. This helps reduce the bundle size of the wire harness. 5. Use the EL-38125-10 - tool in order to position the DuraSeal splice sleeve in the proper color nest of the splice sleeve crimp tool. The crimp tool has four nests, one for each color. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17413 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the J-38125-5 - ultra torch , apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 17414 Cruise Control: Electrical Diagrams Cruise Control Schematics Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Page 17415 Cruise Control: Description and Operation Cruise Control Description and Operation Cruise control is a speed control system that maintains a desired vehicle speed under normal driving conditions at speeds above 40 km/h (25 mph). Steep grades may cause variations in the selected vehicle speeds. The following are the main components of the Cruise Control System: * The accelerator pedal * The stop lamp switch * The body control module (BCM) * The cruise control switches * The engine control module (ECM) * The throttle actuator control (TAC) motor * The vehicle speed sensor (VSS) Cruise Control Engaged The Cruise Control System will engage and adjust vehicle speeds, based on the activation of the following cruise control switches, which are located on the steering wheel: * The on/off switch * The + RES switch * The - SET switch The body control module (BCM) monitors the signal circuit of the cruise control switches. The BCM relays the cruise control switch status to the engine control module (ECM) via the GMLAN serial data circuit. The ECM uses the status of the cruise control switch to determine when to capture and maintain the vehicle speed. The ECM monitors the vehicle speed signal circuit in order to determine the desired vehicle speed. The ECM uses the throttle actuator control (TAC) motor in order to maintain the vehicle speed. For further information on the TAC System, refer to Throttle Actuator Control (TAC) System Description () for the 4.3L engine or Throttle Actuator Control (TAC) System Description () for the 4.8L, 5.3L, 6.0L, 6.2L or 7.0L engines. Voltage is supplied to the cruise control switch via the steering wheel control switch reference voltage circuit supplied by the BCM. The cruise control function switches are arranged in a resistive ladder design, with each cruise control function switch having a different resistance value. The BCM detects a specific voltage value that is associated with the cruise control function switch being activated. When the normally open cruise control on/off switch is turned ON, the switch closes and the BCM supplies a ground to the cruise control switch ON indicator circuit as it becomes illuminated. The BCM sends a GMLAN serial data message to the ECM indicating that the on/off switch is active. Similarly, when the normally open + RES switch or the normally open - SET switch are pressed, the switch closes and the BCM detects the predetermined voltage signal on the cruise control set/coast and resume/accel switch signal circuit. The BCM sends a GMLAN serial data message to the ECM indicating that the + RES switch or the - SET switch is active. To engage the Cruise Control System, ensure that the vehicle speed is above 40.2 km/h (25 mph), turn the cruise On/Off switch ON and momentarily press the - SET switch. The ECM will engage the Cruise Control System and record the vehicle speed. The ECM sends a GMLAN serial data message to the driver information center (DIC) in order to illuminate the CRUISE SET TO ### message. The ECM sends a GMLAN serial data message to the instrument panel cluster (IPC) in order to illuminate the Cruise Engaged indicator in the IPC. The - SET switch and the + RES switch will remain inactive when the BCM has not received the predetermined voltage signal from the on/off switch. Pressing the accelerator pedal, while the Cruise Control System is engaged, will allow the driver to override the Cruise Control System in order to accelerate the vehicle beyond the current set vehicle speed. When the accelerator pedal is released, the vehicle will decelerate and resume the current set vehicle speed. The driver can also override the current set vehicle speed via the SET switch and the + RES switch. When the Cruise Control System is engaged, pressing and holding the - SET switch will allow the vehicle to decelerate from the current set vehicle speed without deactivating the Cruise Control System. When the - SET switch is released, the ECM will record the vehicle speed and maintain the vehicle speed as the new set vehicle speed. When the Cruise Control System is engaged, momentarily pressing the - SET switch will allow the vehicle to decelerate at 1.6 km/h (1 mph) increments for each time that the - SET is momentarily pressed, with a minimum vehicle speed of 37 km/h (23 mph). Pressing and holding the + RES switch, when the Cruise Control System is engaged, will allow the vehicle to accelerate to a greater vehicle speed than the current set vehicle speed. When the + RES switch is released, the ECM will record the vehicle speed and maintain the vehicle speed as the new set vehicle speed. When the Cruise Control System is engaged, momentarily pressing the + RES switch will allow the vehicle to accelerate at 1.6 km/h (1 mph) increments for each time that the + RES switch is momentarily pressed, with the maximum acceleration total of 16 km/h (10 mph) over the current set vehicle speed. Momentarily activating the + RES switch will recall the previous vehicle speed, after the cruise control system is disengaged by pressing the brake pedal or by activating the CANCEL switch. Cruise Control Disengaged The engine control module (ECM) disengages the cruise control operation based on the signals from the following switches: * The stop lamp switch * The cruise control On/Off switch * The cruise control cancel switch Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > Diagrams > Page 17416 The body control module (BCM) determines when the cruise control cancel switch is activated. When the normally open cancel switch is closed, the BCM detects the predetermined voltage signal on the cruise control function switch circuit. The BCM sends a GMLAN serial data message to the ECM in order to disengage the cruise control system. The stop lamp switch is mounted on the brake pedal bracket. When the brake pedal is applied, the normally open stop lamp switch closes. The ECM monitors the stop lamp signal circuit through a discrete input and a GMLAN serial data message signal from the BCM indicating the brake status. When both signals indicate the brake pedal is applied, the ECM will disengage the cruise control system. The Cruise Control System will disengage when the cruise control on/off switch is switched OFF. The vehicle speed stored in the memory of the engine control module will be erased when the cruise control On/Off switch is turned OFF, or the ignition switch is turned OFF. The Cruise Control System will disengage when the ECM detects that a driver override function has been active for approximately 60 seconds. When the Cruise Control System has been disengaged, the ECM sends a GMLAN serial message to the instrument panel cluster (IPC) in order to turn OFF the Cruise Engaged indicator, and to the driver information center (DIC) in order to turn OFF the CRUISE SET TO ### message. Each time the Cruise Control System is disengaged, the ECM will keep track of the reason for system disengagement. The last 8 disengagement reasons will be recorded within the ECM memory, and can be viewed with a scan tool. Cruise Control Inhibited The engine control module (ECM) inhibits the cruise control operation when any of the following conditions exist: * The ECM has not detected a brake pedal activation from the body control module (BCM). * A Cruise Control System DTC has been set. * The vehicle speed is less than 40.2 km/h (25 mph). * The vehicle speed is too high. * The vehicle is in PARK, REVERSE, NEUTRAL, or 1st gear. * The engine RPM is too low. * The engine RPM is too high. * The system voltage is not between 9-16 volts. * The Antilock Brake System (ABS)/Traction Control System (TCS) is active for more than 2 seconds. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > System Diagnosis > Symptoms - Cruise Control Cruise Control: Testing and Inspection Symptoms - Cruise Control Symptoms - Cruise Control Important: The following steps must be completed before using the symptom tables. 1. Before using the symptom diagnostic table, perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) , in order to verify the following conditions: * There are no DTCs set. * The module can communicate via the serial data link. 2. Review the system operation in order to understand the system functions. Refer to Cruise Control Description and Operation (See: Description and Operation). Visual/Physical Inspection * Inspect for aftermarket devices which can affect the operation of the cruise control system. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Checking Aftermarket Accessories). * Inspect the accessible system components or the visible system components for obvious damage or for obvious conditions which can cause the symptom. Intermittent Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections ( See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections). Symptom List Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom: * Cruise Control Malfunction (See: Cruise Control Malfunction) * Cruise Control Indicator Malfunction (IPC Indicator Malfunction) (See: Cruise Control Indicator Malfunction (IPC Indicator Malfunction) )Cruise Control Indicator Malfunction (Switch Indicator Malfunction) (See: Cruise Control Indicator Malfunction (Switch Indicator Malfunction) ) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > System Diagnosis > Symptoms - Cruise Control > Page 17419 Cruise Control: Testing and Inspection Cruise Control Indicator Malfunction (Switch Indicator Malfunction) Cruise Control Indicator Malfunction (Switch Indicator Malfunction) Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Diagnostic Fault Information Circuit/System Description The cruise control switch contains an LED that illuminates to indicate the cruise control system has been switched ON. Voltage is applied through the ON/OFF switch to the LED when the switch is pressed. The BCM provides the ground path for the LED through a dedicated control circuit. Pressing the switch again opens the switch and the lamp turns OFF. Reference Information Schematic Reference Cruise Control Schematics (See: Diagrams/Electrical Diagrams) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views) Description and Operation * Cruise Control Description and Operation (See: Description and Operation) * Indicator/Warning Message Description and Operation (See: Instrument Panel, Gauges and Warning Indicators/Description and Operation/Indicator/Warning Message) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning) for scan tool information Circuit/System Verification Ignition ON, observe the cruise control indicator while applying the cruise On/Off switch. The indicator should turn on and off accordingly with the applied switch. Circuit/System Testing Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > System Diagnosis > Symptoms - Cruise Control > Page 17420 Important: Refer to DTC B3794 (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/B Code Charts/B3794) before performing this diagnostic, if this code is set as current or history. 1. Ignition OFF, disconnect the harness connector at the steering wheel controls switch - left. 2. Ignition ON, verify that a test lamp illuminates between the signal circuit terminal 9 and B+. ‹› If the test lamp does not illuminate, test the signal circuit for a short to voltage or an open/high resistance. If the circuit tests normal, replace the BCM. 3. If all circuits test normal, test or replace the steering wheel controls switch - left. Repair Instructions Perform the Diagnostic Repair Verification (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. * Steering Wheel Control Switch Assembly Replacement (See: Accessories and Optional Equipment/Sensors and Switches - Accessories and Optional Equipment/Steering Mounted Controls Assembly/Service and Repair) * Control Module References (See: Testing and Inspection/Programming and Relearning) for BCM replacement, setup and programming Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > System Diagnosis > Symptoms - Cruise Control > Page 17421 Cruise Control: Testing and Inspection Cruise Control Indicator Malfunction (IPC Indicator Malfunction) Cruise Control Indicator Malfunction (IPC Indicator Malfunction) Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Circuit/System Description The instrument panel cluster (IPC) illuminates the cruise control engaged indicator based on serial data messages received from the engine control module (ECM). The indicator is commanded ON when the cruise control system is controlling vehicle speed, and turned OFF with the system disengaged. Reference Information Schematic Reference * Cruise Control Schematics (See: Diagrams/Electrical Diagrams) * Instrument Cluster Schematics (See: Diagrams/Electrical Diagrams/Instrument Panel, Gauges and Warning Indicators/System Diagram/Instrument Cluster Schematics) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views) Description and Operation * Cruise Control Description and Operation (See: Description and Operation) * Indicator/Warning Message Description and Operation (See: Instrument Panel, Gauges and Warning Indicators/Description and Operation/Indicator/Warning Message) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning) for scan tool information Circuit/System Verification Ignition ON, with a scan tool perform the Lamp Test for the instrument panel cluster (IPC) and observe the cruise control indicator. If the cruise control indicator illuminates during the test, replace the ECM. If the cruise control indicator does not illuminates during the test or remains illuminated at all times, replace the IPC. Repair Instructions Perform the Diagnostic Repair Verification (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. Control Module References (See: Testing and Inspection/Programming and Relearning) for ECM or IPC replacement, setup, and programming Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > System Diagnosis > Symptoms - Cruise Control > Page 17422 Cruise Control: Testing and Inspection Cruise Control Malfunction Cruise Control Malfunction Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Diagnostic Fault Information Circuit/System Description The body control module (BCM) supplies battery voltage to the cruise control switch. The cruise control switch signal is an input to the BCM. The BCM monitors the cruise control switch signal circuit in order to detect when the driver has requested to perform a cruise control function. The BCM detects a specific voltage signal on the cruise control switch signal circuit when a switch is applied. Reference Information Schematic Reference * Cruise Control Schematics (See: Diagrams/Electrical Diagrams) * Steering Wheel Secondary/Configurable Control Schematics (See: Accessories and Optional Equipment/Diagrams/Electrical Diagrams/Steering Wheel Secondary/Configurable Control Schematics) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views) Description and Operation Cruise Control Description and Operation (See: Description and Operation) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning) for scan tool information Circuit/System Verification Engine ON, while rotating the steering wheel to both steering stops, observe the scan tool Cruise Control Switch parameter while pressing each of the cruise control switches. The parameter should toggle between On, Off, Resume, Set, and Cancel as the applicable switch is pressed. Circuit/System Testing Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Cruise Control > System Information > System Diagnosis > Symptoms - Cruise Control > Page 17423 1. Ignition OFF, disconnect the harness connector at the steering wheel controls switch - left. 2. Ignition ON, test for B+ between the B+ circuit terminal 1 and ground. ‹› If less than the specified value, test the B+ circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the BCM. 3. Test for B+ between the B+ circuit terminal 1 and the signal circuit terminal 3. ‹› If less than the specified value, test the signal circuit for a short to voltage or an open/high resistance. If the circuit tests normal, replace the BCM. 4. Ignition OFF, disconnect the X1 harness connector at the BCM. 5. Test for infinite resistance between the signal circuit terminal 3 and ground. ‹› If less than the specified value, test the signal circuit for a short to ground. 6. If all circuits test normal, test or replace the steering wheel control switch-left. Component Testing 1. Disconnect the harness connector at the steering wheel controls switch - left. 2. Cruise control switch ON, measure the resistance between terminal 1 and terminal 3 while individually activation and holding each cruise control function switch and compare the resistance reading to the values in the table below. ‹› If not within the specified resistance range, replace the steering wheel controls switch - left. Repair Instructions Perform the Diagnostic Repair Verification (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. * Steering Wheel Control Switch Assembly Replacement (See: Accessories and Optional Equipment/Sensors and Switches - Accessories and Optional Equipment/Steering Mounted Controls Assembly/Service and Repair) * Control Module References (See: Testing and Inspection/Programming and Relearning) for BCM replacement, setup, and programming Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Air Bag Deactivation Indicator > Component Information > Locations Air Bag Deactivation Indicator: Locations Harness Routing Views Overhead Console Harness Routing 1 - X304 (except MEX) 2 - Inflatable Restraint Passenger Air Bag On/Off Indicator (AL0/C99 except MEX) 3 - Cellular Telephone Microphone (UE1/U3U/UVB) 4 - Roof Beacon Switch (5X7/5Y0/TRW) 5 - Sliding Rear Window Switch (A48) 6 - Dome/Reading Lamps - Front 7 - J322 (TRW/UG1/A48) 8 - J323 9 - X313 (CF5/TRW/5X7/5Y0) 10 - Blunt Cut - Roof Mounted Beacon Provision (TRW) 11 Roof Beacon Relay (TRW) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Air Bag Deactivation Indicator > Component Information > Locations > Page 17428 Air Bag Deactivation Indicator: Diagrams Component Connector End Views Inflatable Restraint I/P Module Indicator (AL0 or C99 except MEX) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Air Bag Deactivation Indicator > Component Information > Locations > Page 17429 Air Bag Deactivation Indicator: Service and Repair Inflatable Restraint Instrument Panel Module Indicator Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams Audible Warning Device: Diagrams Component Connector End Views Backup Alarm (8S3) Chime Module (UL5) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Page 17433 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions Cigarette Lighter: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Schematic Symbols Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17438 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17439 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17440 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17441 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17442 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17443 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17444 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17445 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17446 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17447 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17448 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17449 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17450 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17451 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17452 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17453 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17454 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17455 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17456 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17457 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17458 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17459 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17460 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17461 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17462 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17463 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17464 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17465 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17466 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17467 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17468 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17469 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17470 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17471 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17472 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17473 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17474 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17475 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17476 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17477 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17478 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17479 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17480 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17481 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17482 Cigarette Lighter: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed with Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17483 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17484 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Connector Test Adapters) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17485 Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Test Lamp) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Fused Jumper Wires) * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage Drop) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Frequency) * Testing Ground and Low Reference Circuits (See: Testing and Inspection/Component Tests and General Diagnostics/Testing Ground and Low Reference Circuits) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fuses) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Circuit Breakers) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fusible Links) Troubleshooting with a Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Testing for a Short to Voltage Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17486 Testing for a Short to Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure tests for a short to voltage in a circuit. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the Digital Multimeter (DMM) to the V (DC) position. 4. Connect the positive lead of the DMM to one end of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. Turn ON the ignition and operate all accessories. 7. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Special Tools J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure). Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents). Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070 . Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17487 The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the frequency of a signal. Note: Connecting the Digital Multimeter (DMM) to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Set to Hz on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17488 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the Digital Multimeter (DMM). 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the difference in voltage potential between 2 points. 1. Set the Digital Multimeter (DMM) to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17489 Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Backprobe Note: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17490 (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for Continuity Testing for Continuity Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures verify good continuity in a circuit. With a Digital Multimeter (DMM) 1. Set the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Select the MIN MAX function on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17491 Testing for Electrical Intermittents Testing for Electrical Intermittents Special Tools J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200 . The J 39200 will generate an audible tone when a change is detected. Note: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200 . The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions). 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17492 visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing for Terminal Fretting Some intermittent conditions can be caused by wire terminal fretting corrosion. Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can pile up enough at the electrical contact spots that the electrical resistance across the connection increases. Movement between the contacting surfaces as small as 10 to 100 microns can cause fretting. To put this in perspective, a sheet of paper is about 100 microns thick, so fretting motion is small and hard to see. Vibration and thermal expansion/contraction are the main sources that create fretting motion. Since vehicles vibrate and can experience large temperature swings, they are a good source for fretting motion. Tin, copper, nickel, and iron surfaces are all susceptible to fretting corrosion. Fretting corrosion can be difficult to see but it looks like small, dark smudges on the terminals contact surface. To correct a fretting condition disconnect the suspect connector and add Nyogel lubricant 760G (dielectric grease) to both sides of the connector terminals. Then reconnect the connector and wipe away any excess lubricant. This will correct the additional terminal contact resistance due to the terminal fretting corrosion. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17493 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics). * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Ground Distribution Schematics). Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Checking Aftermarket Accessories). * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17494 Note: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures test for a short to ground in a circuit. With a Digital Multimeter (DMM) 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohms position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Danger: High voltage circuits should only be tested using a digital multimeter (DMM) and test leads with at least a CAT III rating, such as the J 39200-A Digital Multimeter. Failure to follow the procedures exactly as written may result in serious injury or death. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Digital Multimeter (DMM) Basic Requirements Service information is validated using digital multimeters that meet or exceed the following requirements. Using a multimeter that does not meet these basic requirements may give inaccurate readings which could lead to an incorrect diagnosis. Display and Settings 1. Four digits displayed 2. Voltage, amperage, resistance, frequency, diode test settings, and min-max function 3. Display positive and negative values Voltage 1. Have at least 10 M ohm input impedance Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17495 2. Test a DC voltage range of 0.1-1000 V. 3. Test an AC voltage range of 0.1-1000 V. Amperage 1. Test a DC amperage range of 0.1µA-10 A. 2. Test an AC amperage range of 0.1µA-10 A. Resistance Test a resistance range of 0.1 ohm-40 Mohm and displays infinite for a value greater than 40 M ohm (O.L. (Over-load)) Frequency Test for a frequency range of 0.5 HZ-199 K HZ Diode Test 1. Apply at least 1 mA when performing the diode bias test 2. Display the break over voltage drop (0-3 V) of a forward biased diode 3. Display infinite (O.L. (Over-load)) when a diode is reverse biased Min-Max Readings 1. Can update at a 1 ms sample rate 2. Saves and displays minimum and maximum values Note: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Probe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors). * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the EL-38125-580 GM Approved Terminal Release Tool Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the EL-38125-580 GM Approved Terminal Release Tool Kit , ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the EL-38125-580 GM Approved Terminal Release Tool Kit label on the inside of the EL-38125-580 GM Approved Terminal Release Tool Kit for the correct adapter along with the connector end view for terminal size. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17496 Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/EPC Connectors AFL/EPC Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17497 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 3. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17498 View showing depressing of the lever lock release tab. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17499 6. Release the rear lower half of the wiredress cover. 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17500 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17501 Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Bosch Connectors (ECM) Bosch Connectors (ECM) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17502 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. 2. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17503 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-bladed tool to release the locking tabs and remove the dress cover. 4. The terminal positive assurance (TPA) is located in the front of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17504 5. Use a small flat-blade tool to remove TPA from the connector. 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17505 Note: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17506 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17507 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Terminal Replacement Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17508 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17509 5. Insert the J 38125-557 into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Position Assurance Locks) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Terminal Position Assurance Locks) * AFL/EPC Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/AFL/EPC Connectors) * Bosch Connectors (BSK) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (BSK))Bosch Connectors (0.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (0.64))Bosch Connectors (2.8 JPT) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (2.8 JPT))Bosch Connectors (ECM) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors (ECM)) * Delphi Connectors (Weather Pack) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Weather Pack))Delphi Connectors (Push To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Push to Seat))Delphi Connectors Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17510 (Pull To Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Pull to Seat))Delphi Connectors (Micro-Pack 100W) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro-Pack 100W))Delphi Connectors (Micro.64) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (Micro .64))Delphi Connectors (12-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors (12-Way)) * FCI Connectors (Lever Lock) (See: General Electrical Diagnostic Procedures/Connector Repairs/FCI Connectors (Lever Lock)) * JST Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/JST Connectors) * Kostal Connectors (Glow Plug Control Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Glow Plug Control Module))Kostal Connectors (Transmission) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors (Transmission)) * Molex Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Molex Connectors) * Sumitomo Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Sumitomo Connectors) * Tyco/AMP Connectors (CM 42-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (CM 42-Way))Tyco/AMP Connectors (Sensor) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Sensor))Tyco/AMP Connectors (0.25 Cap) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (0.25 Cap))Tyco/AMP Connectors (43-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (43-Way))Tyco/AMP Connectors (Door Module) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Door Module))Tyco/AMP Connectors (102-Way Inline) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (102-Way Inline))Tyco/AMP Connectors (Seat) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (Seat))Tyco/AMP Connectors (SIR) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors (SIR)) * Yazaki Connectors (2-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (2-Way))Yazaki Connectors (16-Way) (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors (16-Way)) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17511 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17512 * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17513 * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17514 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17515 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17516 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Push to Seat) Delphi Connectors (Push To Seat) Special Tools J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17517 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs). 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Terminated Lead Repair 1. Remove the terminal. 2. Find the appropriate terminated lead. 3. Use the appropriate splice sleeves depending on the gauge size. 4. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Delphi Connectors (Pull to Seat) Delphi Connectors (Pull To Seat) Special Tools Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17518 J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Note: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17519 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. View of a typical Micro 64 connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17520 Depress the lock and pull the lever over and past the lock. View of the connector when released from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17521 View of another type of Micro 64 connector. Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17522 View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17523 Note: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17524 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17525 Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Note: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17526 1. Disconnect the connector from the component. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17527 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17528 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17529 1. Cut the wire as close to the terminal as possible. Note: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gauge wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17530 Terminal Replacement Procedure After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Special Tools J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Note: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals). 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12-Way) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17531 Delphi Connectors (12-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17532 4. Release the lower wire dress cover locking tab. 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17533 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17534 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors (Lever Lock) FCI Connectors (Lever Lock) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17535 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. The release tab is located on the top of the wiredress cover. 3. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17536 6. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17537 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17538 1. While depressing the lock, remove the connector from the component. 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17539 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. 4. View of the TPA when removed from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17540 5. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Glow Plug Control Module) Kostal Connectors (Glow Plug Control Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17541 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17542 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17543 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. Note: The front TPA cannot be removed from the connector. Only move it to the preset position. 6. Use a small flat-blade tool to move the front TPA to the preset position, outboard approximately 0.125 in. (3 mm). 7. Use a small flat-blade tool to completely remove the rear TPA from the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17544 8. Use the J 38125-24 or the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors (Transmission) Kostal Connectors (Transmission) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17545 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17546 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Terminal Replacement Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17547 After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17548 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17549 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17550 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17551 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17552 3. To assemble the connector, reverse the connector disassembly procedure. Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17553 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17554 7. Pressing the J 38125-12A tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17555 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17556 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17557 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17558 Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17559 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17560 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17561 6. Use the J 38125-12A tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (102-Way Inline) Tyco/AMP Connectors (102-Way Inline) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17562 View of a typical connector in the assembled position. 1. Pull the locking lever to the 90 degree position from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17563 2. With the locking lever in the 90 degree position and the male connector body separated, it can be slid outward for removal. 3. Slide the male connector body out away from the guide plates. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17564 Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 4. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. 5. Using terminal release tool J 38125-566, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17565 6. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 7. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17566 8. The female connector body may have an additional connector hooked to the edge of the body. Use terminal release tool J-38125-11A or equivalent to release the locking tab and slide the connector off the female body. 9. Move the locking lever 180 degrees from the connected position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17567 10. With the locking lever in the 180 degree position the guide plates can be removed from the connector body. Note: During assembly the TPA will not fully seat if any terminal is not fully seated. 11. Using terminal release tool J 38125-11A or equivalent, remove the TPA from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17568 12. Using terminal release tool J 38125-216, lift the terminal plate past the terminals and out of the connector body cavity. 13. Terminal plate will bind slightly on each corner. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17569 14. Using terminal release tool J 38125-221, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 15. Using terminal release tool J 38125-212, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17570 16. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 17. Press the terminal plate back into the female connector to the preset position. The plate will bind slightly on each corner. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17571 18. With the locking lever in the 180 degree position, align the guide plates to mesh with the gears on the locking lever. 19. Slide the male connector body back inward toward the guide plates. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17572 20. With the locking lever in the 90 degree position and the male connector body connected, it can be slid inward for assembly. 21. Move the lever into the locked position or in the assembled position. This will pull the male connector down into the female connector. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Seat) Tyco/AMP Connectors (Seat) Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17573 Removal Procedure 1. Grasp the locking slide lever and pull outward from the end of the connector. 2. As the slide lever is pulled out the mating connector is lifted from the seated position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17574 Note: TPA is keyed and can only be inserted in one direction. 3. Using terminal release tool J 38125-11A or equivalent, push the TPA tabs into the connector body. 4. Pull the TPA from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17575 5. Using terminal release tool J 38125-11A or equivalent, release the connector wire dress cover locking tab. 6. With the lock tab released, lift the connector wire dress cover from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17576 7. Using terminal release tool J 38125-212, press the prongs into the holes each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. 8. Using terminal release tool J 38125-560, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17577 9. Using terminal release tool J 38125-556, press the prongs into the holes on each side of the terminal to be removed to release the lock tabs and pull the terminal out of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (SIR) Tyco/AMP Connectors (SIR) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17578 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17579 3. Using terminal tool J-38125-11A or equivalent, release the wire dress cover locking tabs. 4. Pivot connector wire dress cover while removing from the connector body. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17580 5. Using terminal tool J-38125-11A or equivalent, remove the TPA by lifting straight off the connector body. 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Repairing Connector Terminals Repairing Connector Terminals Special Tools J-38125 Terminal Repair Kit Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17581 Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gauge size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17582 2. Disconnect the connector from the component. 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17583 4. Relieve the tension on the nose piece retainers by inserting J 38125-12A into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. 5. Once the nose piece retainers are relaxed, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17584 6. On the opposite side of the nose piece, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17585 8. Insert the J 38125-553 tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17586 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. If the TPA is removed, be sure to reinstall it before reconnecting the connector. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Insert the J 38125-11A tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17587 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Special Tools Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17588 J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Note: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17589 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17590 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17591 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Special Tools J-38125 Terminal Repair Kit Removal Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17592 1. While depressing the lock, pull the two connector halves apart. Note: The TPA is fragile and may break if not done carefully. 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. 3. View of the male half of the connector with female terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17593 4. View of the female half of the connector with male terminals. 5. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. View of the female half of the connector with male terminals. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17594 7. View of the male half of the connector with female terminals. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 . Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17595 The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are a one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine if the element in the fuse is broken (2). If not broken (1), also check for continuity using a Digital Multimeter (DMM) or a continuity tester. If the element is broken or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a Digital Multimeter (DMM) at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gauge size. Repairing a Fusible Link Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17596 Flat Wire Repairs The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Special Tools J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool * J 38125-5 Ultra Torch Special Tool The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Note: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation). GMLAN Connector Terminal Repair Note: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125 . If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) for the appropriate connector repair procedure. GMLAN Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 . Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17597 Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17598 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Special Tools J-38125 Terminal Repair Kit Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17599 repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125 . High Temperature Wiring Repairs High Temperature Wiring Repairs Special Tools J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gauge size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17600 splice. Note: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17601 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17602 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the wire insulation has been chafed, or broken, enough to show the conductive portion of the wire, and the wire is not damaged, determine the length of insulation that needs to be repaired. If the repair is less than 280 mm (11 in), cut the wire within the damaged area. Then slide the appropriate heat shrink tubing (listed below) over the wire, and repair the wire by splicing the wires together. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Once the wire is spliced together slide heat shrink tubing over the damaged area and apply heat to seal the repaired wire. If the wire is damaged, or the damaged area is larger than 280 mm (11 in), then replace the damaged wire by splicing in a new section of wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17603 SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Special Tools J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17604 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17605 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17606 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Special Tools J-38125 Terminal Repair Kit Note: Use only DuraSeal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use DuraSeal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use DuraSeal splice sleeves where there are special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17607 * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17608 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17609 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the instructions for Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Staggering the splices by 65 mm (2.5 in) is recommended. Note: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. If the mylar tape is damaged, use 3M product AL-36FR to replace the damaged mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Flat Wire Repairs) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/GMLAN Wiring Repairs) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Heated Oxygen Sensor Wiring Repairs) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves) * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Twisted or Shielded Cable) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Inline Harness Diodes) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/SIR/SRS Wiring Repairs) US English/Metric Conversion US English/Metric Conversion Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17610 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17611 Testing Ground and Low Reference Circuits Testing Ground and Low Reference Circuits Because a test lamp can light with up to 200 ohm in a ground or low reference circuit they are not recommended to be used for this type of test. A low impedance test lamp can light and indicate the circuit is good when there is as much as 20-30 ohm present, while a high impedance test lamp can light with up to 200 ohm present in the circuit. This is why the Digital Multi-Meter (DMM) is used when validating a ground or low reference circuit continuity. When using the DMM there are many vehicle conditions that can affect the ground and low reference continuity testing. If these conditions are not met, a ground or low reference circuit test can fail on a good circuit. This may cause longer diagnosis time and incorrect component replacement. Any current flow through a ground or low reference circuit, while being tested, will skew the DMM continuity reading, or display a reading higher than when there is no current flowing. Performing a ground or low reference circuit continuity test, in reference to the vehicles battery negative terminal, will have the highest risk of failing a good ground or low reference circuit test than any other ground reference point. The best ground test points would be a control module housing (if the control modules housing is metal and grounded), door jamb striker (if attached to metal), under dash metal frame work, engine block, or body ground studs (other than where the negative battery cable is attached). A typical DMM ground or low reference circuit continuity reading can be as high as 100 ohm with the ignition ON, and drop to 15-25 ohm after the ignition is turned OFF. The reading will drop below 10 ohm after 30-40 seconds, then below 5 ohm after 60 seconds. Once the vehicle completely goes to sleep (generally 3-10 minutes) the reading will drop below 0.3 ohm. The following list of conditions may need to be met to ensure a valid continuity reading on a ground or low reference circuit: * Ignition OFF * Key out of the ignition switch (when not equipped with keyless entry and remote start) * Retained Accessory Power (RAP) OFF (open and close the driver door after ignition OFF) * Battery charger set at a 2 A or less charge rate * Scan tool not communicating with any vehicle control module (in some cases it may need to be disconnected from the DLC) * All entry doors closed * Headlamps OFF (auto headlamps disabled) * Any delay lighting OFF * HVAC after blow OFF * Any accessory that can work when the ignition is OFF * Wait up to 60 seconds (after all other listed conditions are met) Activating the DOOR LOCK function with a key fob can greatly reduce the time to achieve a valid ground or low reference continuity test result. Terminal Removal Terminal Removal Special Tools * EL-38125-580 - Terminal Release Tool Kit * EL-35616 - Connector Test Adapter Kit For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repair procedures. 1. Find the appropriate connector end view within the connector end view section. The connector end view has the following information: Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17612 * Diagnostic probe tool * Terminal release tool * Terminal/terminated lead part numbers Note: Not using the proper test kit probe may cause damage to the terminal(s) that are probed. 2. Determine if a terminal is damaged. * Locate the diagnostic probe tool from the connector end view. The connector end view describes the color and part number to help the technician find and use the correct tool. * Connect the probe tool to the Digital Multimeter. * Insert the probe tool into the cavity and follow the procedures from the Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter). 3. Disconnect the connector body to perform the repair. 4. Use the following procedure to remove the terminal from the connector body. Note: Several procedures for specific connector bodies are called out in the Wiring Repairs section. * The terminal position assurance (TPA) and connector position assurance (CPA) should be removed before releasing the terminal for the connector body. * Look at the connector end view to locate the cavity of the damaged terminal and find the proper terminal release tool from the terminal release tool kit. Note: Using the incorrect terminal release tool can damage the connector body. * Insert the terminal release tool into the cavity. Note: Some terminals have a lever that must be disengaged before the terminal can be released. 5. Gently pull the wire out of the back of the connector. 6. Repair the terminal by following the Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) procedure. 7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminated Lead Repair Terminated Lead Repair Special Tools * J-38125-8 - Splice Sleeve Crimp Tool Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17613 * J-38125-5 - Ultra Torch For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) procedures. Terminated leads are terminals that are crimped onto wires. The terminated lead can be used throughout the vehicle since it is designed for temperatures up to 150°C. The length of the wire is 450 mm. The DuraSeal splice sleeve has the following 2 critical features: * A special heat shrink tubing that environmentally seals the splice. The shrink tubing contains a sealing adhesive inside the shrink tubing. * A cross hatched (knurled) core crimp that provides the necessary contact integrity for sensitive low energy circuits. 1. Use the connector end view to identify the correct terminated lead. 2. The terminated lead package should include a DuraSeal splice sleeve. If not, use the chart to identify the correct part. 3. Open the harness by removing any tape: Use a sewing seam ripper, or a comparable tool, to cut open the harness, to avoid wire insulation damage. 4. Depending on how many terminals need repairs, cut the terminal and wire back at least 40 mm. Try to keep the harness wire length the same. If more than one terminated lead is required, stagger the lengths by 40 mm. This helps reduce the bundle size of the wire harness. 5. Use the EL-38125-10 - tool in order to position the DuraSeal splice sleeve in the proper color nest of the splice sleeve crimp tool. The crimp tool has four nests, one for each color. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17614 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the J-38125-5 - ultra torch , apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 17615 Cigarette Lighter: Electrical Diagrams Cigar Lighter/Power Outlet Schematics Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Page 17616 Cigarette Lighter: Service and Repair Cigar Lighter Receptacle or 12-Volt Accessory Power Receptacle Replacement Tools Required J 42059 Cigar Lighter Socket Remover Removal Procedure 1. Remove the auxiliary power outlet fuse from the fuse block. 2. Remove the receptacle: 1. Look into the receptacle. There are two 3 mm (0.11 in) tab windows 12 mm (0.47 in) from the front of the receptacle. The J 42059 pushes the plastic latches from these tab windows and the receptacle can be pulled straight out. 2. Place one side of the "T" portion of the J 42059 into the tab window. The J 42059 will not fit straight into the receptacle. Angle the J 42059 slightly for insertion into the receptacle. 3. Insert the other side of the "T" into the opposite tab window. You must move the J 42059 handle toward horizontal to engage the other tab window. 4. Use the J 42059 to pull the receptacle straight out. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Page 17617 3. If J 42059 tool fails to release the lighter socket from the retainer, perform the following alternate method: 1. Insert a small grinding tool with a cutoff wheel into the socket. 2. Remove the plastic latches in the 3 mm (0.11 in) square windows. 3. Use the J 42059 as directed above to remove the socket. Installation Procedure 1. Route the connector through the retainer. Align the accessory power receptacle retainer to the slot in the opening. 2. Install the retainer by pressing into place fully seated. 3. Connect the electrical connector to the receptacle. 4. Align the tabs on the receptacle to the slots in the retainer. Install the accessory power receptacle by pressing into place until fully seated. 5. Install the accessory power receptacle fuse. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams Compass: Diagrams Component Connector End Views Electronic Compass Module (YE9) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Diagrams > Page 17621 Compass: Service and Repair Electronic Compass Module Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling SIR component location affects how a vehicle should be serviced. There are parts of the SIR system installed in various locations around a vehicle. To find the location of the SIR components refer to SIR Identification Views (See: Restraint Systems/Air Bag Systems/Locations). There are several reasons for disabling the SIR system, such as repairs to the SIR system or servicing a component near or attached to an SIR component. There are several ways to disable the SIR system depending on what type of service is being performed. The following information covers the proper procedures for disabling/enabling the SIR system. SIR Service Precautions Warning When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. The inflatable restraint sensing and diagnostic module (SDM) maintains a reserved energy supply. The reserved energy supply provides deployment power for the air bags if the SDM loses battery power during a collision. Deployment power is available for as much as 1 minute after disconnecting the vehicle power. Waiting 1 minute before working on the system after disabling the SIR system prevents deployment of the air bags from the reserved energy supply. General Service Instructions The following are general service instructions which must be followed in order to properly repair the vehicle and return it to its original integrity: * Do not expose air bags to temperatures above 65°C (149°F). * Verify the correct replacement part number. Do not substitute a component from a different vehicle. * Use only original GM replacement parts available from your authorized GM dealer. Do not use salvaged parts for repairs to the SIR system. Discard any of the following components if it has been dropped from a height of 92 cm (3 feet) or greater: * Inflatable restraint sensing and diagnostic module (SDM) * Any air bag * Driver steering wheel air bag coil * Any impact sensor * Seat belt anchor and/or retractor pretensioners * Passenger presence module and/or occupant sensor Disabling Procedure - Air Bag Fuse 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. Note: The SDM may have more than one fused power input. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove all fuses supplying power to the SDM. With all SDM fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate a SIR system malfunction. 3. Locate and remove the fuse(s) supplying power to the SDM. Refer to SIR Schematics (See: Diagrams/Electrical Diagrams/Air Bag Systems) or Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse/Application and ID). 4. Wait 1 minute before working on the system. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Page 17626 Enabling Procedure - Air Bag Fuse 1. Place the ignition in the OFF position. 2. Install the fuse(s) supplying power to the SDM. Refer to SIR Schematics (See: Diagrams/Electrical Diagrams/Air Bag Systems) or Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse/Application and ID). 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle). Disabling Procedure - Negative Battery Cable 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. 3. Disconnect the negative battery cable from the battery. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 4. Wait 1 minute before working on system. Enabling Procedure - Negative Battery Cable 1. Place the ignition in the OFF position. 2. Connect the negative battery cable to the battery. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Diagrams Dimmer Switch: Diagrams Component Connector End Views Headlamp and Panel Dimmer Switch Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp > Component Information > Description and Operation > Door Ajar Indicator (w/AN3) Door/Trunk Ajar Indicator/Lamp: Description and Operation Door Ajar Indicator (w/AN3) Door Ajar Indicator Description and Operation (w/AN3) Door Ajar Indicator System Components The door ajar indicator system consists of the following components: * The driver door switch (DDS) * The passenger door switch (PDS) * The body control module (BCM) * The instrument panel cluster (IPC) * The driver door ajar switch * The passenger door ajar switch * The left rear door ajar switch * The right rear door ajar switch Driver Door Ajar And Passenger Door Ajar The driver door switch (DDS) and passenger door switch (PDS) receive a discrete input from the respective door ajar switch to indicate the status of the door. The DDS or PDS then communicates this status to the instrument panel cluster (IPC) via GMLAN message. The IPC, upon receipt of this GMLAN message, will illuminate the appropriate door ajar message in the driver information center (DIC) and also send a GMLAN message to the radio to activate the door ajar audible warning when the following conditions are met: * The transmission is removed from PARK * The vehicle speed is greater then 8.05 km/h (5 mph) Left Rear Door Ajar And Right Rear Door Ajar The body control module (BCM) receives a discrete inputs from both the left and right rear door ajar switches to indicate the status of the rear doors. The BCM then communicates this status to the instrument panel cluster (IPC) via GMLAN message. The IPC, upon receipt of this GMLAN message, will illuminate the appropriate door ajar message in the driver information center (DIC) and also send a GMLAN message to the radio to activate the door ajar audible warning when the following conditions are met: * The transmission is removed from PARK * The vehicle speed is greater then 8.05 km/h (5 mph) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp > Component Information > Description and Operation > Door Ajar Indicator (w/AN3) > Page 17634 Door/Trunk Ajar Indicator/Lamp: Description and Operation Door Ajar Indicator (w/o AN3) Door Ajar Indicator Description and Operation (w/o AN3) Door Ajar Indicator System Components The door ajar indicator system consists of the following components: * The body control module (BCM) * The instrument panel cluster (IPC) * The driver door ajar switch * The passenger door ajar switch * The left rear door ajar switch * The right rear door ajar switch The body control module (BCM) receives a discrete inputs from the front and rear door ajar switches to indicate the status of the doors. The BCM then communicates this status to the instrument panel cluster (IPC) via GMLAN message. The IPC, upon receipt of this GMLAN message, will illuminate the appropriate door ajar message in the driver information center (DIC) and also send a GMLAN message to the radio to activate the door ajar audible warning when the following conditions are met: * The transmission is removed from PARK * The vehicle speed is greater then 8.05 km/h (5 mph) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver / Vehicle Information Display Switch > Component Information > Diagrams Driver / Vehicle Information Display Switch: Diagrams Component Connector End Views Driver Information Center (DIC) Switch (except MEX or 8S8) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver / Vehicle Information Display Switch > Component Information > Service and Repair > Driver Information Display Switch Replacement (with RPO SLT) Driver / Vehicle Information Display Switch: Service and Repair Driver Information Display Switch Replacement (with RPO SLT) Driver Information Display Switch Replacement (with RPO SLT) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver / Vehicle Information Display Switch > Component Information > Service and Repair > Driver Information Display Switch Replacement (with RPO SLT) > Page 17640 Driver / Vehicle Information Display Switch: Service and Repair Driver Information Display Switch Replacement (without RPO SLT) Driver Information Display Switch Replacement (without RPO SLT) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Service and Repair Fuel Gauge Sender: Service and Repair Fuel Sender Assembly Replacement Special Tools J 45722 Fuel Sender Lock Ring Wrench Removal Procedure 1. Remove the fuel tank. Refer to Fuel Tank Replacement (Pickup) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (Cab/Chassis Front) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (Cab/Chassis - Rear) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement). 2. Disconnect the fuel lines from the sending unit. Refer to Metal Collar Quick Connect Fitting Service (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Metal Collar Quick Connect Fitting Service) or Plastic Collar Quick Connect Fitting Service (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). Caution: Avoid damaging the lock ring. Use only J-45722 to prevent damage to the lock ring. Caution: Do Not handle the fuel sender assembly by the fuel pipes. The amount of leverage generated by handling the fuel pipes could damage the joints. Note: Do NOT use impact tools. Significant force will be required to release the lock ring. The use of a hammer and screwdriver is not recommended. Secure the fuel tank in order to prevent fuel tank rotation. 3. Use the J 45722 and a long breaker-bar in order to unlock the fuel sender lock ring. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Service and Repair > Page 17644 4. Remove the sending unit and seal. Discard the seal. 5. Clean the sending unit sealing surfaces. Note: Some lock rings were manufactured with "DO NOT REUSE" stamped into them. These lock rings may be reused if they are not damaged or warped. Note: Inspect the lock ring for damage due to improper removal or installation procedures. If damage is found, install a NEW lock ring. Note: Check the lock ring for flatness. 6. Place the lock ring on a flat surface. Measure the clearance between the lock ring and the flat surface using a feeler gauge at 7 points. 7. If warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement. 8. If warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Service and Repair > Page 17645 1. Install the sending unit and a NEW seal. Note: Always replace the fuel sender seal when installing the fuel sender assembly. Replace the lock ring if necessary. DO NOT apply any type of lubrication in the seal groove. Ensure the lock ring is installed with the correct side facing upward. A correctly installed lock ring will only turn in a clockwise direction. 2. Use the J 45722 in order to install the fuel sender lock ring. Turn the fuel sender lock ring in a clockwise direction. 3. Connect the fuel lines to the sending unit. Refer to Metal Collar Quick Connect Fitting Service (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Metal Collar Quick Connect Fitting Service) or Plastic Collar Quick Connect Fitting Service (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). 4. Install the fuel tank. Refer to Fuel Tank Replacement (Pickup) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (Cab/Chassis - Front) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (Cab/Chassis - Rear) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > High Idle Switch > Component Information > Testing and Inspection High Idle Switch: Testing and Inspection High Idle Switch Diagnosis Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions )provide an overview of each diagnostic category. Diagnostic Fault Information Reference Information Schematic Reference Engine Controls Schematics (See: Powertrain Management/Diagrams/Electrical Diagrams) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning)for scan tool information Circuit/System Verification Ignition ON, observe the scan tool High Idle switch parameter while exercising the switch. The reading should change between ON/OFF. Circuit/System Testing 1. Ignition OFF, disconnect the harness connector at the high idle switch. 2. Test for less than 5 ohms between the ground circuit terminal A and ground. ‹› If greater than 5 ohms, test the ground circuit for an open/high resistance. 3. Ignition ON, verify the scan tool High Idle switch parameter is OFF. ‹› If not OFF, test the signal circuit for a short to ground. If the circuit tests normal, replace the ECM. 4. Install a 3A fused jumper wire between the signal circuit terminal C and ground. Verify the scan tool High Idle switch parameter is ON. ‹› If not ON, test the signal circuit for a short to voltage or an open/high resistance. If the circuit tests normal, replace the ECM. 5. If all circuits test normal, test or replace the high idle switch. Component Testing Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > High Idle Switch > Component Information > Testing and Inspection > Page 17649 1. Ignition OFF, disconnect the harness connector at the high idle switch. 2. Test for infinite resistance between the signal terminal C and the ground circuit terminal A with the switch in the open position. ‹› If less than infinite resistance, replace the high idle switch. 3. Test for less than 1 ohm between the signal terminal C and the ground terminal A with the switch in the closed position. ‹› If greater than 1 ohm, replace the high idle switch. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling SIR component location affects how a vehicle should be serviced. There are parts of the SIR system installed in various locations around a vehicle. To find the location of the SIR components refer to SIR Identification Views (See: Restraint Systems/Air Bag Systems/Locations). There are several reasons for disabling the SIR system, such as repairs to the SIR system or servicing a component near or attached to an SIR component. There are several ways to disable the SIR system depending on what type of service is being performed. The following information covers the proper procedures for disabling/enabling the SIR system. SIR Service Precautions Warning When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. The inflatable restraint sensing and diagnostic module (SDM) maintains a reserved energy supply. The reserved energy supply provides deployment power for the air bags if the SDM loses battery power during a collision. Deployment power is available for as much as 1 minute after disconnecting the vehicle power. Waiting 1 minute before working on the system after disabling the SIR system prevents deployment of the air bags from the reserved energy supply. General Service Instructions The following are general service instructions which must be followed in order to properly repair the vehicle and return it to its original integrity: * Do not expose air bags to temperatures above 65°C (149°F). * Verify the correct replacement part number. Do not substitute a component from a different vehicle. * Use only original GM replacement parts available from your authorized GM dealer. Do not use salvaged parts for repairs to the SIR system. Discard any of the following components if it has been dropped from a height of 92 cm (3 feet) or greater: * Inflatable restraint sensing and diagnostic module (SDM) * Any air bag * Driver steering wheel air bag coil * Any impact sensor * Seat belt anchor and/or retractor pretensioners * Passenger presence module and/or occupant sensor Disabling Procedure - Air Bag Fuse 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. Note: The SDM may have more than one fused power input. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove all fuses supplying power to the SDM. With all SDM fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate a SIR system malfunction. 3. Locate and remove the fuse(s) supplying power to the SDM. Refer to SIR Schematics (See: Diagrams/Electrical Diagrams/Air Bag Systems) or Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse/Application and ID). 4. Wait 1 minute before working on the system. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Page 17654 Enabling Procedure - Air Bag Fuse 1. Place the ignition in the OFF position. 2. Install the fuse(s) supplying power to the SDM. Refer to SIR Schematics (See: Diagrams/Electrical Diagrams/Air Bag Systems) or Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse/Application and ID). 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle). Disabling Procedure - Negative Battery Cable 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. 3. Disconnect the negative battery cable from the battery. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 4. Wait 1 minute before working on system. Enabling Procedure - Negative Battery Cable 1. Place the ignition in the OFF position. 2. Connect the negative battery cable to the battery. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Lamp Out Indicator > Component Information > Technical Service Bulletins > Customer Interest for Lamp Out Indicator: > 07-08-42-006E > Nov > 10 > Instruments - Bulb Outage Detection Restoration Lamp Out Indicator: Customer Interest Instruments - Bulb Outage Detection Restoration INFORMATION Bulletin No.: 07-08-42-006E Date: November 11, 2010 Subject: Information on BCM Calibrations Available to Restore Bulb Outage Detection on Vehicles Produced by a Second Stage Manufacturer, Turn Signals Flash Fast after Factory Box Removed (Upfitter) Models: 2007-2011 Chevrolet Silverado 2007-2011 GMC Sierra Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 07-08-42-006D (Section 08 - Body and Accessories). The information contained in this bulletin applies to vehicles that are to be completed by a second stage manufacturer (upfitter) and may need to have the Body Control Module (BCM) rear turn signal bulb outage detection capability changed. All production vehicles will be manufactured with one of the following BCM rear turn signal bulb outage detection software options: 1. A standard production vehicle will have BCM software that checks for two bulbs functioning in each rear turn signal bulb circuit. If one or more bulbs are inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 2. Certain 2500 and 3500 models can be ordered with a new option (RPO 9U5) where the BCM checks for one bulb functioning in each rear turn signal bulb circuit. If the bulb goes inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 3. A vehicle built with a pickup box delete or chassis cab option (RPO ZW9) will be produced with a BCM program that has no turn signal bulb outage detection capability (LED compatible). The IPC turn signal indicator will flash at the same rate no matter how many turn signal bulbs are inoperative. In some cases, the upfitter may wish to change the turn signal bulb outage detection capability so that the turn signals work correctly with their upfit or to meet certain requirements. This will require contacting the Techline Customer Support Center (TCSC) to open a case and obtain a Vehicle Configuration Index (VCI) number. Advise the TCSC consultant which turn signal bulb outage detection capability is needed: 1. Factory standard production TWO bulb outage detection. 2. Optional (RPO 9U5) ONE bulb outage detection. NOTE: ONLY AVAILABLE ON CERTAIN 2007-2011 MODEL 2500 AND 3500 VEHICLES. 3. NO bulb outage detection (LED compatible). The BCM can then be reprogrammed with the correct software. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Lamp Out Indicator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Lamp Out Indicator: > 07-08-42-006E > Nov > 10 > Instruments - Bulb Outage Detection Restoration Lamp Out Indicator: All Technical Service Bulletins Instruments - Bulb Outage Detection Restoration INFORMATION Bulletin No.: 07-08-42-006E Date: November 11, 2010 Subject: Information on BCM Calibrations Available to Restore Bulb Outage Detection on Vehicles Produced by a Second Stage Manufacturer, Turn Signals Flash Fast after Factory Box Removed (Upfitter) Models: 2007-2011 Chevrolet Silverado 2007-2011 GMC Sierra Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 07-08-42-006D (Section 08 - Body and Accessories). The information contained in this bulletin applies to vehicles that are to be completed by a second stage manufacturer (upfitter) and may need to have the Body Control Module (BCM) rear turn signal bulb outage detection capability changed. All production vehicles will be manufactured with one of the following BCM rear turn signal bulb outage detection software options: 1. A standard production vehicle will have BCM software that checks for two bulbs functioning in each rear turn signal bulb circuit. If one or more bulbs are inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 2. Certain 2500 and 3500 models can be ordered with a new option (RPO 9U5) where the BCM checks for one bulb functioning in each rear turn signal bulb circuit. If the bulb goes inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 3. A vehicle built with a pickup box delete or chassis cab option (RPO ZW9) will be produced with a BCM program that has no turn signal bulb outage detection capability (LED compatible). The IPC turn signal indicator will flash at the same rate no matter how many turn signal bulbs are inoperative. In some cases, the upfitter may wish to change the turn signal bulb outage detection capability so that the turn signals work correctly with their upfit or to meet certain requirements. This will require contacting the Techline Customer Support Center (TCSC) to open a case and obtain a Vehicle Configuration Index (VCI) number. Advise the TCSC consultant which turn signal bulb outage detection capability is needed: 1. Factory standard production TWO bulb outage detection. 2. Optional (RPO 9U5) ONE bulb outage detection. NOTE: ONLY AVAILABLE ON CERTAIN 2007-2011 MODEL 2500 AND 3500 VEHICLES. 3. NO bulb outage detection (LED compatible). The BCM can then be reprogrammed with the correct software. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips Low Tire Pressure Indicator: Technical Service Bulletins Tire Pressure Monitor - TPM System Message/Service Tips # 09-03-16-002A: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire Pressure Monitor (TPM) System Message, Light and Customer Information - (Apr 27, 2010) Subject: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire Pressure Monitor (TPM) System Message, Light and Customer Information Models: 2006-2011 Cars and Light Duty Trucks (Including Saturn and Saab) 2006-2010 HUMMER H2, H3 ATTENTION The information found in this bulletin is to be used as a dealership service consultant procedures for customers coming into the service lane with an illuminated "low tire light" or comments on a check tire pressure/low tire pressure/add air to tire or service tire monitor system message. Maintaining proper tire pressures is an Owner's Maintenance item and is not covered under warranty. This bulletin is being revised to add model years and update additional bulletin reference information. Please discard Corporate Bulletin Number 09-03-16-002 (Section 03 -- Suspension). Customer Concerns and Confusion with the Tire Pressure Monitoring (TPM) System The following procedure should be used by dealership service consultants when a customer comes into the service drive with a "low tire light" on or comments on a check tire pressure/low tire pressure/add air to tire or service tire monitor system message. The service consultant should perform the following steps: Procedure Turn the key to ON, without starting the engine. ^ If the low tire light comes on and stays on solid with a check tire pressure/low tire pressure/add air to tire message (on vehicles equipped with DIC), advise the customer: - The system is working properly. - Properly adjusting all tire air pressures to the recommended levels and driving the vehicle will turn the light off (refer to the Tire and Loading Information label on the driver side door). - More detailed information can be found in the Owner Manual. - Service is not covered under warranty - this maintenance is the responsibility of the owner. - Give the customer a copy of the "GM Customer TPMS Information". ^ If the Tire Pressure Monitor (TPM) light blinks for one minute then stays on solid with a service tire monitor system message (on vehicles equipped with DIC): - A TPM system problem exists. The vehicle should be written up accordingly and sent to your service department for further DTC diagnosis and service. - If dashes (--) are displayed in only one or two of the tire pressure readouts, it is likely caused by a previous TPM system relearn that was performed incorrectly due to interference from another vehicle's TPM system during the relearn process (refer to the Important statement later in this bulletin regarding TPM relearn with a Tech 2(R)). - If dashes (--) are displayed in all four of the tire pressure readouts, there is a system problem. Follow the appropriate SI service procedures. ^ If a customer indicates the low tire light comes on for a few minutes when the vehicle is started, then goes off after driving a while, advise the customer: - The system is working properly. - Most likely, air pressure in one or more of the tires is low enough to turn the light on when tires are cold. After driving for a while, tires will heat Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 17672 up, allowing tire air pressure to increase above the threshold causing the light to go off. Properly adjusting all tire air pressures to the recommended levels will correct this (Refer to the Tire and Loading Information Label on the driver side door). - More detailed information can be found in the Owner Manual. - Service is not covered under warranty - this maintenance is the responsibility of the owner. - Give the customer a copy of the "GM Customer TPMS Information". For more detailed information, refer to Corporate Bulletin Number 07-03-16-004C and TPMS Training Course 13044.12T2. Tire Pressure Light At key on, without starting the vehicle: Steady Solid Glowing TPM Indicator If the TPM indicator appears as a steady glowing yellow lamp (as above), the system is functioning properly and you should add air to the tires to correct this condition. Blinking TPM Indicator If the TPM indicator appears as a BLINKING yellow lamp for one minute and then stays on solid, diagnostic service is needed. The Effect of Outside Temperature on Tire Pressures Important: As a rule of thumb, tire pressure will change about 7kPa (1 psi) for every 6°C (10°F) decrease in temperature - Tire pressure will drop when it gets colder outside, and rise when it gets warmer. Under certain situations such as extreme outside temperature changes, the system may bring on a solid light with a check tire pressure message. This should be considered normal and the system is working properly. The light will turn off upon adding the proper amount of air to the tires (refer to the Tire & Loading Information label in the driver's door opening). When properly adjusting tire air pressure, the following steps are important to help optimize the system and prolong bringing a tire pressure light on: ^ Use an accurate, high quality tire pressure gauge. ^ Never set the tire pressure below the specified placard value regardless of tire temperature or ambient temperature. ^ Tire pressure should be set to the specified placard pressure at the lowest seasonal temperature the vehicle will encounter during operation. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 17673 ^ When adding proper tire air pressure, it is important to remember fluctuations in outside air temperatures and tire temperatures effect tire air pressures. ^ After you have added the proper tire pressure, if the vehicle has a DIC (after the system has updated), check to see if DIC displays are the same readings as the tire pressure gauge used (adjust as necessary). ^ Only perform a TPM sensor re-learn after a tire rotation or system part replacements and use the Tech 2(R) to initiate the relearn whenever possible to avoid invalid sensor I.D. learns. Important: Always take outside temperature and tire temperature into consideration to properly set tire pressures. Foe example, on colder days (20°F/-7°C), if setting tire pressure when the vehicle has been indoors (60°F/16°C) or the tires are warm from being driven, it will be necessary to compensate for the low outside temperature by adding 21-27 kPa (3-4 psi) more then the placecard pressure. At some later time, when the vehicle has been parked outside for a while, the tires will cool off and the pressures will drop back into the placecard range. Important: Recently, nitrogen gas (for use in inflating tires) has become available to the general customer through some retailers. The use of nitrogen gas to inflate tires is a technology used in automobile racing. Tires inflated with nitrogen gas may exhibit less of a pressure change in response to outside temperature changes. Nitrogen gas inflation is compatible with GM TPM sensors. For additional information, refer to Corporate Service Bulletin 05-03-10-020C. Important: All Models (Except the Pontiac Vibe): Do not perform a TPM relearn at PDI, the system has already been set at the Assembly Plant. Do not perform a TPM relearn after adding air to the tires. The low tire light is similar to the low fuel indicator and adding something (fuel, air) to the vehicle makes that light turn back off again. Note that because of system behavior, some vehicles must be driven a short distance before the sensors recognize the increase in pressure and turns the light off again. Pontiac Vibe Only: Do not use the TPMS reset button to turn off the light. The system will update and light will turn off when all tire pressures have been adjusted followed by short distance drive. Important: All models (except the Pontiac Vibe): Each tire monitor sensor is learned to a specific vehicle corner. When performing a TPM relearn (only after a tire rotation or replacement of a TPM sensor or Module), always use the Tech2(R) to initiate the J 46079 relearned process. Tech 2(R) - initiated relearns lock out other vehicle TPM signals that may be broadcasting in the area. Only signals initiated by the J 46079 tool will be accepted. This method avoids storing false TPM I.D.s and will prevent customers from returning with dashes (--) displayed in tire pressure readouts and/or a flashing tire pressure monitor (TPM) light. Checking the four TPM I.D.s with the Tech 2(R) prior to and following relearn to verify they are the same can prevent invalid I.D. learns. Pontiac Vibe Only: Tire Monitor Sensors are not learned to a specific vehicle corner. Do not perform a TPM Reset after tire rotation. The TPMS Reset button must only be used during pre-delivery inspection by the dealer to initialize the system (after all tire pressures have been adjusted properly) or when a Tire Pressure Monitor System component is replaced. The J 46079 tool does not work on Vibe TPM sensors. A TPMS relearn on Vibe must be preformed with a Tech 2(R) to set the TPMS Module in learn mode. The TPMS sensor IDs are entered through the Tech 2(R). Refer to SI for further Vibe TPMS information. Labor Operation and Repair Order/Warranty System Claim Required Documentation Important: The ONLY time labor operation E0726 or E0722 should be used is to diagnose for a system issue. That should ONLY occur if, at key ON, without starting the engine, the Tire Pressure Monitor (TPM) blinks for one minute and then stays on solid with a Service Tire Monitor System message (on vehicles equipped with a DIC) If that occurs, a TPM system problem exists and the system will have set a DTC. If one of these operastions is used, the following Repair Order and Warranty System documentation are required: ^ Document the customer complaint on the Repair Order. ^ Document the TPMS DTC that has set on the Repair Order. ^ Enter the TPMS DTC in the Warranty System (WINS) in the Failure Code/DTC field on the claim submission (refer to the Claims Processing Manual, Section IV, Warranty claim Data, Page 6, Item G). If the above information is not documented on the Repair Order and Warranty System, the claim may be rejected. If the Warranty Parts Center (WPC) generates a request, this repair order documentation must be sent back. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 17674 Customer TPMS Information Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 17675 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 17676 Frequently Asked Questions Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Maintenance Required Lamp/Indicator > Component Information > Service and Repair Maintenance Required Lamp/Indicator: Service and Repair SERVICE VEHICLE SOON or SERVICE ENGINE SOON INDICATOR If your vehicle is equipped with a "SERVICE VEHICLE SOON"or a "SERVICE ENGINE SOON" indicator. This indicator is not a maintenance indicator and does not mean a maintenance service is required. For additional "SERVICE VEHICLE SOON"or a "SERVICE ENGINE SOON" indicator information refer to Malfunction Indicator Lamp. For Maintenance Required Lamp/Indicator, refer to Oil Change Reminder Lamp. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Testing and Inspection Malfunction Indicator Lamp: Testing and Inspection Malfunction Indicator Lamp (MIL) Diagnosis Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Circuit/System Description The malfunction indicator lamp (MIL) is located on the instrument panel cluster (IPC). The MIL informs the driver that an emission system fault has occurred and that the engine control system requires service. The engine control module (ECM) monitors the MIL control circuit for conditions that are incorrect for the commanded states of the MIL. For example, a failure condition exists if the ECM detects low voltage when the MIL is commanded OFF, or high voltage when the MIL is commanded ON. Diagnostic Aids An intermittent or poor connection at the MIL control circuit at the inline harness connector may cause this DTC to set. Inspect the connector terminals for any condition that may result in excessive resistance. Refer to Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections). Reference Information Schematic Reference * Engine Controls Schematics (See: Powertrain Management/Diagrams/Electrical Diagrams) * Instrument Cluster Schematics (See: Diagrams/Electrical Diagrams/Instrument Cluster Schematics) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) DTC Type Reference Powertrain Diagnostic Trouble Code (DTC) Type Definitions (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Powertrain Diagnostic Trouble Code (DTC) Type Definitions) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning) for scan tool information Circuit/System Verification Ignition ON, command the MIL ON and OFF with a scan tool. The MIL should turn ON and OFF with each command. Circuit/System Testing 1. Ignition ON, verify that the IPC warning indicators are illuminated. ‹› If the IPC warning indicators are not illuminated, test the IPC ignition circuit for a short to ground or an open/high resistance. If the circuit tests normal and the ignition circuit fuse is open, replace the IPC. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Testing and Inspection > Page 17683 2. Ignition OFF, disconnect the ECM X2 harness connector. Ignition ON, the MIL should not illuminate. ‹› If the MIL is illuminated, test the MIL control circuit terminal X2-30 for a short to ground. If the circuit tests normal, replace the IPC. 3. Ignition ON, connect a 3A fused jumper wire between the MIL control circuit terminal X2-30 and ground. The MIL should illuminate. ‹› If the MIL does not illuminate, test the MIL control circuit for a short to voltage, or an open/high resistance. If the circuit tests normal, replace the IPC/bulb. 4. If all circuits/connectors test normal, replace the ECM. Repair Instructions Perform the Diagnostic Repair Verification (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. * Instrument Cluster Replacement (Without RPO SLT) (See: Instrument Cluster / Carrier/Service and Repair/Instrument Cluster Replacement (Without RPO SLT))Instrument Cluster Replacement (With RPO SLT) (See: Instrument Cluster / Carrier/Service and Repair/Instrument Cluster Replacement (With RPO SLT)) * Control Module References (See: Testing and Inspection/Programming and Relearning) for ECM and ICM replacement, setup, and programming Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > Instruments - IPC Odometer Programming Reference Guide Odometer: Technical Service Bulletins Instruments - IPC Odometer Programming Reference Guide INFORMATION Bulletin No.: 07-08-49-020D Date: December 06, 2010 Subject: IPC Odometer Programming Method Quick Reference Guide Models: 2003-2011 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2, H3 2005-2009 Saab 9-7X Attention: This bulletin applies to vehicles sold in the U.S. and Canada Only. Supercede: This bulletin is being revised to add information for the 2011 model year and add new 2011 vehicles. Please discard Corporate Bulletin Number 07-08-49-020C (Section 08 - Body and Accessories). The purpose of this bulletin is to provide a reference guide to help identify which season odometer programming method to use after replacing the instrument panel cluster (IPC). The three season odometer programming methods in use today are listed below. In addition, this reference guide lists the component where the season odometer value is stored. The season odometer value may be stored in the IPC, the driver information center (DIC) or the integrated body control module (IBCM), also commonly called a body control module (BCM). Season Odometer Programming Methods in Use Today 1. IPC reprogramming and setup using the service programming system (SPS). 2. Odometer setup at the electronic service center (ESC) when using an exchange IPC/DIC. 3. Tech 2(R) - The Tech 2 is used to set up a replacement BCM, which includes loading the odometer value that is displayed and stored in the IPC. A replacement IPC will display the previously stored vehicle odometer value, communicated from the BCM, after cycling the ignition or driving the vehicle. *The odometer programming is integrated as part of the BCM programming procedure. It is not a stand-alone event. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > Instruments - IPC Odometer Programming Reference Guide > Page 17688 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > Instruments - IPC Odometer Programming Reference Guide > Page 17689 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > Instruments - IPC Odometer Programming Reference Guide > Page 17690 Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Change Reminder Lamp > Component Information > Service and Repair Oil Change Reminder Lamp: Service and Repair GM Oil Life System Resetting When the system has calculated that oil life has been diminished, it will indicate that an oil change is necessary. A CHANGE ENGINE OIL SOON message will come on. Change the engine oil as soon as possible within the next 1 000 km (600 miles). It is possible that, if driving under the best conditions, the oil life system may not indicate that an oil change is necessary for over a year. However, the engine oil and filter must be changed at least once a year and at this time the system must be reset. If the system is ever reset accidentally, change the engine oil at 5 000 km (3,000 miles) since last oil change. How to Reset the Engine Oil Life System The Engine Oil Life System calculates when to change the engine oil and filter based on vehicle use. Anytime the oil is changed, reset the system so it can calculate when the next oil change is required. If a situation occurs where the oil is changed prior to a CHANGE ENGINE OIL SOON message being turned on, reset the system. If the vehicle does not have a Driver Information Center (DIC), do the following: 1. Turn the ignition to ON, with the engine OFF. 2. Fully press and release the accelerator pedal slowly three times within five seconds. 3. Turn the key to OFF. If the CHANGE ENGINE OIL SOON message comes back on when you start the vehicle, the engine oil life system has not reset. Repeat the procedure. If the vehicle has a DIC, do the following: 1. Turn the ignition to ON, with the engine OFF. 2. Press the MODE button until the DIC reads OIL LIFE LEFT/HOLD SET TO RESET. 3. Press and hold the SET button until 100 percent is displayed. You will hear three chimes and the CHANGE ENGINE OIL SOON message will go off. 4. Turn the key to OFF. If the CHANGE ENGINE OIL SOON message comes back on when you start the vehicle, the engine oil life system has not reset. Repeat the procedure. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Assist Warning Indicator > Component Information > Service and Repair Parking Assist Warning Indicator: Service and Repair Information Center Telltale Assembly Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Diagrams Parking Brake Warning Switch: Diagrams Component Connector End Views Park Brake Switch Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Diagrams > Page 17700 Parking Brake Warning Switch: Service and Repair Parking Brake Indicator Switch Replacement Removal Procedure Warning: Refer to Battery Disconnect Warning (See: Starting and Charging/Battery/Service Precautions). 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 2. Without disconnecting the electrical connectors, remove the left side instrument panel electrical center/junction block and position aside. Refer to Instrument Panel Electrical Center or Junction Block Replacement - Left Side (See: Maintenance/Fuses and Circuit Breakers/Fuse Block/Service and Repair/Removal and Replacement/Instrument Panel Electrical Center or Junction Block Replacement - Left Side). 3. Disconnect the park brake warning lamp switch electrical connector. 4. Remove the park brake warning lamp switch bolt. 5. Remove the park brake warning lamp switch. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Diagrams > Page 17701 1. Install the park brake warning lamp switch. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the park brake warning lamp switch bolt and tighten to 3 Nm (27 lb in). 3. Connect the park brake warning lamp switch electrical connector. 4. Install the left side instrument panel electrical center/junction block. Refer to Instrument Panel Electrical Center or Junction Block Replacement Left Side (See: Maintenance/Fuses and Circuit Breakers/Fuse Block/Service and Repair/Removal and Replacement/Instrument Panel Electrical Center or Junction Block Replacement - Left Side). 5. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams Dimmer Switch: Diagrams Component Connector End Views Headlamp and Panel Dimmer Switch Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Service and Repair Fuel Gauge Sender: Service and Repair Fuel Sender Assembly Replacement Special Tools J 45722 Fuel Sender Lock Ring Wrench Removal Procedure 1. Remove the fuel tank. Refer to Fuel Tank Replacement (Pickup) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (Cab/Chassis Front) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (Cab/Chassis - Rear) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement). 2. Disconnect the fuel lines from the sending unit. Refer to Metal Collar Quick Connect Fitting Service (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Metal Collar Quick Connect Fitting Service) or Plastic Collar Quick Connect Fitting Service (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). Caution: Avoid damaging the lock ring. Use only J-45722 to prevent damage to the lock ring. Caution: Do Not handle the fuel sender assembly by the fuel pipes. The amount of leverage generated by handling the fuel pipes could damage the joints. Note: Do NOT use impact tools. Significant force will be required to release the lock ring. The use of a hammer and screwdriver is not recommended. Secure the fuel tank in order to prevent fuel tank rotation. 3. Use the J 45722 and a long breaker-bar in order to unlock the fuel sender lock ring. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Service and Repair > Page 17709 4. Remove the sending unit and seal. Discard the seal. 5. Clean the sending unit sealing surfaces. Note: Some lock rings were manufactured with "DO NOT REUSE" stamped into them. These lock rings may be reused if they are not damaged or warped. Note: Inspect the lock ring for damage due to improper removal or installation procedures. If damage is found, install a NEW lock ring. Note: Check the lock ring for flatness. 6. Place the lock ring on a flat surface. Measure the clearance between the lock ring and the flat surface using a feeler gauge at 7 points. 7. If warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement. 8. If warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Service and Repair > Page 17710 1. Install the sending unit and a NEW seal. Note: Always replace the fuel sender seal when installing the fuel sender assembly. Replace the lock ring if necessary. DO NOT apply any type of lubrication in the seal groove. Ensure the lock ring is installed with the correct side facing upward. A correctly installed lock ring will only turn in a clockwise direction. 2. Use the J 45722 in order to install the fuel sender lock ring. Turn the fuel sender lock ring in a clockwise direction. 3. Connect the fuel lines to the sending unit. Refer to Metal Collar Quick Connect Fitting Service (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Metal Collar Quick Connect Fitting Service) or Plastic Collar Quick Connect Fitting Service (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). 4. Install the fuel tank. Refer to Fuel Tank Replacement (Pickup) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (Cab/Chassis - Front) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement)Fuel Tank Replacement (Cab/Chassis - Rear) (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Diagrams Parking Brake Warning Switch: Diagrams Component Connector End Views Park Brake Switch Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Diagrams > Page 17714 Parking Brake Warning Switch: Service and Repair Parking Brake Indicator Switch Replacement Removal Procedure Warning: Refer to Battery Disconnect Warning (See: Starting and Charging/Battery/Service Precautions). 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). 2. Without disconnecting the electrical connectors, remove the left side instrument panel electrical center/junction block and position aside. Refer to Instrument Panel Electrical Center or Junction Block Replacement - Left Side (See: Maintenance/Fuses and Circuit Breakers/Fuse Block/Service and Repair/Removal and Replacement/Instrument Panel Electrical Center or Junction Block Replacement - Left Side). 3. Disconnect the park brake warning lamp switch electrical connector. 4. Remove the park brake warning lamp switch bolt. 5. Remove the park brake warning lamp switch. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Diagrams > Page 17715 1. Install the park brake warning lamp switch. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the park brake warning lamp switch bolt and tighten to 3 Nm (27 lb in). 3. Connect the park brake warning lamp switch electrical connector. 4. Install the left side instrument panel electrical center/junction block. Refer to Instrument Panel Electrical Center or Junction Block Replacement Left Side (See: Maintenance/Fuses and Circuit Breakers/Fuse Block/Service and Repair/Removal and Replacement/Instrument Panel Electrical Center or Junction Block Replacement - Left Side). 5. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Dual Batteries) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Water In Fuel Sensor > Component Information > Diagrams Water In Fuel Sensor: Diagrams Component Connector End Views Water in Fuel Sensor (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips Low Tire Pressure Indicator: Technical Service Bulletins Tire Pressure Monitor - TPM System Message/Service Tips # 09-03-16-002A: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire Pressure Monitor (TPM) System Message, Light and Customer Information - (Apr 27, 2010) Subject: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire Pressure Monitor (TPM) System Message, Light and Customer Information Models: 2006-2011 Cars and Light Duty Trucks (Including Saturn and Saab) 2006-2010 HUMMER H2, H3 ATTENTION The information found in this bulletin is to be used as a dealership service consultant procedures for customers coming into the service lane with an illuminated "low tire light" or comments on a check tire pressure/low tire pressure/add air to tire or service tire monitor system message. Maintaining proper tire pressures is an Owner's Maintenance item and is not covered under warranty. This bulletin is being revised to add model years and update additional bulletin reference information. Please discard Corporate Bulletin Number 09-03-16-002 (Section 03 -- Suspension). Customer Concerns and Confusion with the Tire Pressure Monitoring (TPM) System The following procedure should be used by dealership service consultants when a customer comes into the service drive with a "low tire light" on or comments on a check tire pressure/low tire pressure/add air to tire or service tire monitor system message. The service consultant should perform the following steps: Procedure Turn the key to ON, without starting the engine. ^ If the low tire light comes on and stays on solid with a check tire pressure/low tire pressure/add air to tire message (on vehicles equipped with DIC), advise the customer: - The system is working properly. - Properly adjusting all tire air pressures to the recommended levels and driving the vehicle will turn the light off (refer to the Tire and Loading Information label on the driver side door). - More detailed information can be found in the Owner Manual. - Service is not covered under warranty - this maintenance is the responsibility of the owner. - Give the customer a copy of the "GM Customer TPMS Information". ^ If the Tire Pressure Monitor (TPM) light blinks for one minute then stays on solid with a service tire monitor system message (on vehicles equipped with DIC): - A TPM system problem exists. The vehicle should be written up accordingly and sent to your service department for further DTC diagnosis and service. - If dashes (--) are displayed in only one or two of the tire pressure readouts, it is likely caused by a previous TPM system relearn that was performed incorrectly due to interference from another vehicle's TPM system during the relearn process (refer to the Important statement later in this bulletin regarding TPM relearn with a Tech 2(R)). - If dashes (--) are displayed in all four of the tire pressure readouts, there is a system problem. Follow the appropriate SI service procedures. ^ If a customer indicates the low tire light comes on for a few minutes when the vehicle is started, then goes off after driving a while, advise the customer: - The system is working properly. - Most likely, air pressure in one or more of the tires is low enough to turn the light on when tires are cold. After driving for a while, tires will heat Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 17724 up, allowing tire air pressure to increase above the threshold causing the light to go off. Properly adjusting all tire air pressures to the recommended levels will correct this (Refer to the Tire and Loading Information Label on the driver side door). - More detailed information can be found in the Owner Manual. - Service is not covered under warranty - this maintenance is the responsibility of the owner. - Give the customer a copy of the "GM Customer TPMS Information". For more detailed information, refer to Corporate Bulletin Number 07-03-16-004C and TPMS Training Course 13044.12T2. Tire Pressure Light At key on, without starting the vehicle: Steady Solid Glowing TPM Indicator If the TPM indicator appears as a steady glowing yellow lamp (as above), the system is functioning properly and you should add air to the tires to correct this condition. Blinking TPM Indicator If the TPM indicator appears as a BLINKING yellow lamp for one minute and then stays on solid, diagnostic service is needed. The Effect of Outside Temperature on Tire Pressures Important: As a rule of thumb, tire pressure will change about 7kPa (1 psi) for every 6°C (10°F) decrease in temperature - Tire pressure will drop when it gets colder outside, and rise when it gets warmer. Under certain situations such as extreme outside temperature changes, the system may bring on a solid light with a check tire pressure message. This should be considered normal and the system is working properly. The light will turn off upon adding the proper amount of air to the tires (refer to the Tire & Loading Information label in the driver's door opening). When properly adjusting tire air pressure, the following steps are important to help optimize the system and prolong bringing a tire pressure light on: ^ Use an accurate, high quality tire pressure gauge. ^ Never set the tire pressure below the specified placard value regardless of tire temperature or ambient temperature. ^ Tire pressure should be set to the specified placard pressure at the lowest seasonal temperature the vehicle will encounter during operation. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 17725 ^ When adding proper tire air pressure, it is important to remember fluctuations in outside air temperatures and tire temperatures effect tire air pressures. ^ After you have added the proper tire pressure, if the vehicle has a DIC (after the system has updated), check to see if DIC displays are the same readings as the tire pressure gauge used (adjust as necessary). ^ Only perform a TPM sensor re-learn after a tire rotation or system part replacements and use the Tech 2(R) to initiate the relearn whenever possible to avoid invalid sensor I.D. learns. Important: Always take outside temperature and tire temperature into consideration to properly set tire pressures. Foe example, on colder days (20°F/-7°C), if setting tire pressure when the vehicle has been indoors (60°F/16°C) or the tires are warm from being driven, it will be necessary to compensate for the low outside temperature by adding 21-27 kPa (3-4 psi) more then the placecard pressure. At some later time, when the vehicle has been parked outside for a while, the tires will cool off and the pressures will drop back into the placecard range. Important: Recently, nitrogen gas (for use in inflating tires) has become available to the general customer through some retailers. The use of nitrogen gas to inflate tires is a technology used in automobile racing. Tires inflated with nitrogen gas may exhibit less of a pressure change in response to outside temperature changes. Nitrogen gas inflation is compatible with GM TPM sensors. For additional information, refer to Corporate Service Bulletin 05-03-10-020C. Important: All Models (Except the Pontiac Vibe): Do not perform a TPM relearn at PDI, the system has already been set at the Assembly Plant. Do not perform a TPM relearn after adding air to the tires. The low tire light is similar to the low fuel indicator and adding something (fuel, air) to the vehicle makes that light turn back off again. Note that because of system behavior, some vehicles must be driven a short distance before the sensors recognize the increase in pressure and turns the light off again. Pontiac Vibe Only: Do not use the TPMS reset button to turn off the light. The system will update and light will turn off when all tire pressures have been adjusted followed by short distance drive. Important: All models (except the Pontiac Vibe): Each tire monitor sensor is learned to a specific vehicle corner. When performing a TPM relearn (only after a tire rotation or replacement of a TPM sensor or Module), always use the Tech2(R) to initiate the J 46079 relearned process. Tech 2(R) - initiated relearns lock out other vehicle TPM signals that may be broadcasting in the area. Only signals initiated by the J 46079 tool will be accepted. This method avoids storing false TPM I.D.s and will prevent customers from returning with dashes (--) displayed in tire pressure readouts and/or a flashing tire pressure monitor (TPM) light. Checking the four TPM I.D.s with the Tech 2(R) prior to and following relearn to verify they are the same can prevent invalid I.D. learns. Pontiac Vibe Only: Tire Monitor Sensors are not learned to a specific vehicle corner. Do not perform a TPM Reset after tire rotation. The TPMS Reset button must only be used during pre-delivery inspection by the dealer to initialize the system (after all tire pressures have been adjusted properly) or when a Tire Pressure Monitor System component is replaced. The J 46079 tool does not work on Vibe TPM sensors. A TPMS relearn on Vibe must be preformed with a Tech 2(R) to set the TPMS Module in learn mode. The TPMS sensor IDs are entered through the Tech 2(R). Refer to SI for further Vibe TPMS information. Labor Operation and Repair Order/Warranty System Claim Required Documentation Important: The ONLY time labor operation E0726 or E0722 should be used is to diagnose for a system issue. That should ONLY occur if, at key ON, without starting the engine, the Tire Pressure Monitor (TPM) blinks for one minute and then stays on solid with a Service Tire Monitor System message (on vehicles equipped with a DIC) If that occurs, a TPM system problem exists and the system will have set a DTC. If one of these operastions is used, the following Repair Order and Warranty System documentation are required: ^ Document the customer complaint on the Repair Order. ^ Document the TPMS DTC that has set on the Repair Order. ^ Enter the TPMS DTC in the Warranty System (WINS) in the Failure Code/DTC field on the claim submission (refer to the Claims Processing Manual, Section IV, Warranty claim Data, Page 6, Item G). If the above information is not documented on the Repair Order and Warranty System, the claim may be rejected. If the Warranty Parts Center (WPC) generates a request, this repair order documentation must be sent back. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 17726 Customer TPMS Information Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 17727 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Technical Service Bulletins > Tire Pressure Monitor - TPM System Message/Service Tips > Page 17728 Frequently Asked Questions Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Module > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Technical Service Bulletins > Page 17737 Tire Pressure Sensor: Testing and Inspection Tire Pressure Indicator Sensor Learn Special Tools J-46079 Tire Pressure Monitor Diagnostic Tool Learn Mode Description The tire pressure monitor (TPM) system uses the instrument panel cluster (IPC), body control module (BCM), remote control door lock receiver (RCDLR), keyless entry transmitter, 4 radio frequency transmitting pressure sensors, and the serial data circuit to perform the TPM learn mode functions. The sensor learn procedure must be performed after every tire rotation, RCDLR replacement, or sensor replacement. Once the learn mode has been enabled, each of the sensors unique identification codes can be learned into the RCDLR memory. When a sensor ID has been learned, the RCDLR sends a serial data message to the BCM to sound a horn chirp. This verifies the sensor has transmitted its ID and the RCDLR has received and learned it. The RCDLR must learn the sensor IDs in the proper sequence to determine correct sensor location. The first learned ID is assigned to the left front location, the second to right front, the third to right rear and the fourth to left rear. The turn signals will individually illuminate indicating which location is to be learned in the proper sequence. Sensor Functions Using J-46079 Each sensor has an internal low frequency coil. When the J-46079 is used in activate mode, it produces a low frequency transmission that activates the sensor. The sensor responds to a low frequency activation by transmitting in learn mode. When the RCDLR receives a learn mode transmission while in TPM learn mode, it will assign that sensors ID to the location on the vehicle relative to the order in which it was learned. Sensor Functions Using Pressure Increase/Decrease Method Each sensor takes a pressure measurement sample once every 30 seconds while in stationary mode. If the tire pressure increases, or decreases by more than 8.3 kPa (1.2 psi) from the last pressure measurement, another measurement will occur immediately to verify the change in pressure. If a pressure change has indeed occurred, the sensor transmits in Learn mode. When the RCDLR receives a Learn mode transmission while in TPM learn mode, it will assign that sensor's ID to the location on the vehicle relative to the order in which it was learned. Learn Mode Cancellation The learn mode will cancel if the ignition is cycled to OFF or if more than 2 minutes has elapsed for any sensor that has not been learned. If the learn mode is cancelled before the first sensor is learned, the original sensor IDs will be maintained. If the learn mode is canceled after the first sensor is learned, the following will occur: * All stored sensor IDs will be invalidated in the RCDLR memory. * If equipped, the DIC will display dashes instead of tire pressures. * DTC C0775 will be set. These conditions will now require the learn procedure to be repeated for the system to function properly. TPM Learn Procedure Note: If using the scan tool to enable the learn mode, the J-46079 must be used to activate the sensors. When this preferred method is used, any stray sensor signals will not affect the learn procedure. In the event a particular sensor's information is displayed on the special tool upon activation but the horn does not chirp, it may be necessary to rotate the wheel valve stem to a different position due to the sensor signal is being blocked by another component. If using the keyless entry transmitter or DIC buttons to enable the learn mode, the J-46079 or Pressure Increase/Decrease Method may be used. Before proceeding with this method, ensure that no other learn procedure is being performed simultaneously or that tire pressures are not being adjusted on another TPM equipped vehicle within close proximity. Stray signals from other TPM equipped vehicles just driving by can be inadvertently learned. If any random horn chirps are heard from the vehicle while performing the learn procedure, most likely a stray sensor has been learned and the procedure will need to be cancelled and repeated. Under these circumstances, performing the TPM Learn Procedure away from other vehicles would be highly recommended. In the event a particular sensor activation does not cause the horn to chirp, it may be necessary to rotate the wheel valve stem to a different position due to the sensor signal is being blocked by another component. Preferred Scan Tool Learn Enable Method 1. Using a scan tool, initiate the TPM Learn Mode. A double horn chirp will sound indicating the Learn Mode has been enabled. The left front turn signal will also be illuminated. 2. Starting with the left front tire, active the sensor by holding the antenna of the J-46079 aimed upward against the tire sidewall close to the wheel rim at the valve stem location. Press and release the Activate button and wait for a horn chirp. Once the horn chirp has sounded, the sensor information is learned and the turn signal in the next location to be learned will illuminate. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Technical Service Bulletins > Page 17738 3. After the horn chirp has sounded and the right front turn signal is illuminated, repeat step 2 for the remaining 3 sensors in the following order: 1. Right front 2. Right rear 3. Left rear 4. When the left rear sensor has been learned and a double horn chirp has sounded, the learn process is complete and the RCDLR exits the learn mode. 5. Ignition OFF, adjust all tires to the recommended pressures. Refer to Vehicle Certification, Tire Placard, Anti-Theft, and Service Parts ID Label ( See: Application and ID/Vehicle Certification, Tire Placard, Anti-Theft and Service Parts ID Label). Alternate Keyless Entry Transmitter or DIC Learn Enable Method 1. Ignition ON, initiate the TPM Learn Mode using one of the following procedures: * On vehicles equipped with keyless entry, simultaneously press the keyless entry transmitters lock and unlock buttons until a double horn chirp sounds indicating the Learn Mode has been enabled. The left front turn signal will also be illuminated. * On vehicles not equipped with keyless entry, press and release the driver information center (DIC) INFO button until the TIRE LEARN message appears on the DIC display. Press and hold the SET/RESET button until a double horn chirp sounds indicating the Learn Mode has been enabled. The left front turn signal will also be illuminated. 2. Starting with the left front tire, learn the tire pressure using one of the following methods: * Hold the antenna of the J-46079 aimed upward against the tire sidewall close to the wheel rim at the valve stem location. Press and release the activate button and wait for a horn chirp. Once the horn chirp has sounded, the sensor information is learned and the turn signal in the next location to be learned will illuminate. Warning Over inflating tires may cause personal injury or damage to the tires and wheels. When increasing tire pressure do not exceed the maximum inflation pressure as noted on the tire sidewall. * Increase/decrease the tire pressure for 8-10 seconds then wait for a horn chirp. The horn chirp may occur before or up to 30 seconds after the 8-10 second pressure increase/decrease time period has been reached. Once the horn chirp has sounded, the sensor information is learned and the turn signal in the next location to be learned will illuminate. 3. After the horn chirp has sounded and the right front turn signal is illuminated, repeat step 2 for the remaining 3 sensors in the following order: 1. Right front 2. Right rear 3. Left rear 4. When the left rear sensor has been learned and a double horn chirp has sounded, the learn process is complete and the RCDLR exits the learn mode. 5. Ignition OFF, adjust all tires to the recommended pressures. Refer to Vehicle Certification, Tire Placard, Anti-Theft, and Service Parts ID Label ( See: Application and ID/Vehicle Certification, Tire Placard, Anti-Theft and Service Parts ID Label). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement (Clamp In Style) Tire Pressure Sensor: Service and Repair Tire Pressure Indicator Sensor Replacement (Clamp In Style) Tire Pressure Indicator Sensor Replacement (Clamp In Style) Removal Procedure 1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the tire/wheel assembly from the vehicle. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). Note: Before the tire is removed from the wheel, note the following items to avoid tire pressure sensor damage upon tire dismounting: * Place the sensors cap and valve on a dry clean surface after removal. The cap is aluminum and the valve is nickel plated to prevent corrosion and are not to be substituted with a cap or valve made of any other material. * When separating the tire bead from the wheel, position the bead breaking fixture 90 degrees from the valve stem. * Position the mounting/dismounting head so the tire iron, or pry bar can be inserted slightly clockwise of the sensor body when prying the tire bead up and over the mounting/dismounting head. * Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the out side of the wheel rim. * Repeat items for inner bead. 3. Remove the tire from the wheel. Refer to Tire Dismounting and Mounting (See: Maintenance/Wheels and Tires/Tires/Service and Repair/Removal and Replacement). Note: If any tire sealant is noted upon tire dismounting, remove all residual liquid sealant from the inside of the tire and wheel surfaces. 4. Remove the tire pressure sensor nut. 5. Remove the tire pressure sensor. Installation Procedure 1. Clean any dirt or debris from the grommet sealing area. 2. Insert the sensor in the wheel hole with the air passage facing away from the wheel. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the sensor nut and position the sensor body parallel to the inside wheel surface while torquing. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement (Clamp In Style) > Page 17741 Tighten the sensor nut to 7 Nm (62 lb in). Note: Before reinstalling the tire on the wheel, note the following items to avoid tire pressure sensor damage upon tire mounting: * Position the mounting/dismounting head 180 degrees from the valve stem. * Position the bead transition area 45 degrees counterclockwise of the valve stem. * Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the inside of the wheel rim. * Repeat items for outer bead. 4. Install the tire on the wheel. Refer to Tire Dismounting and Mounting (See: Maintenance/Wheels and Tires/Tires/Service and Repair/Removal and Replacement). Note: A service replacement tire pressure sensor is shipped in OFF mode. In this mode the sensor unique identification code cannot be learned into the remote control door lock receiver (RCDLR) memory. The sensor must be taken out of OFF mode by spinning the tire/wheel assembly above 32 km/h (20 mph) in order to close the sensors internal roll switch for at least 10 seconds. 5. Install the tire/wheel assembly on the vehicle. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 6. Lower the vehicle. 7. Learn the tire pressure sensors. Refer to Tire Pressure Indicator Sensor Learn (See: Service and Repair/Service Manual Tire Pressure Sensor Learn). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement (Clamp In Style) > Page 17742 Tire Pressure Sensor: Service and Repair Tire Pressure Indicator Sensor Replacement (Snap In Style) Tire Pressure Indicator Sensor Replacement (Snap In Style) Removal Procedure 1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the tire/wheel assembly from the vehicle. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 3. Dismount the tire from the rim. Refer to Tire Dismounting and Mounting (See: Maintenance/Wheels and Tires/Tires/Service and Repair/Removal and Replacement). Note: When servicing the tire pressure sensor always use a new Schrader(R) tire pressure monitor (TPM) and a new TORX screw during installation. 4. Remove the TORX screw (1) from the tire pressure sensor (2) and pull it straight off the tire pressure valve stem (3). Caution: Do not scratch or damage the clear coating on aluminum wheels with the tire changing equipment. Scratching the clear coating could cause the aluminum wheel to corrode and the clear coating to peel from the wheel. 5. Remove the tire pressure valve stem by pulling it through the rim. Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement (Clamp In Style) > Page 17743 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Note: * Ensure the flat of the valve, lines up with the flats of the snap in the enclosure. * TPM valves and TORX screws are one-time use only. 1. Assemble the tire pressure sensor (2) to the valve stem and install the new TORX screw (3) and tighten to 1.3 Nm (11.5 lb in). Note: Use and approved tire mounting lubricant. DO NOT use silicon or corrosive base compounds to lubricate the tire bead and the wheel rim. A corrosive type compound can cause tire or rim deterioration. 2. Apply tire soap to the rubber portion of the valve stem (1). 3. Using a tire valve stem mounting tool, pull the valve stem through in a direction parallel to the valve hole on the rim. Note: Snap Fit TPM sensors are still shipped in the OFF mode. However, the TPM no longer needs to be spun to remove it from the OFF mode. The sensor will exit its OFF state when the tire is inflated. The technician can then program the vehicle as normal. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Indicator Sensor Replacement (Clamp In Style) > Page 17744 4. Mount the tire to the rim. Refer to Tire Dismounting and Mounting (See: Maintenance/Wheels and Tires/Tires/Service and Repair/Removal and Replacement). 5. Install the tire/wheel assembly on the vehicle. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 6. Lower the vehicle. 7. Learn the tire pressure sensors. Refer to Tire Pressure Indicator Sensor Learn (See: Service and Repair/Service Manual Tire Pressure Sensor Learn). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Volt Meter Gauge > Component Information > Technical Service Bulletins > Charging System - Volt Meter Fluctuation Information Volt Meter Gauge: Technical Service Bulletins Charging System - Volt Meter Fluctuation Information INFORMATION Bulletin No.: 07-06-03-009B Date: February 05, 2010 Subject: Information on Voltmeter Gauge Fluctuation Due to Regulated Voltage Control System and Concerns About Camper/Trailer Battery Charging Models: 2005-2010 Cadillac Escalade Models 2005-2010 Chevrolet Avalanche, Silverado, Silverado Classic, Suburban, Tahoe 2005-2010 GMC Sierra, Sierra Classic, Yukon Models Supercede: This bulletin is being revised to add the 2010 model year. Please discard Corporate Bulletin Number 07-06-03-009A (Section 06 - Engine/Propulsion System). Voltmeter Fluctuation Condition Some customers may comment that the voltmeter is fluctuating between 12 and 14 volts on their full size pickup or utility vehicle. Starting with the 2005 model year, light duty full size pickups and utilities are equipped with a Regulated Voltage Control (RVC) system. This system reduces the targeted output of the generator to 12.6-13.1 volts when in "Fuel Economy Mode" to improve fuel economy. The generator may exit "Fuel Economy Mode" if additional voltage is required. This will cause the voltmeter to fluctuate between 12 and 14 volts as opposed to non-regulated systems that usually maintain a more consistent reading of 14 volts. This fluctuation with the RVC system is normal system operation and NO repairs should be attempted. Camper/Trailer Battery Charging Concerns Some customers may comment that when towing or hauling a camper/trailer, the auxiliary battery for the camper/trailer will not stay charged. In most cases, this concern is blamed on the new RVC system. While the RVC system does reduce the generator's targeted output voltage to 12.6-13.1 volts when in "Fuel Economy Mode", this feature is bypassed if the tow/haul feature is enabled. With the tow/haul feature enabled, the RVC system will stay in "Charge Mode" and the targeted generator output voltage will be 13.9-15.5 volts, depending on the battery state of charge and the estimated battery temperature. To keep the generator in the "Charge Mode", use either of the following two methods. - The first method is to use the tow/haul mode when towing or hauling a camper or trailer. - The second method is to turn on the headlights, which will increase the generator's targeted output voltage to 13.9-14.5 volts. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Water In Fuel Indicator > Water In Fuel Sensor > Component Information > Diagrams Water In Fuel Sensor: Diagrams Component Connector End Views Water in Fuel Sensor (Diesel) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Service and Repair Ambient Light Sensor: Service and Repair Ambient Light Sensor Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Relay > Component Information > Locations Backup Lamp Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Relay > Component Information > Locations > Page 17761 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Relay > Component Information > Locations > Page 17762 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Relay > Component Information > Locations > Page 17763 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Relay > Component Information > Locations > Page 17764 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Relay > Component Information > Locations > Page 17765 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Relay > Component Information > Locations > Page 17766 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Relay > Component Information > Locations > Page 17767 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams Backup Lamp Switch: Diagrams Component Connector End Views Backup Lamp Switch (TZ0) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Service and Repair > Tremec 5-Speed (M96) - Manual Transmission Backup Lamp Switch: Service and Repair Tremec 5-Speed (M96) - Manual Transmission Backup Lamp Switch Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Service and Repair > Tremec 5-Speed (M96) - Manual Transmission > Page 17773 Backup Lamp Switch: Service and Repair Tremec 5-Speed (TZ0) - Manual Transmission Backup Lamp Switch Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the backup lamp switch electrical connector (3). 3. Remove the backup lamp switch. Installation Procedure Caution: Refer to Component Fastener Tightening Caution (See: Service Precautions/Vehicle Damage Warnings/Component Fastener Tightening Caution). Note: The backup lamp switch has pre-applied thread sealant on the threads. 1. Install the backup lamp switch. Tighten the switch to 37 Nm (27 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Service and Repair > Tremec 5-Speed (M96) - Manual Transmission > Page 17774 2. Connect the backup lamp switch electrical connector (3). 3. Lower the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Light Bulb > Component Information > Service and Repair Backup Light Bulb: Service and Repair Backup Lamp Bulb Replacement (Chevrolet) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins > Lighting - Exterior Lamp Condensation and Replacement Brake Lamp: Technical Service Bulletins Lighting - Exterior Lamp Condensation and Replacement INFORMATION Bulletin No.: 01-08-42-001H Date: January 05, 2011 Subject: Exterior Lamp Condensation and Replacement Guidelines Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 01-08-42-001G (Section 08 - Body and Accessories). The following information is being provided to better define the causes of condensation in exterior lamps and includes guidelines for determining the difference between a lamp with a normal atmospheric condition (condensation) and a lamp with a water leak. Some exterior lamps, such as cornering, turn signal, backup, headlamps or tail lamps may exhibit very small droplets of water, a fine mist or white fog (condensation) on the inside of the lamp lens. This may be more noticeable on lamps with "multi-lens" designs and may be normal during certain weather conditions. Condensation occurs when the air inside the lamp assembly, through atmospheric changes, reaches the "dew point". When this takes place, the moisture in the air within the lamp assembly condenses, creating a fine mist or white fog on the inside surface of the lamp lens. Most exterior lamps on General Motors vehicles use a vented design and feature a replaceable bulb assembly. They are designed to remove any accumulated moisture vapor by expelling it through a vent system. The vent system operates at all times, however, it is most effective when the lamps are ON or when the vehicle is in motion. Depending on the size, shape and location of the lamp on the vehicle, and the atmospheric conditions occurring, the amount of time required to clear the lamp may vary from 2 to 6 hours. Completely sealed headlamp assemblies (sealed beams) are still used on a limited number of models being manufactured today. These lamps require the replacement of the complete lamp assembly if a bulb filament burns out. Condensation 2006 TrailBlazer Shown A Fine Mist or White Fog on the Inside Surface of the Lamp Lens Occurring After a Period of High Humidity - May be located primarily in the lens corners (near the vents) and SHOULD NOT cover more than half the lens surface. - The condition should clear of moisture when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a SIMILAR performance. If the above conditions are noted, the customer should be advised that replacement of a lamp assembly may not correct this condition. Water Leak New Style Pickup Shown Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins > Lighting - Exterior Lamp Condensation and Replacement > Page 17782 Numerous & Various Size Drops of Water Collecting on the Inside Surface of the Lamp Lens After the Vehicle Has Been Exposed to Rain or a Car Washing Environment - A condition that covers more than half the surface of the lamp lens. - An accumulation of water in the bottom of the lamp assembly. - A condition that WON'T clear when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a different performance. Any of the above conditions would indicate the need to service the lens or lamp assembly. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins > Page 17783 Brake Lamp: Diagrams Component Connector End Views Tail/Stop and Turn Signal Lamp - Lower Left Tail/Stop and Turn Signal Lamp - Lower Right Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins > Page 17784 Tail/Stop and Turn Signal Lamp - Upper Left Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins > Page 17785 Tail/Stop and Turn Signal Lamp - Upper Right Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins > Page 17786 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams Brake Light Switch: Diagrams Component Connector End Views Stop Lamp Switch Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Service and Repair > Stop Lamp Switch Replacement (With Adjustable Pedals) Brake Light Switch: Service and Repair Stop Lamp Switch Replacement (With Adjustable Pedals) Stop Lamp Switch Replacement (With Adjustable Pedals) Removal Procedure 1. Apply the park brake. 2. Remove the driver knee bolster. Refer to Knee Bolster Replacement (With SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (With SLT))Knee Bolster Replacement (Without SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (Without SLT)). 3. Disconnect the stoplamp switch electrical connector. 4. Remove the power vacuum brake booster pushrod retainer bolt (1). 5. Remove the power vacuum brake booster pushrod retainer (1). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Service and Repair > Stop Lamp Switch Replacement (With Adjustable Pedals) > Page 17792 6. Slide the power vacuum brake booster pushrod off of the brake pedal pin and remove the stoplamp switch (1). Installation Procedure 1. Install the stoplamp switch (1) to the power vacuum brake booster pushrod. 2. Install the power vacuum brake booster pushrod with the stoplamp switch to the brake pedal pin. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Service and Repair > Stop Lamp Switch Replacement (With Adjustable Pedals) > Page 17793 3. Install the power vacuum brake booster pushrod retainer (1). 4. Rotate the pushrod retainer 360 degrees to verify the retainer is fully engaged in the groove on the brake pedal pin. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Install the power vacuum brake booster pushrod retainer bolt (1) and tighten to 10 Nm (89 lb in). 6. Connect the stoplamp switch electrical connector. 7. Install the driver knee bolster. Refer to Knee Bolster Replacement (With SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (With SLT))Knee Bolster Replacement (Without SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (Without SLT)). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Service and Repair > Stop Lamp Switch Replacement (With Adjustable Pedals) > Page 17794 Brake Light Switch: Service and Repair Stop Lamp Switch Replacement (Without Adjustable Pedals) Stop Lamp Switch Replacement (Without Adjustable Pedals) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Center Mounted Brake Lamp Bulb > Component Information > Service and Repair Center Mounted Brake Lamp Bulb: Service and Repair High Mount Stop Lamp Bulb Replacement (GMC Denali) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Center Mounted Brake Lamp Relay > Component Information > Locations Center Mounted Brake Lamp Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Center Mounted Brake Lamp Relay > Component Information > Locations > Page 17802 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Center Mounted Brake Lamp Relay > Component Information > Locations > Page 17803 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Center Mounted Brake Lamp Relay > Component Information > Locations > Page 17804 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Center Mounted Brake Lamp Relay > Component Information > Locations > Page 17805 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Center Mounted Brake Lamp Relay > Component Information > Locations > Page 17806 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Center Mounted Brake Lamp Relay > Component Information > Locations > Page 17807 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Center Mounted Brake Lamp Relay > Component Information > Locations > Page 17808 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Clearance Lamp > Component Information > Diagrams Clearance Lamp: Diagrams Component Connector End Views Rear Fender Clearance Lamp - Left Front (RO5) Rear Fender Clearance Lamp - Left Rear (RO5) Rear Fender Clearance Lamp - Right Front (RO5) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Clearance Lamp > Component Information > Diagrams > Page 17812 Rear Fender Clearance Lamp - Right Rear (RO5) Roof Clearance Lamp - Left Front Outer (U01) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Clearance Lamp > Component Information > Diagrams > Page 17813 Roof Clearance Lamp - Front Middle (U01) Roof Clearance Lamp - Right Front Outer (U01) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Clearance Lamp > Component Information > Diagrams > Page 17814 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Clearance Lamp > Component Information > Diagrams > Page 17815 Clearance Lamp: Service and Repair Rear Fender Clearance Lamp Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Service and Repair > Outside Rearview Mirror Courtesy Lamp Replacement Courtesy Lamp: Service and Repair Outside Rearview Mirror Courtesy Lamp Replacement Outside Rearview Mirror Courtesy Lamp Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Service and Repair > Outside Rearview Mirror Courtesy Lamp Replacement > Page 17820 Courtesy Lamp: Service and Repair Pickup Box Identification Lamp Replacement (GMC HD) Pickup Box Identification Lamp Replacement (GMC HD) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Service and Repair > Outside Rearview Mirror Courtesy Lamp Replacement > Page 17821 Courtesy Lamp: Service and Repair Pickup Box Identification Lamp Replacement (Chevrolet HD) Pickup Box Identification Lamp Replacement (Chevrolet HD) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Diagrams Dimmer Switch: Diagrams Component Connector End Views Headlamp and Panel Dimmer Switch Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams Dome Lamp: Diagrams Component Connector End Views Dome/Reading Lamps - Front Dome/Reading Lamps - Rear (Crew Cab or Extended Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Page 17828 Dome Lamp: Service and Repair Dome Lamp Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Bulb > Component Information > Service and Repair Fog/Driving Lamp Bulb: Service and Repair Front Fog Lamp Bulb Replacement (Chevrolet) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations Fog/Driving Lamp Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations > Page 17836 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations > Page 17837 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations > Page 17838 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations > Page 17839 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations > Page 17840 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations > Page 17841 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations > Page 17842 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Service and Repair > Fog Lamp Switch Replacement (with RPO SLT) Fog/Driving Lamp Switch: Service and Repair Fog Lamp Switch Replacement (with RPO SLT) Fog Lamp Switch Replacement (with RPO SLT) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Service and Repair > Fog Lamp Switch Replacement (with RPO SLT) > Page 17847 Fog/Driving Lamp Switch: Service and Repair Fog Lamp Switch Replacement (without RPO SLT) Fog Lamp Switch Replacement (without RPO SLT) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Flasher Relay > Component Information > Diagrams Hazard Flasher Relay: Diagrams Component Connector End Views Roof Beacon Relay (TRW) Emergency Vehicle Roof Lamp Relay (5Y0) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Flasher Relay > Component Information > Diagrams > Page 17852 Wrecker Relay X1 (5X7) Wrecker Relay X2 (5X7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Flasher Relay > Component Information > Diagrams > Page 17853 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams Hazard Warning Switch: Diagrams Component Connector End Views Roof Beacon Switch (5X7, 5Y0 or TRW) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Headlamp Bulb: > 10-08-42-001B > Jan > 11 > Lighting - Low Beam Headlamp(s) Inoperative Headlamp Bulb: All Technical Service Bulletins Lighting - Low Beam Headlamp(s) Inoperative TECHNICAL Bulletin No.: 10-08-42-001B Date: January 24, 2011 Subject: Low Beam Headlamp Bulb Diagnosis/Replacement (Inspect Bulb and Connector) Models: 2008-2011 Buick Enclave 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2008-2011 Cadillac CTS, CTS-V 2010-2011 Cadillac CTS Sport Wagon, SRX 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2011 Chevrolet Malibu 2009-2011 Chevrolet Traverse 2010-2011 Chevrolet Equinox 2007-2011 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2010-2011 GMC Terrain 2006-2010 Pontiac G6 2007-2010 Saturn AURA, OUTLOOK Attention: This bulletin DOES NOT apply to vehicles equipped with High Intensity Discharge (HID) lamps. Supercede: This bulletin is being revised to update the part number for the recommended splice sleeve. Please discard Corporate Bulletin Number 10-08-42-001A (Section 08 - Body and Accessories). Condition Some customers may comment that the low beam headlamp is inoperative. Correction DO NOT replace the entire headlamp assembly for this condition. Replace the bulb and inspect the connector following the procedure below. 1. Remove the headlamp bulb. Refer to Headlamp Bulb Replacement procedure in SI. 2. Inspect the connector. - If the connector is NOT discolored or damaged, replace the bulb only. For bulb part numbers, see Headlamp Bulb (Low Beam) in Group 02.727 of the appropriate Parts Catalog. - If the connector is discolored at the bulb interface, replace the connector (service pigtail listed below) and bulb. Important Use only Duraseal splice sleeves (salmon, P/N 19168446). Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Refer to Splicing Copper Wire Using Splice Sleeves in SI for splicing procedures. 1. Cut the wires of the connector approximately 45 mm (13/4 in) from the connector and splice in the service pigtail connector. Ensure that the splices are not above the connector when re-installing. 2. Replace the bulb. 3. Verify that the headlamp is fully functional. Parts Information Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Headlamp Bulb: > 10-08-42-001B > Jan > 11 > Lighting - Low Beam Headlamp(s) Inoperative > Page 17866 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Headlamp Bulb: > 10-08-42-001 > May > 10 > Lighting - Low Beam Headlamp(s) Inoperative Headlamp Bulb: All Technical Service Bulletins Lighting - Low Beam Headlamp(s) Inoperative TECHNICAL Bulletin No.: 10-08-42-001 Date: May 14, 2010 Subject: Low Beam Headlamp Bulb Diagnosis/Replacement (Inspect Bulb and Connector) Models: 2008-2010 Buick Enclave 2008-2010 Cadillac CTS, CTS-V 2010 Cadillac CTS Sport Wagon, SRX 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Malibu 2009-2010 Chevrolet Traverse 2007-2010 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2006-2010 Pontiac G6 2007-2010 Saturn AURA Attention: This bulletin DOES NOT apply to vehicles equipped with High Intensity Discharge (HID) lamps. Condition Some customers may comment that the low beam headlamp is inoperative. Correction DO NOT replace the entire headlamp assembly for this condition. Replace the bulb and inspect the connector following the procedure below. 1. Remove the lamp assembly, then remove the bulb. Refer to Headlamp Assembly Replacement in SI. 2. Inspect the connector. - If the connector is NOT discolored or damaged, replace the bulb only. For bulb part numbers, see Headlamp Bulb (Low Beam) in Group 02.727 of the appropriate Parts Catalog. - If the connector is discolored at the bulb interface, replace the connector (service pigtail listed below) and bulb. Important Use only Duraseal splice sleeves (salmon, P/N 12089189). Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Refer to Splicing Copper Wire Using Splice Sleeves in SI for splicing procedures. 1. Cut the wires of the connector approximately 45 mm (1-3/4 in) from the connector and splice in the service pigtail connector. Ensure that the splices are not above the connector when re-installing. 2. Replace the bulb. 3. Verify that the headlamp is fully functional. Parts Information Warranty Information For vehicles repaired under warranty, use: Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Headlamp Bulb: > 10-08-42-001 > May > 10 > Lighting - Low Beam Headlamp(s) Inoperative > Page 17871 If only bulbs are replaced, use labor operation N0440 or N0441. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Technical Service Bulletins > Customer Interest for Headlamp Bulb: > 10-08-42-001B > Jan > 11 > Lighting - Low Beam Headlamp(s) Inoperative Headlamp Bulb: Customer Interest Lighting - Low Beam Headlamp(s) Inoperative TECHNICAL Bulletin No.: 10-08-42-001B Date: January 24, 2011 Subject: Low Beam Headlamp Bulb Diagnosis/Replacement (Inspect Bulb and Connector) Models: 2008-2011 Buick Enclave 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2008-2011 Cadillac CTS, CTS-V 2010-2011 Cadillac CTS Sport Wagon, SRX 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2011 Chevrolet Malibu 2009-2011 Chevrolet Traverse 2010-2011 Chevrolet Equinox 2007-2011 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2010-2011 GMC Terrain 2006-2010 Pontiac G6 2007-2010 Saturn AURA, OUTLOOK Attention: This bulletin DOES NOT apply to vehicles equipped with High Intensity Discharge (HID) lamps. Supercede: This bulletin is being revised to update the part number for the recommended splice sleeve. Please discard Corporate Bulletin Number 10-08-42-001A (Section 08 - Body and Accessories). Condition Some customers may comment that the low beam headlamp is inoperative. Correction DO NOT replace the entire headlamp assembly for this condition. Replace the bulb and inspect the connector following the procedure below. 1. Remove the headlamp bulb. Refer to Headlamp Bulb Replacement procedure in SI. 2. Inspect the connector. - If the connector is NOT discolored or damaged, replace the bulb only. For bulb part numbers, see Headlamp Bulb (Low Beam) in Group 02.727 of the appropriate Parts Catalog. - If the connector is discolored at the bulb interface, replace the connector (service pigtail listed below) and bulb. Important Use only Duraseal splice sleeves (salmon, P/N 19168446). Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Refer to Splicing Copper Wire Using Splice Sleeves in SI for splicing procedures. 1. Cut the wires of the connector approximately 45 mm (13/4 in) from the connector and splice in the service pigtail connector. Ensure that the splices are not above the connector when re-installing. 2. Replace the bulb. 3. Verify that the headlamp is fully functional. Parts Information Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Technical Service Bulletins > Customer Interest for Headlamp Bulb: > 10-08-42-001B > Jan > 11 > Lighting - Low Beam Headlamp(s) Inoperative > Page 17877 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Technical Service Bulletins > Customer Interest for Headlamp Bulb: > 10-08-42-001 > May > 10 > Lighting - Low Beam Headlamp(s) Inoperative Headlamp Bulb: Customer Interest Lighting - Low Beam Headlamp(s) Inoperative TECHNICAL Bulletin No.: 10-08-42-001 Date: May 14, 2010 Subject: Low Beam Headlamp Bulb Diagnosis/Replacement (Inspect Bulb and Connector) Models: 2008-2010 Buick Enclave 2008-2010 Cadillac CTS, CTS-V 2010 Cadillac CTS Sport Wagon, SRX 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Malibu 2009-2010 Chevrolet Traverse 2007-2010 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2006-2010 Pontiac G6 2007-2010 Saturn AURA Attention: This bulletin DOES NOT apply to vehicles equipped with High Intensity Discharge (HID) lamps. Condition Some customers may comment that the low beam headlamp is inoperative. Correction DO NOT replace the entire headlamp assembly for this condition. Replace the bulb and inspect the connector following the procedure below. 1. Remove the lamp assembly, then remove the bulb. Refer to Headlamp Assembly Replacement in SI. 2. Inspect the connector. - If the connector is NOT discolored or damaged, replace the bulb only. For bulb part numbers, see Headlamp Bulb (Low Beam) in Group 02.727 of the appropriate Parts Catalog. - If the connector is discolored at the bulb interface, replace the connector (service pigtail listed below) and bulb. Important Use only Duraseal splice sleeves (salmon, P/N 12089189). Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Refer to Splicing Copper Wire Using Splice Sleeves in SI for splicing procedures. 1. Cut the wires of the connector approximately 45 mm (1-3/4 in) from the connector and splice in the service pigtail connector. Ensure that the splices are not above the connector when re-installing. 2. Replace the bulb. 3. Verify that the headlamp is fully functional. Parts Information Warranty Information For vehicles repaired under warranty, use: Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Technical Service Bulletins > Customer Interest for Headlamp Bulb: > 10-08-42-001 > May > 10 > Lighting - Low Beam Headlamp(s) Inoperative > Page 17882 If only bulbs are replaced, use labor operation N0440 or N0441. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Technical Service Bulletins > Page 17883 Headlamp Bulb: Service and Repair Headlamp Bulb Replacement (Chevrolet) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Lens > Component Information > Technical Service Bulletins > Lighting - Headlamp Polycarbonate Lens Damage Prevention Headlamp Lens: Technical Service Bulletins Lighting - Headlamp Polycarbonate Lens Damage Prevention INFORMATION Bulletin No.: 02-08-42-001D Date: June 21, 2010 Subject: Headlamp Lens Overheating When Covered and Chemical Damage to Exterior Polycarbonate Headlamp Lenses Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add model years and to revise the warning statements. Please discard Corporate Bulletin Number 02-08-42-001C (Section 08 - Body and Accessories). The bulletin is being issued to make dealers and customers aware of chemical damage that may be caused to exterior polycarbonate headlamp lenses. Most late model vehicles have these types of headlamp lenses. This material is used because of its temperature and high impact resistance. A variety of chemicals can cause crazing or cracking of the headlamp lens. Headlamp lenses are very sensitive. Care should be exercised to avoid contact with all exterior headlamp lenses when treating a vehicle with any type of chemical, such as those recommended for rail dust removal. Rubbing compound, grease tar and oil removers, tire cleaners, cleaner waxes and even car wash soaps in too high a concentration may also attribute to this condition. This could result in the need to replace the entire headlamp housing. Warning Use only lukewarm or cold water, a soft cloth and a car washing soap to clean exterior lamps and lenses. Also, crazing or deformations of the lens may occur if a shop mat or fender cover is draped over the fender and covers a portion or all of the headlamp assembly while the DRL or headlamps are on. This action restricts the amount of heat dissipated by the headlamps. Warning Care should be taken to not cover headlamps with shop mats or fender covers if the vehicle is being serviced with the headlamps or DRL illuminated. Covering an illuminated lamp can cause excessive heat build up and crazing/deformation of the lens may occur. The degradation of the lens can be unnoticeable at first and eventually become hairline cracks in the lens. In extreme cases, it could cause the lens to deform. This damage can also be caused by aftermarket shields that are often tinted in color. Once a heat buildup is generated by the headlamp, a degradation of the headlamp lens begins. This degradation of the lens can be unnoticeable at first and eventually manifest as spider cracks. In more extreme cases, it will begin to melt the lens of the headlamp. Notice Headlamps damaged by chemicals, improper cleaning, or overheating due to being covered are not covered under the new vehicle warranty. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Locations Headlamp Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Locations > Page 17891 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Locations > Page 17892 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Locations > Page 17893 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Locations > Page 17894 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Locations > Page 17895 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Locations > Page 17896 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Locations > Page 17897 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Service and Repair > Headlamp Switch Replacement (with RPO SLT) Headlamp Switch: Service and Repair Headlamp Switch Replacement (with RPO SLT) Headlamp Switch Replacement (with RPO SLT) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Service and Repair > Headlamp Switch Replacement (with RPO SLT) > Page 17902 Headlamp Switch: Service and Repair Headlamp Switch Replacement (without RPO SLT) Headlamp Switch Replacement (without RPO SLT) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations Horn Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 17907 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 17908 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 17909 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 17910 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 17911 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 17912 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 17913 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Service and Repair Horn Switch: Service and Repair Steering Wheel Horn Switch Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Lamp Out Indicator > Component Information > Technical Service Bulletins > Customer Interest for Lamp Out Indicator: > 07-08-42-006E > Nov > 10 > Instruments - Bulb Outage Detection Restoration Lamp Out Indicator: Customer Interest Instruments - Bulb Outage Detection Restoration INFORMATION Bulletin No.: 07-08-42-006E Date: November 11, 2010 Subject: Information on BCM Calibrations Available to Restore Bulb Outage Detection on Vehicles Produced by a Second Stage Manufacturer, Turn Signals Flash Fast after Factory Box Removed (Upfitter) Models: 2007-2011 Chevrolet Silverado 2007-2011 GMC Sierra Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 07-08-42-006D (Section 08 - Body and Accessories). The information contained in this bulletin applies to vehicles that are to be completed by a second stage manufacturer (upfitter) and may need to have the Body Control Module (BCM) rear turn signal bulb outage detection capability changed. All production vehicles will be manufactured with one of the following BCM rear turn signal bulb outage detection software options: 1. A standard production vehicle will have BCM software that checks for two bulbs functioning in each rear turn signal bulb circuit. If one or more bulbs are inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 2. Certain 2500 and 3500 models can be ordered with a new option (RPO 9U5) where the BCM checks for one bulb functioning in each rear turn signal bulb circuit. If the bulb goes inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 3. A vehicle built with a pickup box delete or chassis cab option (RPO ZW9) will be produced with a BCM program that has no turn signal bulb outage detection capability (LED compatible). The IPC turn signal indicator will flash at the same rate no matter how many turn signal bulbs are inoperative. In some cases, the upfitter may wish to change the turn signal bulb outage detection capability so that the turn signals work correctly with their upfit or to meet certain requirements. This will require contacting the Techline Customer Support Center (TCSC) to open a case and obtain a Vehicle Configuration Index (VCI) number. Advise the TCSC consultant which turn signal bulb outage detection capability is needed: 1. Factory standard production TWO bulb outage detection. 2. Optional (RPO 9U5) ONE bulb outage detection. NOTE: ONLY AVAILABLE ON CERTAIN 2007-2011 MODEL 2500 AND 3500 VEHICLES. 3. NO bulb outage detection (LED compatible). The BCM can then be reprogrammed with the correct software. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Lamp Out Indicator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Lamp Out Indicator: > 07-08-42-006E > Nov > 10 > Instruments - Bulb Outage Detection Restoration Lamp Out Indicator: All Technical Service Bulletins Instruments - Bulb Outage Detection Restoration INFORMATION Bulletin No.: 07-08-42-006E Date: November 11, 2010 Subject: Information on BCM Calibrations Available to Restore Bulb Outage Detection on Vehicles Produced by a Second Stage Manufacturer, Turn Signals Flash Fast after Factory Box Removed (Upfitter) Models: 2007-2011 Chevrolet Silverado 2007-2011 GMC Sierra Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 07-08-42-006D (Section 08 - Body and Accessories). The information contained in this bulletin applies to vehicles that are to be completed by a second stage manufacturer (upfitter) and may need to have the Body Control Module (BCM) rear turn signal bulb outage detection capability changed. All production vehicles will be manufactured with one of the following BCM rear turn signal bulb outage detection software options: 1. A standard production vehicle will have BCM software that checks for two bulbs functioning in each rear turn signal bulb circuit. If one or more bulbs are inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 2. Certain 2500 and 3500 models can be ordered with a new option (RPO 9U5) where the BCM checks for one bulb functioning in each rear turn signal bulb circuit. If the bulb goes inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 3. A vehicle built with a pickup box delete or chassis cab option (RPO ZW9) will be produced with a BCM program that has no turn signal bulb outage detection capability (LED compatible). The IPC turn signal indicator will flash at the same rate no matter how many turn signal bulbs are inoperative. In some cases, the upfitter may wish to change the turn signal bulb outage detection capability so that the turn signals work correctly with their upfit or to meet certain requirements. This will require contacting the Techline Customer Support Center (TCSC) to open a case and obtain a Vehicle Configuration Index (VCI) number. Advise the TCSC consultant which turn signal bulb outage detection capability is needed: 1. Factory standard production TWO bulb outage detection. 2. Optional (RPO 9U5) ONE bulb outage detection. NOTE: ONLY AVAILABLE ON CERTAIN 2007-2011 MODEL 2500 AND 3500 VEHICLES. 3. NO bulb outage detection (LED compatible). The BCM can then be reprogrammed with the correct software. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams License Plate Lamp: Diagrams Component Connector End Views License Lamp - Left License Lamp - Right Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Service and Repair > Rear License Plate Lamp Replacement (VF7) License Plate Lamp: Service and Repair Rear License Plate Lamp Replacement (VF7) Rear License Plate Lamp Replacement (VF7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Service and Repair > Rear License Plate Lamp Replacement (VF7) > Page 17935 License Plate Lamp: Service and Repair Rear License Plate Lamp Bulb Replacement Rear License Plate Lamp Bulb Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Service and Repair > Rear License Plate Lamp Replacement (VF7) > Page 17936 License Plate Lamp: Service and Repair Rear License Plate Lamp Replacement Rear License Plate Lamp Replacement (Chevrolet GMC) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Marker Lamp Bulb > Component Information > Service and Repair > Front Side Marker Lamp Bulb Replacement (GMC) Marker Lamp Bulb: Service and Repair Front Side Marker Lamp Bulb Replacement (GMC) Front Side Marker Lamp Bulb Replacement (GMC) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Marker Lamp Bulb > Component Information > Service and Repair > Front Side Marker Lamp Bulb Replacement (GMC) > Page 17942 Marker Lamp Bulb: Service and Repair Roof Clearance Center Lamp Replacement (U01) Roof Clearance Center Lamp Replacement (U01) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Marker Lamp Bulb > Component Information > Service and Repair > Front Side Marker Lamp Bulb Replacement (GMC) > Page 17943 Marker Lamp Bulb: Service and Repair Roof Clearance Outer Lamp Replacement (U01) Roof Clearance Outer Lamp Replacement (U01) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Locations Parking Lamp Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Locations > Page 17948 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Locations > Page 17949 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Locations > Page 17950 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Locations > Page 17951 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Locations > Page 17952 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Locations > Page 17953 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Locations > Page 17954 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Light Bulb > Component Information > Service and Repair Parking Light Bulb: Service and Repair Parking and Turn Signal Lamp Bulb Replacement (Chevrolet) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Locations Backup Lamp Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Locations > Page 17962 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Locations > Page 17963 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Locations > Page 17964 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Locations > Page 17965 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Locations > Page 17966 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Locations > Page 17967 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Backup Lamp Relay > Component Information > Locations > Page 17968 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Center Mounted Brake Lamp Relay > Component Information > Locations Center Mounted Brake Lamp Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Center Mounted Brake Lamp Relay > Component Information > Locations > Page 17972 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Center Mounted Brake Lamp Relay > Component Information > Locations > Page 17973 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Center Mounted Brake Lamp Relay > Component Information > Locations > Page 17974 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Center Mounted Brake Lamp Relay > Component Information > Locations > Page 17975 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Center Mounted Brake Lamp Relay > Component Information > Locations > Page 17976 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Center Mounted Brake Lamp Relay > Component Information > Locations > Page 17977 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Center Mounted Brake Lamp Relay > Component Information > Locations > Page 17978 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations Fog/Driving Lamp Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 17982 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 17983 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 17984 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 17985 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 17986 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 17987 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 17988 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Hazard Flasher Relay > Component Information > Diagrams Hazard Flasher Relay: Diagrams Component Connector End Views Roof Beacon Relay (TRW) Emergency Vehicle Roof Lamp Relay (5Y0) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Hazard Flasher Relay > Component Information > Diagrams > Page 17992 Wrecker Relay X1 (5X7) Wrecker Relay X2 (5X7) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Hazard Flasher Relay > Component Information > Diagrams > Page 17993 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations Headlamp Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 17997 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 17998 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 17999 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 18000 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 18001 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 18002 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 18003 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Horn Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 18007 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 18008 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 18009 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 18010 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 18011 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 18012 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 18013 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations Parking Lamp Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 18017 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 18018 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 18019 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 18020 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 18021 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 18022 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 18023 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations Trailer Lighting Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Page 18027 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Page 18028 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Page 18029 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Page 18030 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Page 18031 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Page 18032 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Page 18033 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Page 18034 Trailer Lighting Relay: Diagrams Component Connector End Views Trailer Stop/Turn Relay (TZ0) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Service and Repair Ambient Light Sensor: Service and Repair Ambient Light Sensor Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams Backup Lamp Switch: Diagrams Component Connector End Views Backup Lamp Switch (TZ0) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Service and Repair > Tremec 5-Speed (M96) - Manual Transmission Backup Lamp Switch: Service and Repair Tremec 5-Speed (M96) - Manual Transmission Backup Lamp Switch Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Service and Repair > Tremec 5-Speed (M96) - Manual Transmission > Page 18044 Backup Lamp Switch: Service and Repair Tremec 5-Speed (TZ0) - Manual Transmission Backup Lamp Switch Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Disconnect the backup lamp switch electrical connector (3). 3. Remove the backup lamp switch. Installation Procedure Caution: Refer to Component Fastener Tightening Caution (See: Service Precautions/Vehicle Damage Warnings/Component Fastener Tightening Caution). Note: The backup lamp switch has pre-applied thread sealant on the threads. 1. Install the backup lamp switch. Tighten the switch to 37 Nm (27 lb ft). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Service and Repair > Tremec 5-Speed (M96) - Manual Transmission > Page 18045 2. Connect the backup lamp switch electrical connector (3). 3. Lower the vehicle. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams Brake Light Switch: Diagrams Component Connector End Views Stop Lamp Switch Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Service and Repair > Stop Lamp Switch Replacement (With Adjustable Pedals) Brake Light Switch: Service and Repair Stop Lamp Switch Replacement (With Adjustable Pedals) Stop Lamp Switch Replacement (With Adjustable Pedals) Removal Procedure 1. Apply the park brake. 2. Remove the driver knee bolster. Refer to Knee Bolster Replacement (With SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (With SLT))Knee Bolster Replacement (Without SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (Without SLT)). 3. Disconnect the stoplamp switch electrical connector. 4. Remove the power vacuum brake booster pushrod retainer bolt (1). 5. Remove the power vacuum brake booster pushrod retainer (1). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Service and Repair > Stop Lamp Switch Replacement (With Adjustable Pedals) > Page 18051 6. Slide the power vacuum brake booster pushrod off of the brake pedal pin and remove the stoplamp switch (1). Installation Procedure 1. Install the stoplamp switch (1) to the power vacuum brake booster pushrod. 2. Install the power vacuum brake booster pushrod with the stoplamp switch to the brake pedal pin. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Service and Repair > Stop Lamp Switch Replacement (With Adjustable Pedals) > Page 18052 3. Install the power vacuum brake booster pushrod retainer (1). 4. Rotate the pushrod retainer 360 degrees to verify the retainer is fully engaged in the groove on the brake pedal pin. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Install the power vacuum brake booster pushrod retainer bolt (1) and tighten to 10 Nm (89 lb in). 6. Connect the stoplamp switch electrical connector. 7. Install the driver knee bolster. Refer to Knee Bolster Replacement (With SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (With SLT))Knee Bolster Replacement (Without SLT) (See: Restraint Systems/Knee Diverter/Service and Repair/Knee Bolster Replacement (Without SLT)). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Service and Repair > Stop Lamp Switch Replacement (With Adjustable Pedals) > Page 18053 Brake Light Switch: Service and Repair Stop Lamp Switch Replacement (Without Adjustable Pedals) Stop Lamp Switch Replacement (Without Adjustable Pedals) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Diagrams Combination Switch: Diagrams Component Connector End Views Turn Signal/Multifunction Switch X1 Turn Signal/Multifunction Switch X2 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Diagrams > Page 18057 Turn Signal/Multifunction Switch X3 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Service and Repair > Fog Lamp Switch Replacement (with RPO SLT) Fog/Driving Lamp Switch: Service and Repair Fog Lamp Switch Replacement (with RPO SLT) Fog Lamp Switch Replacement (with RPO SLT) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Service and Repair > Fog Lamp Switch Replacement (with RPO SLT) > Page 18062 Fog/Driving Lamp Switch: Service and Repair Fog Lamp Switch Replacement (without RPO SLT) Fog Lamp Switch Replacement (without RPO SLT) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams Hazard Warning Switch: Diagrams Component Connector End Views Roof Beacon Switch (5X7, 5Y0 or TRW) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Service and Repair > Headlamp Switch Replacement (with RPO SLT) Headlamp Switch: Service and Repair Headlamp Switch Replacement (with RPO SLT) Headlamp Switch Replacement (with RPO SLT) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Service and Repair > Headlamp Switch Replacement (with RPO SLT) > Page 18070 Headlamp Switch: Service and Repair Headlamp Switch Replacement (without RPO SLT) Headlamp Switch Replacement (without RPO SLT) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Service and Repair Horn Switch: Service and Repair Steering Wheel Horn Switch Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams Turn Signal Switch: Diagrams Component Connector End Views Turn Signal/Multifunction Switch X1 Turn Signal/Multifunction Switch X2 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 18077 Turn Signal/Multifunction Switch X3 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Service and Repair > Turn Signal Multifunction Switch Replacement Turn Signal Switch: Service and Repair Turn Signal Multifunction Switch Replacement Turn Signal Multifunction Switch Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Service and Repair > Turn Signal Multifunction Switch Replacement > Page 18080 Turn Signal Switch: Service and Repair Turn Signal Switch Cancel Cam Position Plate Replacement Turn Signal Switch Cancel Cam Position Plate Replacement Tools Required * J 23653-SIR Steering Column Lock Plate Compressor * J 42137 Cam Orientation Plate Adapter Removal Procedure 1. Remove the inflatable restraint steering wheel module coil and the inflatable restraint steering wheel module coil wave washer. Refer to Steering Wheel Inflatable Restraint Module Coil Replacement (See: Restraint Systems/Air Bag Systems/Clockspring Assembly / Spiral Cable/Service and Repair/Removal and Replacement). Important: DISCARD the old steering shaft lock plate ring. 2. Remove the following parts from the steering shaft: 1. Steering shaft lock plate retaining ring (1) using compressor J 23653-SIR and adapter J 42137 . 2. Turn signal switch cancel cam position plate (2) 3. Turn signal switch cancel cam (3) Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Service and Repair > Turn Signal Multifunction Switch Replacement > Page 18081 Important: Use a NEW steering shaft lock plate retaining ring. 1. Install the following parts onto the steering shaft: 1. Lubricate the turn signal switch cancel cam (3) with GM P/N 12377900 (Canadian P/N 10953529). 2. Turn signal switch cancel cam position plate (2) 3. Steering shaft lock plate retaining ring (1) using compressor J 23653-SIR and adapter J 42137 . 2. Install the inflatable restraint steering wheel module coil and the inflatable restraint steering wheel module coil wave washer. Refer to Steering Wheel Inflatable Restraint Module Coil Replacement (See: Restraint Systems/Air Bag Systems/Clockspring Assembly / Spiral Cable/Service and Repair/Removal and Replacement). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Tail Light Bulb > Component Information > Service and Repair Tail Light Bulb: Service and Repair Tail Lamp Bulb Replacement (Chevrolet) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Locations Trailer Lighting Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Page 18089 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Page 18090 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Page 18091 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Page 18092 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Page 18093 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Page 18094 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Page 18095 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Page 18096 Trailer Lighting Relay: Diagrams Component Connector End Views Trailer Stop/Turn Relay (TZ0) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Diagrams Combination Switch: Diagrams Component Connector End Views Turn Signal/Multifunction Switch X1 Turn Signal/Multifunction Switch X2 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Diagrams > Page 18101 Turn Signal/Multifunction Switch X3 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Turn Signal Bulb > Component Information > Service and Repair Turn Signal Bulb: Service and Repair Parking and Turn Signal Lamp Bulb Replacement (Chevrolet) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams Turn Signal Switch: Diagrams Component Connector End Views Turn Signal/Multifunction Switch X1 Turn Signal/Multifunction Switch X2 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Page 18109 Turn Signal/Multifunction Switch X3 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Service and Repair > Turn Signal Multifunction Switch Replacement Turn Signal Switch: Service and Repair Turn Signal Multifunction Switch Replacement Turn Signal Multifunction Switch Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Service and Repair > Turn Signal Multifunction Switch Replacement > Page 18112 Turn Signal Switch: Service and Repair Turn Signal Switch Cancel Cam Position Plate Replacement Turn Signal Switch Cancel Cam Position Plate Replacement Tools Required * J 23653-SIR Steering Column Lock Plate Compressor * J 42137 Cam Orientation Plate Adapter Removal Procedure 1. Remove the inflatable restraint steering wheel module coil and the inflatable restraint steering wheel module coil wave washer. Refer to Steering Wheel Inflatable Restraint Module Coil Replacement (See: Restraint Systems/Air Bag Systems/Clockspring Assembly / Spiral Cable/Service and Repair/Removal and Replacement). Important: DISCARD the old steering shaft lock plate ring. 2. Remove the following parts from the steering shaft: 1. Steering shaft lock plate retaining ring (1) using compressor J 23653-SIR and adapter J 42137 . 2. Turn signal switch cancel cam position plate (2) 3. Turn signal switch cancel cam (3) Installation Procedure Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Service and Repair > Turn Signal Multifunction Switch Replacement > Page 18113 Important: Use a NEW steering shaft lock plate retaining ring. 1. Install the following parts onto the steering shaft: 1. Lubricate the turn signal switch cancel cam (3) with GM P/N 12377900 (Canadian P/N 10953529). 2. Turn signal switch cancel cam position plate (2) 3. Steering shaft lock plate retaining ring (1) using compressor J 23653-SIR and adapter J 42137 . 2. Install the inflatable restraint steering wheel module coil and the inflatable restraint steering wheel module coil wave washer. Refer to Steering Wheel Inflatable Restraint Module Coil Replacement (See: Restraint Systems/Air Bag Systems/Clockspring Assembly / Spiral Cable/Service and Repair/Removal and Replacement). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations Heated Glass Element Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations > Page 18119 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations > Page 18120 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations > Page 18121 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations > Page 18122 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations > Page 18123 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations > Page 18124 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations > Page 18125 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations Heated Glass Element Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 18130 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 18131 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 18132 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 18133 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 18134 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 18135 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 18136 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Diagrams Power Window Relay: Diagrams Component Connector End Views Sliding Rear Window Close Relay (A48) Sliding Rear Window Open Relay (A48) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Diagrams > Page 18140 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations Power Window Switch: Locations Harness Routing Views Overhead Console Harness Routing 1 - X304 (except MEX) 2 - Inflatable Restraint Passenger Air Bag On/Off Indicator (AL0/C99 except MEX) 3 - Cellular Telephone Microphone (UE1/U3U/UVB) 4 - Roof Beacon Switch (5X7/5Y0/TRW) 5 - Sliding Rear Window Switch (A48) 6 - Dome/Reading Lamps - Front 7 - J322 (TRW/UG1/A48) 8 - J323 9 - X313 (CF5/TRW/5X7/5Y0) 10 - Blunt Cut - Roof Mounted Beacon Provision (TRW) 11 Roof Beacon Relay (TRW) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 18145 Power Window Switch: Diagrams Component Connector End Views Door Lock Switch - Driver (AU3 without AN3 or DL3) Door Lock Switch - Passenger (AU3 without AN3 or DL3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 18146 Door Lock/Window Switch - Driver X1 (AN3 or DL3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 18147 Door Lock/Window Switch - Driver X2 (AN3 or DL3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 18148 Door Lock/Window Switch - Driver X3 (AN3 or DL3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 18149 Door Lock/Window Switch - Driver X4 (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 18150 Door Lock/Window Switch - Driver X7 (AN3 or DL3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 18151 Door Lock/Window Switch - Passenger X1 (AN3 or DL3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 18152 Door Lock/Window Switch - Passenger X2 (AN3 or DL3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 18153 Door Lock/Window Switch - Passenger X3 (AN3 or DL3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 18154 Door Lock/Window Switch - Passenger X4 (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 18155 Door Lock/Window Switch - Passenger X7 (AN3 or DL3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 18156 Sliding Rear Window Switch (A48) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 18157 Window Switch - Driver X1 (A31 without AN3 or DL3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 18158 Window Switch - Driver X2 (A31 without AN3 or DL3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 18159 Window Switch - Left Rear (Crew Cab with A31 or Extended Cab with ABV) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 18160 Window Switch - Passenger (A31 without AN3 or DL3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 18161 Window Switch - Right Rear (Crew Cab with A31 or Extended Cab with ABV) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 18162 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Front Side Door Window and Rear Side Door Window Switch Replacement (with DL8 and without SLT) Power Window Switch: Service and Repair Front Side Door Window and Rear Side Door Window Switch Replacement (with DL8 and without SLT) Front Side Door Window and Rear Side Door Window Switch Replacement (with DL8 and without SLT) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Front Side Door Window and Rear Side Door Window Switch Replacement (with DL8 and without SLT) > Page 18165 Power Window Switch: Service and Repair Rear Side Door Window Switch Replacement (Extended Cab) Rear Side Door Window Switch Replacement (Extended Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Front Side Door Window and Rear Side Door Window Switch Replacement (with DL8 and without SLT) > Page 18166 Power Window Switch: Service and Repair Rear Side Door Window Switch Replacement (Crew Cab) Rear Side Door Window Switch Replacement (Crew Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Front Side Door Window and Rear Side Door Window Switch Replacement (with DL8 and without SLT) > Page 18167 Power Window Switch: Service and Repair Door Lock and Side Window Switch Replacement Driver Side Door Lock and Side Window Switch Replacement - Driver Side Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Front Side Door Window and Rear Side Door Window Switch Replacement (with DL8 and without SLT) > Page 18168 Power Window Switch: Service and Repair Door Lock and Side Window Switch Replacement Passenger Side Door Lock and Side Window Switch Replacement - Passenger Side Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Back Window Motor > Component Information > Diagrams Back Window Motor: Diagrams Component Connector End Views Sliding Rear Window Motor (A48) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Back Window Motor > Component Information > Diagrams > Page 18174 Back Window Motor: Service and Repair Rear Sliding Window Module Replacement Removal Procedure Note: The new rear sliding window motor/module is equipped with the bracket and relays. 1. Remove the rear sliding window lower garnish molding. Refer to Rear Window Lower Garnish Molding Replacement (Ext Cab/Crew Cab w/A48) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Rear Window Lower Garnish Molding Replacement (Ext Cab/Crew Cab w/A48))Rear Window Lower Garnish Molding Replacement (Ext Cab/Crew Cab w/o A48) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Rear Window Lower Garnish Molding Replacement (Ext Cab/Crew Cab w/o A48))Rear Window Lower Garnish Molding Replacement (Regular Cab) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Rear Window Lower Garnish Molding Replacement (Regular Cab)). 2. Cycle the rear sliding window to the fully closed position. 3. Remove the screw (1) from the rear sliding window regulator and cables (2). 4. Pull forward on the regulator and cables (2) to release it from the motor/module. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Back Window Motor > Component Information > Diagrams > Page 18175 5. Remove the rear sliding window motor/module nuts (2). 6. Disconnect the rear sliding window electrical connectors from the motor/module and relays (1). 7. Remove the rear sliding window motor/module assembly from the vehicle. Installation Procedure 1. Install the rear sliding window motor/module assembly to the vehicle. 2. Connect the rear sliding window electrical connectors to the motor/module and relays (1). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Back Window Motor > Component Information > Diagrams > Page 18176 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the rear sliding window motor/module nuts (2). Tighten nut to 10 Nm (89 lb in). 4. Install the rear sliding window regulator and cables (2) to the motor/module. 5. Install the bolt (1) to the rear sliding window regulator and cables (2). Tighten bolt to 11 Nm (97 lb in). 6. Install the rear sliding window lower garnish molding. Refer to Rear Window Lower Garnish Molding Replacement (Ext Cab/Crew Cab w/A48) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Rear Window Lower Garnish Molding Replacement (Ext Cab/Crew Cab w/A48))Rear Window Lower Garnish Molding Replacement (Ext Cab/Crew Cab w/o A48) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Rear Window Lower Garnish Molding Replacement (Ext Cab/Crew Cab w/o A48))Rear Window Lower Garnish Molding Replacement (Regular Cab) (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Rear Window Lower Garnish Molding Replacement (Regular Cab)). 7. Inspect the rear sliding window for proper operation. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor > Component Information > Diagrams Front Door Window Motor: Diagrams Component Connector End Views Window Motor - Driver (A31) Window Motor - Passenger (A31) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor > Component Information > Diagrams > Page 18180 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor > Component Information > Diagrams > Page 18181 Front Door Window Motor: Service and Repair Front Side Door Window Regulator Motor Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor > Component Information > Diagrams Rear Door Window Motor: Diagrams Component Connector End Views Window Motor - Left Rear (Crew Cab with A31 or Extended Cab with ABV) Window Motor - Right Rear (Crew Cab with A31 or Extended Cab with ABV) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor > Component Information > Diagrams > Page 18185 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor > Component Information > Service and Repair > Rear Side Door Window Regulator Motor Replacement (Crew Cab) Rear Door Window Motor: Service and Repair Rear Side Door Window Regulator Motor Replacement (Crew Cab) Rear Side Door Window Regulator Motor Replacement (Crew Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor > Component Information > Service and Repair > Rear Side Door Window Regulator Motor Replacement (Crew Cab) > Page 18188 Rear Door Window Motor: Service and Repair Rear Side Door Window Regulator Motor Replacement (Extended Cab) Rear Side Door Window Regulator Motor Replacement (Extended Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Diagrams Power Window Relay: Diagrams Component Connector End Views Sliding Rear Window Close Relay (A48) Sliding Rear Window Open Relay (A48) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Diagrams > Page 18192 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations Power Window Switch: Locations Harness Routing Views Overhead Console Harness Routing 1 - X304 (except MEX) 2 - Inflatable Restraint Passenger Air Bag On/Off Indicator (AL0/C99 except MEX) 3 - Cellular Telephone Microphone (UE1/U3U/UVB) 4 - Roof Beacon Switch (5X7/5Y0/TRW) 5 - Sliding Rear Window Switch (A48) 6 - Dome/Reading Lamps - Front 7 - J322 (TRW/UG1/A48) 8 - J323 9 - X313 (CF5/TRW/5X7/5Y0) 10 - Blunt Cut - Roof Mounted Beacon Provision (TRW) 11 Roof Beacon Relay (TRW) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Page 18196 Power Window Switch: Diagrams Component Connector End Views Door Lock Switch - Driver (AU3 without AN3 or DL3) Door Lock Switch - Passenger (AU3 without AN3 or DL3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Page 18197 Door Lock/Window Switch - Driver X1 (AN3 or DL3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Page 18198 Door Lock/Window Switch - Driver X2 (AN3 or DL3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Page 18199 Door Lock/Window Switch - Driver X3 (AN3 or DL3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Page 18200 Door Lock/Window Switch - Driver X4 (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Page 18201 Door Lock/Window Switch - Driver X7 (AN3 or DL3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Page 18202 Door Lock/Window Switch - Passenger X1 (AN3 or DL3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Page 18203 Door Lock/Window Switch - Passenger X2 (AN3 or DL3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Page 18204 Door Lock/Window Switch - Passenger X3 (AN3 or DL3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Page 18205 Door Lock/Window Switch - Passenger X4 (AN3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Page 18206 Door Lock/Window Switch - Passenger X7 (AN3 or DL3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Page 18207 Sliding Rear Window Switch (A48) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Page 18208 Window Switch - Driver X1 (A31 without AN3 or DL3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Page 18209 Window Switch - Driver X2 (A31 without AN3 or DL3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Page 18210 Window Switch - Left Rear (Crew Cab with A31 or Extended Cab with ABV) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Page 18211 Window Switch - Passenger (A31 without AN3 or DL3) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Page 18212 Window Switch - Right Rear (Crew Cab with A31 or Extended Cab with ABV) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Page 18213 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Service and Repair > Front Side Door Window and Rear Side Door Window Switch Replacement (with DL8 and without SLT) Power Window Switch: Service and Repair Front Side Door Window and Rear Side Door Window Switch Replacement (with DL8 and without SLT) Front Side Door Window and Rear Side Door Window Switch Replacement (with DL8 and without SLT) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Service and Repair > Front Side Door Window and Rear Side Door Window Switch Replacement (with DL8 and without SLT) > Page 18216 Power Window Switch: Service and Repair Rear Side Door Window Switch Replacement (Extended Cab) Rear Side Door Window Switch Replacement (Extended Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Service and Repair > Front Side Door Window and Rear Side Door Window Switch Replacement (with DL8 and without SLT) > Page 18217 Power Window Switch: Service and Repair Rear Side Door Window Switch Replacement (Crew Cab) Rear Side Door Window Switch Replacement (Crew Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Service and Repair > Front Side Door Window and Rear Side Door Window Switch Replacement (with DL8 and without SLT) > Page 18218 Power Window Switch: Service and Repair Door Lock and Side Window Switch Replacement Driver Side Door Lock and Side Window Switch Replacement - Driver Side Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Service and Repair > Front Side Door Window and Rear Side Door Window Switch Replacement (with DL8 and without SLT) > Page 18219 Power Window Switch: Service and Repair Door Lock and Side Window Switch Replacement Passenger Side Door Lock and Side Window Switch Replacement - Passenger Side Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Technical Service Bulletins > Customer Interest: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information Back Window Glass: Customer Interest A/C - Window Defroster Contact/Tab Repair Information INFORMATION Bulletin No.: 03-08-48-006H Date: April 11, 2011 Subject: Repair Information for Reconnection of Rear Window Defroster Contact or Tab Models: 2000-2012 GM Passenger Cars and Trucks 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X 2007-2010 Opel GT 2007-2008 Daewoo G2X Equipped With Electric Rear Window Defroster - RPO C49 Supercede: This bulletin is being revised to add the 2012 model year. Please discard Corporate Bulletin Number 03-08-48-006G (Section 08 - Body and Accessories). Repair Suggestions Soldering Defroster Contact Tabs In many cases the terminal tab will still be in the connector when you examine the vehicle. For Chevrolet Tahoe, Suburban, GMC Yukon, and Cadillac Escalade vehicles (with moveable glass), always replace the defroster tab (GM P/N 25916031) and the defroster electrical power connector (P/N 12034110). For all other vehicles, reconnect the original defroster tab. In most applications it is preferable to create a new solder connection to reattach a separated rear defroster tab. If you take note of the steps below, it is possible to create a new solder joint that is equal to, or stronger than, the original. The generic procedure below is not very time intensive, but does include minor preparation work to create a good bonding surface. Be sure to follow each of the steps, as combined they will produce the strongest bond possible. Please consider the following before attempting the repair: - Soldering introduces significant heat to the glass window of the vehicle. When performing the re-connection of the tab, use only the heat required to do the job. Pre-heat the soldering iron and have the solder in your other hand, ready to go, the moment you have enough heat to melt the solder. - If it is winter, bring the vehicle into the service garage and remove any snow from the back window area. Allow time for the glass to warm to the temperature inside the building. Soldering creates a "hot spot" in the glass. DO NOT solder on cold glass. Caution Heating the glass excessively, or repeatedly without time to cool, may result in glass breakage. ALWAYS wear safety glasses when performing this repair! - You MUST use a silver-bearing solder to make the connection. DO NOT attempt this repair with conventional tin/lead alloy solders. Silver bearing solder will adhere to the electrical buss bar, making a strong and lasting repair. - Protect surfaces under the area to be soldered. It is very easy to drip solder when performing this repair. Placing a shop towel under the soldering area is sufficient protection. Soldering Procedure 1. It is imperative to remove and replace the rear defroster electrical power connector by crimping a new connector to the feed wire. The proper connector P/N 12034110 can be found in the Packard Electrical Assortment, Tray 18, Position 5. - Insert Delphi pick 12094430 to depress the locking tab on the terminal. - Insert Delphi pick 12094429 to release the secondary lock tab. Important DO NOT re-use the existing defroster tab on new-style full-size utility vehicles with moveable glass. 2. Connect the electrical connector to the defroster tab. Fully engage the connector. An improperly seated connector may cause excessive resistance and impede the proper operation of the defroster. Add a small bead of solder to mate the electrical connector tab to the defroster tab. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Technical Service Bulletins > Customer Interest: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 18229 3. Prepare the surface of the used defroster tab (not required for new tabs on new-style full-size utility models) and the defroster buss bar with fine grain (500 grit) sandpaper or Emery cloth. It is not necessary to remove all of the original solder, but it should be scuffed sufficiently so that no oxidation is present. The photo above shows a close up of a properly prepared surface. Tip You may want to mask the glass around the contact area with tape. This is easy to do and will allow you to safely prepare the contact surface without the risk of scratching the glass or the black painted shading. Important Most rear glass has a black painted masking around the edge of the glass. When cleaning up the connection surface, be very careful not to damage the surface of the black shading or the surface of the glass. 4. Wipe the newly prepared contact area with Kent Automotive* Acrysol(TM) (or equivalent) to remove any residual oil or dirt. Important Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Technical Service Bulletins > Customer Interest: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 18230 You MUST use a silver-bearing solder to make the solder joint. DO NOT attempt this repair with conventional tin/lead alloy solders. Most suppliers have this type of solder available and it is available nationally at Radio Shack(R)*. It is sold in several diameters and either are acceptable for this repair. 5. For this step, it is permitted that two technicians be used if required. Heat the new connector on the surface of the buss bar that is to be soldered. Long nose pliers are suggested to hold the electrical connector and the defroster tab in place. Keep the solder ready and begin flowing out the solder as soon as the melting temperature has been reached. Tip If a single technician is attempting this repair, it is beneficial to wrap one turn of the solder around the new contacts base. In this manner, as the melting point of the solder is reached, a layer is deposited on the bottom side of the contact. Important Try to align the new contact so that it is positioned with the same orientation as the original contact. 6. The above illustrates an ideal finished solder joint. Additional stray solder will not harm the performance of the bond; however, while it is unlikely that customers may refer to the appearance of the rear window defroster and its components as a positive styling feature of the vehicle interior, it is easy to elicit the opposite reaction due to a poor cosmetic application. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Acrysol(TM) can be ordered directly from Kent Automotive at 1-800-654-6333 (in Canada, 1-800-563-1717). Radio Shack(R) products can be found nationally at retail locations, www.radioshack.com, or at 1-800-843-7422. All other parts can be ordered through GMSPO or SSPO. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Technical Service Bulletins > Customer Interest: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 18231 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Back Window Glass: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information Back Window Glass: All Technical Service Bulletins A/C - Window Defroster Contact/Tab Repair Information INFORMATION Bulletin No.: 03-08-48-006H Date: April 11, 2011 Subject: Repair Information for Reconnection of Rear Window Defroster Contact or Tab Models: 2000-2012 GM Passenger Cars and Trucks 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X 2007-2010 Opel GT 2007-2008 Daewoo G2X Equipped With Electric Rear Window Defroster - RPO C49 Supercede: This bulletin is being revised to add the 2012 model year. Please discard Corporate Bulletin Number 03-08-48-006G (Section 08 - Body and Accessories). Repair Suggestions Soldering Defroster Contact Tabs In many cases the terminal tab will still be in the connector when you examine the vehicle. For Chevrolet Tahoe, Suburban, GMC Yukon, and Cadillac Escalade vehicles (with moveable glass), always replace the defroster tab (GM P/N 25916031) and the defroster electrical power connector (P/N 12034110). For all other vehicles, reconnect the original defroster tab. In most applications it is preferable to create a new solder connection to reattach a separated rear defroster tab. If you take note of the steps below, it is possible to create a new solder joint that is equal to, or stronger than, the original. The generic procedure below is not very time intensive, but does include minor preparation work to create a good bonding surface. Be sure to follow each of the steps, as combined they will produce the strongest bond possible. Please consider the following before attempting the repair: - Soldering introduces significant heat to the glass window of the vehicle. When performing the re-connection of the tab, use only the heat required to do the job. Pre-heat the soldering iron and have the solder in your other hand, ready to go, the moment you have enough heat to melt the solder. - If it is winter, bring the vehicle into the service garage and remove any snow from the back window area. Allow time for the glass to warm to the temperature inside the building. Soldering creates a "hot spot" in the glass. DO NOT solder on cold glass. Caution Heating the glass excessively, or repeatedly without time to cool, may result in glass breakage. ALWAYS wear safety glasses when performing this repair! - You MUST use a silver-bearing solder to make the connection. DO NOT attempt this repair with conventional tin/lead alloy solders. Silver bearing solder will adhere to the electrical buss bar, making a strong and lasting repair. - Protect surfaces under the area to be soldered. It is very easy to drip solder when performing this repair. Placing a shop towel under the soldering area is sufficient protection. Soldering Procedure 1. It is imperative to remove and replace the rear defroster electrical power connector by crimping a new connector to the feed wire. The proper connector P/N 12034110 can be found in the Packard Electrical Assortment, Tray 18, Position 5. - Insert Delphi pick 12094430 to depress the locking tab on the terminal. - Insert Delphi pick 12094429 to release the secondary lock tab. Important DO NOT re-use the existing defroster tab on new-style full-size utility vehicles with moveable glass. 2. Connect the electrical connector to the defroster tab. Fully engage the connector. An improperly seated connector may cause excessive resistance and impede the proper operation of the defroster. Add a small bead of solder to mate the electrical connector tab to the defroster tab. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Back Window Glass: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 18237 3. Prepare the surface of the used defroster tab (not required for new tabs on new-style full-size utility models) and the defroster buss bar with fine grain (500 grit) sandpaper or Emery cloth. It is not necessary to remove all of the original solder, but it should be scuffed sufficiently so that no oxidation is present. The photo above shows a close up of a properly prepared surface. Tip You may want to mask the glass around the contact area with tape. This is easy to do and will allow you to safely prepare the contact surface without the risk of scratching the glass or the black painted shading. Important Most rear glass has a black painted masking around the edge of the glass. When cleaning up the connection surface, be very careful not to damage the surface of the black shading or the surface of the glass. 4. Wipe the newly prepared contact area with Kent Automotive* Acrysol(TM) (or equivalent) to remove any residual oil or dirt. Important Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Back Window Glass: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 18238 You MUST use a silver-bearing solder to make the solder joint. DO NOT attempt this repair with conventional tin/lead alloy solders. Most suppliers have this type of solder available and it is available nationally at Radio Shack(R)*. It is sold in several diameters and either are acceptable for this repair. 5. For this step, it is permitted that two technicians be used if required. Heat the new connector on the surface of the buss bar that is to be soldered. Long nose pliers are suggested to hold the electrical connector and the defroster tab in place. Keep the solder ready and begin flowing out the solder as soon as the melting temperature has been reached. Tip If a single technician is attempting this repair, it is beneficial to wrap one turn of the solder around the new contacts base. In this manner, as the melting point of the solder is reached, a layer is deposited on the bottom side of the contact. Important Try to align the new contact so that it is positioned with the same orientation as the original contact. 6. The above illustrates an ideal finished solder joint. Additional stray solder will not harm the performance of the bond; however, while it is unlikely that customers may refer to the appearance of the rear window defroster and its components as a positive styling feature of the vehicle interior, it is easy to elicit the opposite reaction due to a poor cosmetic application. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Acrysol(TM) can be ordered directly from Kent Automotive at 1-800-654-6333 (in Canada, 1-800-563-1717). Radio Shack(R) products can be found nationally at retail locations, www.radioshack.com, or at 1-800-843-7422. All other parts can be ordered through GMSPO or SSPO. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Back Window Glass: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 18239 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Back Window Glass: > 00-08-48-005D > Sep > 10 > Body - Vehicle Glass Distortion Information Back Window Glass: All Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Technical Service Bulletins > All Other Service Bulletins for Back Window Glass: > 00-08-48-005D > Sep > 10 > Body - Vehicle Glass Distortion Information Back Window Glass: All Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Corner Window Glass > Component Information > Technical Service Bulletins > Body - Vehicle Glass Distortion Information Front Corner Window Glass: Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Technical Service Bulletins > Customer Interest: > 07-08-64-019C > Apr > 11 > Body - Front Door Window Regulator Squeak Noise Front Door Window Glass: Customer Interest Body - Front Door Window Regulator Squeak Noise TECHNICAL Bulletin No.: 07-08-64-019C Date: April 08, 2011 Subject: Front Door Window Regulator Squeak Noise When Operated (Apply Lubricant) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add the 2011 and 2012 model years. Please discard Corporate Bulletin Number 07-08-64-019B (Section 08 - Body and Accessories). Condition Some customers may comment on a front door glass squeak when operated up or down. Cause There may be insufficient lubrication on the regulator rails. Correction Lubricate BOTH front door regulators at time of repair using the following procedure. 1. Remove the regulator following SI procedures. 2. Brush a small amount of lubricant on the entire length of both regulator rails. Refer to the illustration for lubricant location. 3. Cycle the door glass to verify that the noise is gone. 4. Reinstall the regulator following SI procedures. Parts Information Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Technical Service Bulletins > Customer Interest: > 07-08-64-019C > Apr > 11 > Body - Front Door Window Regulator Squeak Noise > Page 18261 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass: > 07-08-64-019C > Apr > 11 > Body - Front Door Window Regulator Squeak Noise Front Door Window Glass: All Technical Service Bulletins Body - Front Door Window Regulator Squeak Noise TECHNICAL Bulletin No.: 07-08-64-019C Date: April 08, 2011 Subject: Front Door Window Regulator Squeak Noise When Operated (Apply Lubricant) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add the 2011 and 2012 model years. Please discard Corporate Bulletin Number 07-08-64-019B (Section 08 - Body and Accessories). Condition Some customers may comment on a front door glass squeak when operated up or down. Cause There may be insufficient lubrication on the regulator rails. Correction Lubricate BOTH front door regulators at time of repair using the following procedure. 1. Remove the regulator following SI procedures. 2. Brush a small amount of lubricant on the entire length of both regulator rails. Refer to the illustration for lubricant location. 3. Cycle the door glass to verify that the noise is gone. 4. Reinstall the regulator following SI procedures. Parts Information Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass: > 07-08-64-019C > Apr > 11 > Body - Front Door Window Regulator Squeak Noise > Page 18267 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass: > 00-08-48-005D > Sep > 10 > Body - Vehicle Glass Distortion Information Front Door Window Glass: All Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass: > 06-08-64-001B > Oct > 09 > Body - Side Window Chipping Information Front Door Window Glass: All Technical Service Bulletins Body - Side Window Chipping Information INFORMATION Bulletin No.: 06-08-64-001B Date: October 20, 2009 Subject: Information on Side Door Window Glass Chipping Caused by Hanging Vehicle Key Lock Box Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add vehicles and model years and to include all types of door window glass. Please discard Corporate Bulletin Number 06-08-64-001A (Section 08 - Body & Accessories). - In several warranty parts review cases, side door window glass was observed with a chip or chips on the top side of the window glass. Dealer contacts confirmed that they use a vehicle key lock box on the front side door window glass. - A random selection of side door glass returns will be conducted to confirm adherence. If a side door glass is discovered with a chip or chips in the location previously described, the side door glass will be returned to the dealership for debit. Example of Side Door Glass - DO NOT place a vehicle key lock box on a side door window glass. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass: > 06-08-64-001B > Oct > 09 > Body - Side Window Chipping Information > Page 18276 Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Window Glass: > 08-08-48-003F > Apr > 11 > Body - Tapping/Clicking/Ticking Noise at Windshield Area Windshield Moulding / Trim: All Technical Service Bulletins Body - Tapping/Clicking/Ticking Noise at Windshield Area TECHNICAL Bulletin No.: 08-08-48-003F Date: April 06, 2011 Subject: Tapping, Clicking or Ticking Noise at Windshield Area (R&R; Right and Left Windshield Side Reveal Moldings to Add Double Sided Tape) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Sierra Denali, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 08-08-48-003E (Section 08 - Body and Accessories). Condition Some customers may comment on hearing a tapping, clicking or ticking noise at the windshield area. This condition occurs more frequently while driving at highway speeds and could be exaggerated on vehicles with front bug guard deflectors. Cause This condition may be caused by air/wind causing the windshield side reveal moldings to move, generating a noise. Correction Remove both windshield reveal moldings, add double-sided tape and re-install the moldings following the steps below: 1. Using tape (1) or a grease pencil, mark the position of the inboard edge (2) of both left and right reveal moldings onto the windshield, following the contour of the molding. 2. Remove the left and right windshield side reveal moldings. Refer to Windshield Side Reveal Molding Replacement in SI. 3. Being careful not to affect the tape or grease pencil marks, clean and prep the glass at the seal interface with Glass Adhesion Promoter, P/N 12378555 (in Canada, use 88901239). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Window Glass: > 08-08-48-003F > Apr > 11 > Body - Tapping/Clicking/Ticking Noise at Windshield Area > Page 18282 4. Apply 3M Automotive Adhesion Promoter 06396, or equivalent, to the underside of the reveal molding seals. Tip An approximate 600 mm (24 in) length of tape should allow for overlap at the top to be trimmed back leaving a tail of release liner (1) and, at minimum, should reach the fender cut line at the bottom. 5. Apply a 600 mm (24 in) length of 3M Automotive Acrylic Plus Attachment Tape 06386 (1.14 mm (0.045 in) thick x 6.35 mm (0.25 in) wide), or equivalent, to both sides of the windshield. Ensure the tape (1) position is centered between the windshield edge (2) and the tape/grease pencil line (3). Do not remove the release lining from the tape yet. 6. Reinstall the reveal molding to one side by sliding the molding downward and ensuring that the top lip is engaged at the upper edge of the windshield. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Window Glass: > 08-08-48-003F > Apr > 11 > Body - Tapping/Clicking/Ticking Noise at Windshield Area > Page 18283 7. Install the fasteners to the reveal molding, starting from the top. Refer to Windshield Side Reveal Molding Replacement in SI. 8. Lifting the top edge of the reveal molding, grab the tail of the release lining and pull downward removing the lining. 9. Press or roll the reveal molding against the windshield ensuring adhesion of the tape to the glass. 10. Repeat steps 6-9 on the opposite side. 11. Remove tape or clean the grease pencil marks from the windshield. 12. If positioned correctly, trimming of the double sided tape should not be necessary, however inspect the reveal moldings for any tape not covered and trim off any exposed tape. Important After taping the windshield reveal moldings, avoid washing the vehicle as well as excessive contact with the windshield reveal moldings for a minimum of 72 hours. Parts Information 3M(TM) products may be purchased through your local distributor. Information about 3M product retailers in your area may be obtained by calling 1-866-364-3577 (U.S. and Canada). Warranty Information Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Window Glass: > 08-08-48-003F > Apr > 11 > Body - Tapping/Clicking/Ticking Noise at Windshield Area > Page 18284 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Window Glass: > Page 18285 Front Door Window Glass: By Symptom Technical Service Bulletin # 07-08-64-019C Date: 110408 Body - Front Door Window Regulator Squeak Noise TECHNICAL Bulletin No.: 07-08-64-019C Date: April 08, 2011 Subject: Front Door Window Regulator Squeak Noise When Operated (Apply Lubricant) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add the 2011 and 2012 model years. Please discard Corporate Bulletin Number 07-08-64-019B (Section 08 - Body and Accessories). Condition Some customers may comment on a front door glass squeak when operated up or down. Cause There may be insufficient lubrication on the regulator rails. Correction Lubricate BOTH front door regulators at time of repair using the following procedure. 1. Remove the regulator following SI procedures. 2. Brush a small amount of lubricant on the entire length of both regulator rails. Refer to the illustration for lubricant location. 3. Cycle the door glass to verify that the noise is gone. 4. Reinstall the regulator following SI procedures. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Window Glass: > Page 18286 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 07-08-64-019C Date: 110408 Body - Front Door Window Regulator Squeak Noise TECHNICAL Bulletin No.: 07-08-64-019C Date: April 08, 2011 Subject: Front Door Window Regulator Squeak Noise When Operated (Apply Lubricant) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add the 2011 and 2012 model years. Please discard Corporate Bulletin Number 07-08-64-019B (Section 08 - Body and Accessories). Condition Some customers may comment on a front door glass squeak when operated up or down. Cause There may be insufficient lubrication on the regulator rails. Correction Lubricate BOTH front door regulators at time of repair using the following procedure. 1. Remove the regulator following SI procedures. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Window Glass: > Page 18287 2. Brush a small amount of lubricant on the entire length of both regulator rails. Refer to the illustration for lubricant location. 3. Cycle the door glass to verify that the noise is gone. 4. Reinstall the regulator following SI procedures. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Technical Service Bulletins > Page 18288 Front Door Window Glass: Service and Repair Front Side Door Window Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Technical Service Bulletins > Body - Vehicle Glass Distortion Information Quarter Window Glass: Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > System Information > Service and Repair > Rear Side Door Window Replacement (Crew Cab) Rear Door Window Glass: Service and Repair Rear Side Door Window Replacement (Crew Cab) Rear Side Door Window Replacement (Crew Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > System Information > Service and Repair > Rear Side Door Window Replacement (Crew Cab) > Page 18297 Rear Door Window Glass: Service and Repair Rear Side Door Window Replacement (Extended Cab) Rear Side Door Window Replacement (Extended Cab) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Regulator: > 07-08-64-019C > Apr > 11 > Body - Front Door Window Regulator Squeak Noise Front Door Window Regulator: All Technical Service Bulletins Body - Front Door Window Regulator Squeak Noise TECHNICAL Bulletin No.: 07-08-64-019C Date: April 08, 2011 Subject: Front Door Window Regulator Squeak Noise When Operated (Apply Lubricant) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add the 2011 and 2012 model years. Please discard Corporate Bulletin Number 07-08-64-019B (Section 08 - Body and Accessories). Condition Some customers may comment on a front door glass squeak when operated up or down. Cause There may be insufficient lubrication on the regulator rails. Correction Lubricate BOTH front door regulators at time of repair using the following procedure. 1. Remove the regulator following SI procedures. 2. Brush a small amount of lubricant on the entire length of both regulator rails. Refer to the illustration for lubricant location. 3. Cycle the door glass to verify that the noise is gone. 4. Reinstall the regulator following SI procedures. Parts Information Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Regulator: > 07-08-64-019C > Apr > 11 > Body - Front Door Window Regulator Squeak Noise > Page 18307 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Technical Service Bulletins > Customer Interest for Front Door Window Regulator: > 07-08-64-019C > Apr > 11 > Body - Front Door Window Regulator Squeak Noise Front Door Window Regulator: Customer Interest Body - Front Door Window Regulator Squeak Noise TECHNICAL Bulletin No.: 07-08-64-019C Date: April 08, 2011 Subject: Front Door Window Regulator Squeak Noise When Operated (Apply Lubricant) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add the 2011 and 2012 model years. Please discard Corporate Bulletin Number 07-08-64-019B (Section 08 - Body and Accessories). Condition Some customers may comment on a front door glass squeak when operated up or down. Cause There may be insufficient lubrication on the regulator rails. Correction Lubricate BOTH front door regulators at time of repair using the following procedure. 1. Remove the regulator following SI procedures. 2. Brush a small amount of lubricant on the entire length of both regulator rails. Refer to the illustration for lubricant location. 3. Cycle the door glass to verify that the noise is gone. 4. Reinstall the regulator following SI procedures. Parts Information Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Technical Service Bulletins > Customer Interest for Front Door Window Regulator: > 07-08-64-019C > Apr > 11 > Body - Front Door Window Regulator Squeak Noise > Page 18313 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Technical Service Bulletins > Customer Interest for Front Door Window Regulator: > Page 18314 Front Door Window Regulator: By Symptom Technical Service Bulletin # 07-08-64-019C Date: 110408 Body - Front Door Window Regulator Squeak Noise TECHNICAL Bulletin No.: 07-08-64-019C Date: April 08, 2011 Subject: Front Door Window Regulator Squeak Noise When Operated (Apply Lubricant) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add the 2011 and 2012 model years. Please discard Corporate Bulletin Number 07-08-64-019B (Section 08 - Body and Accessories). Condition Some customers may comment on a front door glass squeak when operated up or down. Cause There may be insufficient lubrication on the regulator rails. Correction Lubricate BOTH front door regulators at time of repair using the following procedure. 1. Remove the regulator following SI procedures. 2. Brush a small amount of lubricant on the entire length of both regulator rails. Refer to the illustration for lubricant location. 3. Cycle the door glass to verify that the noise is gone. 4. Reinstall the regulator following SI procedures. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Technical Service Bulletins > Customer Interest for Front Door Window Regulator: > Page 18315 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 07-08-64-019C Date: 110408 Body - Front Door Window Regulator Squeak Noise TECHNICAL Bulletin No.: 07-08-64-019C Date: April 08, 2011 Subject: Front Door Window Regulator Squeak Noise When Operated (Apply Lubricant) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add the 2011 and 2012 model years. Please discard Corporate Bulletin Number 07-08-64-019B (Section 08 - Body and Accessories). Condition Some customers may comment on a front door glass squeak when operated up or down. Cause There may be insufficient lubrication on the regulator rails. Correction Lubricate BOTH front door regulators at time of repair using the following procedure. 1. Remove the regulator following SI procedures. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Technical Service Bulletins > Customer Interest for Front Door Window Regulator: > Page 18316 2. Brush a small amount of lubricant on the entire length of both regulator rails. Refer to the illustration for lubricant location. 3. Cycle the door glass to verify that the noise is gone. 4. Reinstall the regulator following SI procedures. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Door Window Regulator Handle Replacement Front Door Window Regulator: Service and Repair Door Window Regulator Handle Replacement Door Window Regulator Handle Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Door Window Regulator Handle Replacement > Page 18319 Front Door Window Regulator: Service and Repair Front Side Door Window Regulator Replacement (Manual) Front Side Door Window Regulator Replacement (Manual) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Door Window Regulator Handle Replacement > Page 18320 Front Door Window Regulator: Service and Repair Front Side Door Window Regulator Replacement (Power) Front Side Door Window Regulator Replacement (Power) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair > Rear Side Door Window Regulator Replacement (Crew Cab, Manual) Rear Door Window Regulator: Service and Repair Rear Side Door Window Regulator Replacement (Crew Cab, Manual) Rear Side Door Window Regulator Replacement (Crew Cab, Manual) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair > Rear Side Door Window Regulator Replacement (Crew Cab, Manual) > Page 18325 Rear Door Window Regulator: Service and Repair Rear Side Door Window Regulator Replacement (Crew Cab, Power) Rear Side Door Window Regulator Replacement (Crew Cab, Power) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair > Rear Side Door Window Regulator Replacement (Crew Cab, Manual) > Page 18326 Rear Door Window Regulator: Service and Repair Rear Side Door Window Regulator Replacement (Extended Cab, Power) Rear Side Door Window Regulator Replacement (Extended Cab, Power) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Windshield Moulding / Trim > Component Information > Technical Service Bulletins > Customer Interest for Windshield Moulding / Trim: > 08-08-48-003F > Apr > 11 > Body Tapping/Clicking/Ticking Noise at Windshield Area Windshield Moulding / Trim: Customer Interest Body - Tapping/Clicking/Ticking Noise at Windshield Area TECHNICAL Bulletin No.: 08-08-48-003F Date: April 06, 2011 Subject: Tapping, Clicking or Ticking Noise at Windshield Area (R&R; Right and Left Windshield Side Reveal Moldings to Add Double Sided Tape) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Sierra Denali, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 08-08-48-003E (Section 08 - Body and Accessories). Condition Some customers may comment on hearing a tapping, clicking or ticking noise at the windshield area. This condition occurs more frequently while driving at highway speeds and could be exaggerated on vehicles with front bug guard deflectors. Cause This condition may be caused by air/wind causing the windshield side reveal moldings to move, generating a noise. Correction Remove both windshield reveal moldings, add double-sided tape and re-install the moldings following the steps below: 1. Using tape (1) or a grease pencil, mark the position of the inboard edge (2) of both left and right reveal moldings onto the windshield, following the contour of the molding. 2. Remove the left and right windshield side reveal moldings. Refer to Windshield Side Reveal Molding Replacement in SI. 3. Being careful not to affect the tape or grease pencil marks, clean and prep the glass at the seal interface with Glass Adhesion Promoter, P/N 12378555 (in Canada, use 88901239). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Windshield Moulding / Trim > Component Information > Technical Service Bulletins > Customer Interest for Windshield Moulding / Trim: > 08-08-48-003F > Apr > 11 > Body Tapping/Clicking/Ticking Noise at Windshield Area > Page 18336 4. Apply 3M Automotive Adhesion Promoter 06396, or equivalent, to the underside of the reveal molding seals. Tip An approximate 600 mm (24 in) length of tape should allow for overlap at the top to be trimmed back leaving a tail of release liner (1) and, at minimum, should reach the fender cut line at the bottom. 5. Apply a 600 mm (24 in) length of 3M Automotive Acrylic Plus Attachment Tape 06386 (1.14 mm (0.045 in) thick x 6.35 mm (0.25 in) wide), or equivalent, to both sides of the windshield. Ensure the tape (1) position is centered between the windshield edge (2) and the tape/grease pencil line (3). Do not remove the release lining from the tape yet. 6. Reinstall the reveal molding to one side by sliding the molding downward and ensuring that the top lip is engaged at the upper edge of the windshield. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Windshield Moulding / Trim > Component Information > Technical Service Bulletins > Customer Interest for Windshield Moulding / Trim: > 08-08-48-003F > Apr > 11 > Body Tapping/Clicking/Ticking Noise at Windshield Area > Page 18337 7. Install the fasteners to the reveal molding, starting from the top. Refer to Windshield Side Reveal Molding Replacement in SI. 8. Lifting the top edge of the reveal molding, grab the tail of the release lining and pull downward removing the lining. 9. Press or roll the reveal molding against the windshield ensuring adhesion of the tape to the glass. 10. Repeat steps 6-9 on the opposite side. 11. Remove tape or clean the grease pencil marks from the windshield. 12. If positioned correctly, trimming of the double sided tape should not be necessary, however inspect the reveal moldings for any tape not covered and trim off any exposed tape. Important After taping the windshield reveal moldings, avoid washing the vehicle as well as excessive contact with the windshield reveal moldings for a minimum of 72 hours. Parts Information 3M(TM) products may be purchased through your local distributor. Information about 3M product retailers in your area may be obtained by calling 1-866-364-3577 (U.S. and Canada). Warranty Information Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Windshield Moulding / Trim > Component Information > Technical Service Bulletins > Customer Interest for Windshield Moulding / Trim: > 08-08-48-003F > Apr > 11 > Body Tapping/Clicking/Ticking Noise at Windshield Area > Page 18338 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Windshield Moulding / Trim > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield Moulding / Trim: > 08-08-48-003F > Apr > 11 > Body - Tapping/Clicking/Ticking Noise at Windshield Area Windshield Moulding / Trim: All Technical Service Bulletins Body - Tapping/Clicking/Ticking Noise at Windshield Area TECHNICAL Bulletin No.: 08-08-48-003F Date: April 06, 2011 Subject: Tapping, Clicking or Ticking Noise at Windshield Area (R&R; Right and Left Windshield Side Reveal Moldings to Add Double Sided Tape) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Sierra Denali, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 08-08-48-003E (Section 08 - Body and Accessories). Condition Some customers may comment on hearing a tapping, clicking or ticking noise at the windshield area. This condition occurs more frequently while driving at highway speeds and could be exaggerated on vehicles with front bug guard deflectors. Cause This condition may be caused by air/wind causing the windshield side reveal moldings to move, generating a noise. Correction Remove both windshield reveal moldings, add double-sided tape and re-install the moldings following the steps below: 1. Using tape (1) or a grease pencil, mark the position of the inboard edge (2) of both left and right reveal moldings onto the windshield, following the contour of the molding. 2. Remove the left and right windshield side reveal moldings. Refer to Windshield Side Reveal Molding Replacement in SI. 3. Being careful not to affect the tape or grease pencil marks, clean and prep the glass at the seal interface with Glass Adhesion Promoter, P/N 12378555 (in Canada, use 88901239). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Windshield Moulding / Trim > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield Moulding / Trim: > 08-08-48-003F > Apr > 11 > Body - Tapping/Clicking/Ticking Noise at Windshield Area > Page 18344 4. Apply 3M Automotive Adhesion Promoter 06396, or equivalent, to the underside of the reveal molding seals. Tip An approximate 600 mm (24 in) length of tape should allow for overlap at the top to be trimmed back leaving a tail of release liner (1) and, at minimum, should reach the fender cut line at the bottom. 5. Apply a 600 mm (24 in) length of 3M Automotive Acrylic Plus Attachment Tape 06386 (1.14 mm (0.045 in) thick x 6.35 mm (0.25 in) wide), or equivalent, to both sides of the windshield. Ensure the tape (1) position is centered between the windshield edge (2) and the tape/grease pencil line (3). Do not remove the release lining from the tape yet. 6. Reinstall the reveal molding to one side by sliding the molding downward and ensuring that the top lip is engaged at the upper edge of the windshield. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Windshield Moulding / Trim > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield Moulding / Trim: > 08-08-48-003F > Apr > 11 > Body - Tapping/Clicking/Ticking Noise at Windshield Area > Page 18345 7. Install the fasteners to the reveal molding, starting from the top. Refer to Windshield Side Reveal Molding Replacement in SI. 8. Lifting the top edge of the reveal molding, grab the tail of the release lining and pull downward removing the lining. 9. Press or roll the reveal molding against the windshield ensuring adhesion of the tape to the glass. 10. Repeat steps 6-9 on the opposite side. 11. Remove tape or clean the grease pencil marks from the windshield. 12. If positioned correctly, trimming of the double sided tape should not be necessary, however inspect the reveal moldings for any tape not covered and trim off any exposed tape. Important After taping the windshield reveal moldings, avoid washing the vehicle as well as excessive contact with the windshield reveal moldings for a minimum of 72 hours. Parts Information 3M(TM) products may be purchased through your local distributor. Information about 3M product retailers in your area may be obtained by calling 1-866-364-3577 (U.S. and Canada). Warranty Information Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Windshield Moulding / Trim > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield Moulding / Trim: > 08-08-48-003F > Apr > 11 > Body - Tapping/Clicking/Ticking Noise at Windshield Area > Page 18346 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Rain Sensor > Component Information > Diagrams Rain Sensor: Diagrams Component Connector End Views Windshield Outside Moisture Sensor (CE1) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Rain Sensor > Component Information > Service and Repair > Windshield Outside Moisture Sensor Replacement Rain Sensor: Service and Repair Windshield Outside Moisture Sensor Replacement Windshield Outside Moisture Sensor Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Rain Sensor > Component Information > Service and Repair > Windshield Outside Moisture Sensor Replacement > Page 18353 Rain Sensor: Service and Repair Windshield Outside Moisture Sensor Lens Replacement Windshield Outside Moisture Sensor Lens Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations Windshield Washer Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Page 18358 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Page 18359 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Page 18360 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Page 18361 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Page 18362 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Page 18363 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Page 18364 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations Wiper Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 18368 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 18369 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 18370 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 18371 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 18372 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 18373 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 18374 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Rain Sensor > Component Information > Diagrams Rain Sensor: Diagrams Component Connector End Views Windshield Outside Moisture Sensor (CE1) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Rain Sensor > Component Information > Service and Repair > Windshield Outside Moisture Sensor Replacement Rain Sensor: Service and Repair Windshield Outside Moisture Sensor Replacement Windshield Outside Moisture Sensor Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Rain Sensor > Component Information > Service and Repair > Windshield Outside Moisture Sensor Replacement > Page 18381 Rain Sensor: Service and Repair Windshield Outside Moisture Sensor Lens Replacement Windshield Outside Moisture Sensor Lens Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Diagrams Washer Fluid Level Switch: Diagrams Component Connector End Views Windshield Washer Fluid Level Switch Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Diagrams > Page 18385 Washer Fluid Level Switch: Service and Repair Windshield Washer Solvent Level Switch Replacement (Chevrolet) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Diagrams Washer Fluid Level Switch: Diagrams Component Connector End Views Windshield Washer Fluid Level Switch Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Diagrams > Page 18389 Washer Fluid Level Switch: Service and Repair Windshield Washer Solvent Level Switch Replacement (Chevrolet) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Hose > Component Information > Service and Repair Windshield Washer Hose: Service and Repair Windshield Washer Hose Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Diagrams Windshield Washer Pump: Diagrams Component Connector End Views Windshield Washer Fluid Pump Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Diagrams > Page 18396 Windshield Washer Pump: Service and Repair Washer Pump Replacement (Silverado) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations Windshield Washer Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Page 18400 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Page 18401 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Page 18402 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Page 18403 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Page 18404 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Page 18405 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Page 18406 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Service and Repair Windshield Washer Reservoir: Service and Repair Windshield Washer Solvent Container Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the left front wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 3. Remove the left front wheelhouse liner. Refer to Front Wheelhouse Liner Replacement - Left Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Left Side)Front Wheelhouse Liner Replacement - Left Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Left Side). 4. Remove the lower outer bolt (1) from the washer container prior to lowering the vehicle. 5. Disconnect the washer pump hoses (1, 2) from the left side fender flange. Refer to Windshield Washer Hose Replacement (See: Windshield Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Service and Repair > Page 18410 Washer Hose/Service and Repair). 6. Disconnect the electrical connectors. 7. Lower the vehicle in order to access the hood latch. 8. Open the hood. 9. Remove the windshield washer solvent cap. 10. Remove the auxiliary battery tray, if equipped. Refer to Auxiliary Battery Tray Replacement (See: Starting and Charging/Battery/Battery Tray/Service and Repair/Auxiliary Battery Tray Replacement). Note: Remove the washer container from the underside of the vehicle through the wheelhouse opening. 11. Remove the upper windshield washer solvent container bolts. 12. Remove the windshield washer solvent container assembly (2). 13. Drain the windshield washer solvent into a suitable clean container. Installation Procedure 1. Transfer washer pumps and level indicator to the new washer solvent container (2). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Service and Repair > Page 18411 2. Install the windshield washer container assembly (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the upper windshield washer solvent container bolts and tighten to 9 Nm (80 lb in). 4. Install the auxiliary battery tray, if equipped. Refer to Auxiliary Battery Tray Replacement (See: Starting and Charging/Battery/Battery Tray/Service and Repair/Auxiliary Battery Tray Replacement). 5. Connect the electrical connectors. 6. Connect the washer pump hoses (1, 2). Refer to Windshield Washer Hose Replacement (See: Windshield Washer Hose/Service and Repair). 7. Install the lower outer washer container bolt. 8. Install the left front wheelhouse liner. Refer to Front Wheelhouse Liner Replacement - Left Side (Chevrolet) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Left Side)Front Wheelhouse Liner Replacement - Left Side (GMC) (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Liner Replacement - Left Side). 9. Install the left front wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 10. Fill the washer solvent container with windshield solvent. Refer to Fluid and Lubricant Recommendations (USA and Canada) (See: Maintenance Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Service and Repair > Page 18412 ). 11. Install the windshield washer solvent cap. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair Wiper Arm: Service and Repair Windshield Wiper Arm Replacement (LD) Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > Glass/Body - Windshield Wiper Performance Wiper Blade: Technical Service Bulletins Glass/Body - Windshield Wiper Performance INFORMATION Bulletin No.: 06-08-43-003C Date: February 21, 2011 Subject: Windshield Wiper Performance, Cleaning Instructions and Maintenance Models: 2012 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2010 and Prior Isuzu Medium Duty Trucks 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add the 2011 and 2012 model year. Please discard Corporate Bulletin Number 06-08-43-003B (Section 08 - Body and Accessories). Wiper Concerns Most concerns about windshield wiper performance are the result of dirty wiper blades, damaged wiper blades, or worn out blades that are continuing to be used beyond their useful life. Depending on environmental conditions, wiper blades can have dramatic differences in lifespan. Here are some tips and guidelines to maximize wiper performance to avoid damage to the blades, and to avoid unnecessary replacements. Many wiper blades are being replaced under warranty with reviews showing there is nothing wrong with the returned blades other than a build-up of dirt. Additionally, advise the customer to review the information in their Owner Manual. Inspection and Cleaning Scheduled Maintenance - Inspect your wipers rubber blades every 4-6 months or 12,000 km (7,500 mi) for wear, cracking or contamination. - Clean the windshield and the rubber wiper blades (using the procedure below) if the blades are not clearing the glass satisfactorily. If this does not correct the problem, then replace the rubber elements. Cleaning Procedure Important Avoid getting windshield washer fluid on your hands. Wear rubber gloves or avoid direct contact with washer fluid. Important Do not use gasoline, kerosene, or petroleum based products to clean wiper blades. - Clean the rubber blades using a lint free cloth or paper towel soaked with windshield washer fluid or a mild detergent. You should see significant amounts of dirt being removed on the cloth. - Be sure to wash the windshield thoroughly when you clean the blades. Bugs, road grime, sap and a buildup of car wash/wax treatments may additionally cause wiper streaking. Tip For a larger scale buildup on the windshield, use a non-abrasive cleaner such as Bon-Ami* (www.faultless.com) cleanser with a wet sponge, being sure to use plenty of water to avoid scratching the glass. Flush the surface and body panels completely. Tip For day-to-day exterior glass cleaning and to maintain a streak free appearance, suggest Vehicle Care Glass Cleaner, P/N 88862560 (in Canada, 992727). This product is an easy to use foaming cleaner that quickly removes dirt and grime from glass surfaces. Tip Interior glass should be cleaned with plain, clean water to eliminate any film or haze on the window and help prevent fogging, a major customer dissatisfier. Refer to Corporate Bulletin Number 03-00-89-006D for more information. The New Vehicle Pre-Delivery Inspection form also recommends using plain water to clean interior glass. *"We believe this material to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or equipment from these firms or any such items which may be available from other sources. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > Glass/Body - Windshield Wiper Performance > Page 18420 Avoiding Wiper Damage The following are major contributors to wiper damage. Some of these you can control and others are environmental concerns. - Extremely dusty areas (such as driving on dirt roads) may cause the wipers rubber edge to wear quickly and unevenly. - Sand and salt used on roads for increasing winter traction and ice control will cause the wiper blades to wear quicker. Areas with significant snowfall require more frequent blade replacements. - Heat and time may cause the rubber blades to take a "permanent set" resulting in the rubber not flexing and turning over uniformly. This condition may result in streaking and/or unwiped areas. - Rubber blades are easily cut or torn when using ice scrapers. Likewise pulling blades up off a frozen windshield can tear the rubber. Exercise caution when clearing ice and snow. - Using your wipers to "wear through" frost and ice, instead of allowing the defrosters to melt the ice, can dull, nick or tear the rubber blades. - Banging wipers on the glass to remove ice and snow may cause the blade to bend, dislodging the rubber and causing potential scratching of the windshield. - Ice can form in the pin joints of the wipers, which can cause streaking and unwiped areas. To remove ice from pin joints, compress the blade and rubber edge with your hand to loosen the frozen joints. Consider using Winter Blades that have a rubber cover to avoid this condition. Note GM does not recommend the use of any spray on/wipe on windshield treatments or washer fluid additives. The variation in friction that results on the glass from the use of these products causes wipers to chatter and have premature wear. Disclaimer Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > Page 18421 Wiper Blade: Testing and Inspection Wiper Blade Element Check 1. Remove the wiper blades from the wiper arms. Refer to Windshield Wiper Blade Replacement (See: Service and Repair/Removal and Replacement). 2. Look down the length of the blade element. 3. Replace the wiper blade if the rubber element which contacts the glass is not on the centerline of the blade +/-15 degrees. 4. Install the wiper blades on the wiper arms. Refer to Windshield Wiper Blade Replacement (See: Service and Repair/Removal and Replacement). Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair > Procedures Wiper Blade: Procedures Wiper Blade Element Cleaning Wiper Blade Element Cleaning 1. Lift the wiper blade assemblies off of the windshield glass. 2. Clean the wiper blade element with a clean cloth saturated with full strength washer solution. 3. Rinse the wiper blade assemblies with water. 4. Place the wiper blade assemblies back onto the windshield glass. Wiper Chatter Repair Wiper Chatter Repair Some vehicles may exhibit a condition where the windshield wiper blades chatter or wipe unevenly. Several different conditions can cause the wiper blade chatter. To completely repair wiper blade chatter, all of the following should be checked and repaired as necessary: * The windshield glass must be clean. * The wiper blade element must be clean. * The wiper arm tip pressure must be within specifications. * The wiper blade element set must be within specifications. Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair > Procedures > Page 18424 Wiper Blade: Removal and Replacement Windshield Wiper Blade Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams Wiper Motor: Diagrams Component Connector End Views Windshield Wiper Motor Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Page 18428 Wiper Motor: Service and Repair Windshield Wiper System Module Replacement Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations Wiper Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 18432 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 18433 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 18434 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 18435 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 18436 Chevrolet Silverado 3500 4wd Workshop Manual (V8-6.6L DSL Turbo (2010)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 18437